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LETTER OF AUTHORIZATION
Dear Reader,
We are authorized by K-Electric limitedHumanResource, to preparea reporton
“Internship atBin QasimPower Station-1,K-Electric Limited”.
This is done in partial fulfillment of the Internship Program
Sincerely,
Moiz Akhter
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LETTER OF TRANSMITTAL
K-Electric limited HR
Subject: INTERNSHIP ATBIN QASIM POWER PLANT-1,K-ELECTRIC LIMITED
Respected Sir/Ma’am,
We are submitting our reportof “Internship”, theresultof our
effort as well as our conclusion is embodied in the accompanying report.
Your feedback is valuable to us.
Regards,
Moiz Akhter
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TABLE OF CONTENT
S.NO TOPIC PAGE.NO
1 Letter of Authorization
2 Letter of Transmittal
3 Preface
4 Acknowledgement
5 Day 1st
6 Day 2nd
7 Day 3rd
8 Day 4th
9 Day 5th
10 Day 6th
11 Day 7th
12 Day 8th
13 Day 9th & 10th
14 Day 11th
15 Day 12th
16 Day 13th
17 Day 14th
18 Day 15th
19 Day 16th
20 Day 17th & 18th
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PREFACE
Through different tasks and with great supportfromMr. Shams Tabrez Khan
(Deputy General Manager –M I&C) wehave gained reasonableknowledge of in
the field of Engineering
Through this internship I have learned the useof many electronic components
including switches and transducers. I havealso learned practical application of
different principles. This internship also helped us getting profound knowledgeof
Power Plant. Here we learned how to deal with different technical situations that
can occur that usually are not part of our Academic Syllabus.
This reportwill firstillustrate the basic knowledge aboutBQPS 1, and the task
completed during internship, and the results shall be discussed and analyzed that
our obtained.
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Acknowledgement
This internship has only been successfulbecauseof the help of some people. First
and foremost, I would like to thank our DGM of training Sir: SALEEM SAJJID for
giving me this opportunity fromwhich I could learn many things and also for
guiding me whenever his guidance was necessary.
Next, I would like to thank the following withoutwhosehelp and supportI can’t
able to learn anything.
 Mr. Shams Tabrez Khan
 Mr. Farooq-e-Azam
 Mr. Arif Mehmood
 Mr.Ali Raza
I also wish to express my gratitude to the officials and other staff members of
“Instrument And control Depart” of K-Electric who rendered their help
during the period of Internship. Lastbut not least I wish to avail myself of this
opportunity, express a senseof gratitude to my beloved Parents for their manual
support, strength, and help and for everything.
Duration of Internship
Startdate: 8th
July, 2014
End Date: 15th
August, 2014
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Day 1st
Introduction
I was informed to report at K-Electric BQPS-1, Bin QasimTown HR Office
reception at 7:00 am. Firstly we were briefed about policies and were given guide
lines for our stay at Power Station. They provided me Apron Card & safety
Hamlet. There our attendance was marked, DGM of training SALEEM SAJJID
allocated me to Instrumentation & ControlDepartment.
Orientation of Plant:
I was briefed about Bin QasimThermalPower Station by Mr. Shams and visit the
Plant under the supervision of Mr. shukat
BIN QASIM’S HISTORY
This plant is the biggest in Karachiand its construction is started in 1979. Initially
the projects wereapproved for the installations of 6 units of 210 MW each with
different phases. Hereare some important events in the history of this plant.
SPECIFICATION OF THE DIFFERENT UNITS
BQPS-1 has 6 Boiler Turbine Generation Units, which has a maximum capacity
production of 1260 MW. The specification of each element is:
Boiler: 530 C, 140 bar steam, 680 t/h
Turbine: 525 C steam inlet, 3000 rpm
Generator: 3000 rpm, 3 phase, 210 MW
The Boiler could work on Gas and Oil both. However the overall always process
remains the same.
UNIT
NO
MANF.
BOILER
MANF.
TURBINE
MANF.
GENERATOR
INSTALL
CAPACITY
PRESENT
CAPACITY
COMN
DATE
1 Hitachi Hitachi Hitachi 210 190 1983
2 Hitachi Hitachi Hitachi 210 180 1984
3 Deutche Ansaldo Ercolemarelli 210 120 1989
4 Deutche Ansaldo Ercolemarelli 210 150 1990
5 Hitachi Hitachi Hitachi 210 200 1991
6 Hitachi Hitachi Hitachi 210 195 1997
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Units 1,2,5,6 areconstructed by the collaboration of Japanese companies and
Japanese labor while units 3,4 were installed by Italian company Ansaldo.
OPERATING PRINCIPLE OF BIN QASIM POWER PLANT
According to the laws of magnetic field:
“A moving conductor inthe presence of magnetic fieldhas a voltage inducedin
it this is the basis of generator action.”
This means we need to rotate the turbine blades by means of any force,now this
forcewhich is required to turn the turbine blades is the difference between
different power plants.
Hydrogen Plant:
Hydrogenproduction is the family of industrialmethods for generating hydrogen.
Currently the dominant technology for direct production is steam reforming from
hydrocarbons. Many other methods areknown including electrolysis. Hydrogen is
used as a coolant in generators of Bin Qasimpower plant. This type of cooling
increases the efficiency by decreasing the heat which can melt the insulation, the
hydrogen is kept on cooling by hydrogen coolers.
WORKSHOP:
Various kind of machines are present in the workshop including:
1. Lathe machine
2. Milling machine
3. Drilling Machine
4. Rolling machine
5. Welding machine
6. Electrical Furnace
Parts which are fabricated mostly include sleeves. Argon welding is mostly carried
out to weld parts.
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WATER TREATMENT PLANT
Before the water is fed to the boiler it is treated to removeall impurities and to
dematerialize it i.e. to make it dematerialized water.
TRANSFORMERS USED IN BIN QASIM POWER STATION
Different types of Transformers being used in Bin QasimPower Station:
 6 Main Transformer(1 for each unit)
 6 Auxiliary Transformer(1 for each unit)
 3 Startup Transformer (1 for 2 units)
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Day 2nd
The variety of different departments in the Plant includes:
 Instrumentation & Control
 Mechanical- Boiler
 Mechanical- Turbine
 Electrical
 Electrical HVAC
 Balance of Plant (B.O.P)
 Operations
 Civil
Instrumentation & Control
 Instrumentation is an art and science using instruments in a control process
for the purposeof observation, measurementand control.
 Instruments can beused to measureweight, density, thickness, flow,
temperature, force, humidity, current, voltage, horsepower, phaseangle,
power- factor, frequency, etc.
 Process Control- Activities involved in ensuring a process is predictable,
stable, and consistently operating at the target level of performancewith
only normalvariation.
There are two types of control systems:
1. Pneumatic Control Systems
 Pneumatics is a section of technology that deals with the study and
application of pressurized gas to produce mechanical motion.
 Mechanisms which use air pressureto apply mechanical forceand
displacement (work).
Applications:
a. Gear Shifters.
b. Lifters.
c. Brakes.
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2. Electronic Control System
An electronic systemis a systemthat employs electronic signals to
control devices. The input of an electronic systemis provided by
electronic signals. Electronic devices include semi-conducting diode,
transistors, and capacitors thatthey are usually welded onto
electronic circuit boards.
The control systemis sub divided into open loop and closed loop system.
 Open loop Control Systems:
When an input signal directs the controlelement to respond, an output
will be produced
 Closedloopcontrol system:
Compares the output with the expected resultor command status, then it
takes appropriatecontrolactions to adjustthe input signal.
CONTROL ROOM
 Visited electronic roomand controlroom of unit 3. Each unit has its own
control room.
 The control systemcontrol temperature, pressureflow, level of boiler and
burner etc.
 If any problem in boiler for Eg : high or low of temperature, pressure, level,
flow then L.E.D glow in controlroom according to their requirement
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ELECTRONIC ROOM
 Each unit has its Electronic room. Electronics deals with electrical circuits
that involve active electrical components such as diodes, transistor
integrated circuit etc.
 Electronic room is generally solid state wherethe wired networks of relays
are replaced by softwarelogic running on special-purposecontrol
hardware.
 The fact that the logic is implemented by softwarerather than hard-wired
circuitry greatly facilities the ability to make modification when needed by
reprogramming rather than rewiring. Electronic
 Systemoperates in 24 v dc and 4-20 mA.
How signal operate in electronic room?
LOCAL/FIELD
MARSHALLING
TURBINE
CONTROL
BMS ANALOG BINARY CLOSED
LOOP
CONTROL ROOM
TRANSMITTER
OPEN
LOOP
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Day 3rd
I was simply briefed about Thermal Cycle.
Thermal CYCLES:
Following are three main cycles that are occurring in the main cycle:
1. Condensate cycle
2. Feed water cycle
3. Steam Generation cycle
Condensate cycle:
 The steam from LP Turbine condenses into condenser and stores in Hot-
well.
 Now, condensate cycle starts fromHot-well.
 Fromhot-well, we havethree suction lines for our condensate pumps (CPs).
Condensate pumps aredouble stage pump.
 FirstCP Main pump takes suction fromHot-well
 Then condensate goes through CP second stage or CP booster pump.
 Now we have three low pressureheaters (LPHs) which areused to preheat
the condensatefromLP Turbine extractions.
 Finally fromall these heaters, condensate is delivered to De-aerator where
condensatecycle ends and after removalof dissolved gases, water is stored
in feed water tank and feed-water cycle starts.
Note that we have a back-up reservoir, Cold Condensate Tank (C.C.T) which stores
the water and delivers it where it is required.
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FEED WATER CYCLE:
 The feed water systemreceives condensatefromdearator storagetank.
 Then pumps the feed water tank to reducehardness of water.
 Through feed water high-pressureheaters 5 and 6.
 Finally to the economizer inlet of the boiler, the feed water heated in the
HP heaters by extraction steam and high-pressurecondensatedrains.
 Suring this process the feed water is feed water systemsupplies water to
cold reheat and super heater attemperators to control the steam
temperature.
THE FEED WATER CYCLE
BFP 1, 2, 3
HP heater 5
HP heater 6
Economizer
Feed Water tank
De-aerator
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BOILER DRUM
CONDENSER
PRIMARY SUPER
HEATER
LP TURBINE
SECONDARY
SUPER HEATER
TERTIARY SUPER
HEATER
HP TURBINE
REHEATERIP TURBINE
STEAM CYCLE:
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Day 4th
TRANSFORMERS USED IN BIN QASIM POWER STATION.
I was briefed about Transformer used in Bin Qasim Power Station by Mr. Shams.
Different types of Transformers being used in Bin QasimPower Station:
 6 Main Transformer(1 for each unit)
 6 Auxiliary Transformer(1 for each unit)
 3 Startup Transformer (1 for 2 units)
 6 Excitation Transformer(1 for each unit)
 42 Service Station Transformer(6 connected to each auxiliary and 2
connected to each startup transformer)
MAIN TRANSFORMER
The purpose of Main Transformer is to Step-up the generating voltage from
18KV/21KV to 220KV so that it can be used for transmission purpose. The voltage
which is generated by generator is only upto 18KV/21KV since this voltage is not
enough for transmission so it is step-up by Main Transformer upto 220KV which is
eligible enough to transmit.
21 KV-------------->220KV------------->Transmission line
The ratings are as under:
HV LV
Rated Power 148/247 MVA 148/247 MVA
Rated Voltage 220 kV 21 kV
Rated Current 389/648 A 4075/6791 A
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AUXILIARY TRANSFORMER
Auxiliary Transformers areused in order to run auxiliary (big) motors like Boiler
Feed Pump (BFP) and several different motors used in
turbine/Boilers/Generators. The primary voltage of Auxiliary Transformer is 21KV
which is step down to 6.6KV.Theconnection is given such that Auxiliary
Transformer is given a supply from21KV Generated Voltage line which steps it
down to 6.6KV thus enabling to operate Auxiliary Motors.
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Generated voltage -----------------> Auxiliary Motors
(21 KV) (6.6 KV)
HV LV1 LV2
MVA Ratings ONAN 21.6 10.8 10.8
ONAF 36 18 18
Voltage Ratings 21000 6600 6600
BIL (kV) Line 125 60 60
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START-UP TRANSFORMER
Start-up Transformer is used when there is a total shutdown of plant i.e. neither
of the units is being able to generate the supply. Now there is only the Start-up
transformer which is the solution to this failure. Since the bus bar in operation
have both the incoming and outgoing possibility so in case of complete shutdown
of all units within Bin Qasim Power Station, the emergency bus bar will import a
220KV supply from outer stations which in turn provides a supply to Start-up
Transformer that steps it down to 6.6KV so that Auxiliary Motors which requires
6.6KV to run the necessary motors could be restarted, thus enabling the unit to
restart its operation inspite of the failure occurrence.
Bus Bar Line ----------> Start-up Transformer ------------> For Auxiliaries
(220 KV) (6.6 KV)
HV LV1 Lv2
MVA Ratings ONAN 26.4 13.2 13.2
ONAF 44 22 22
Voltage Ratings 220 kV 6.6 kV 6.6 kV
BIL (kV) LINE 950 60 60
NEUTRAL 150 - -
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EXCITATION TRANSFORMER
Excitation Transformer steps down the generated voltage i.e. 21kV to 0.47kV. This
0.47kV is converted into DC by using Thyristor stacks and then feed to the rotor of
the generator for excitation so the generator could start. The ratings are as under.
LV HV
470 V Rated Voltage 21000 V
2580 A Rated Current 57.7 A
SERVICE TRANSFORMER
Itfurther steps down 6.6 KV into 400 V for lighting and for general purposebut
very important small motors like gear motor, motors used for lubrication purpose
etc.
Rated Power 1600 KVA
Rated Voltage: 6.6/0.4 KV
Rated Current: 139.9/2309.4 A
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Day 5th
BOILER
A boiler is a strong metal tank or vessel composed of tubes, drums and header in
which water is heated by the gases of combustion from steam. Boiler is a steam
generator gets input as Air, Water, Fuel and some source to Burn the Fuel and
outputs Steam and Flue Gases Each Boiler has 12 burners. 4 burners at Each Floor.
CLASSIFICATION OF BOILER
There are two types of boiler:
FIRE TUBE BOILER
In this type, the combustion gases flow thought the tube and water remains
outside of the tubes. Some auxiliary boilers are example of fire type boiler.
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WATER TUBE BOILER
In the type of boiler water remain inside the tube while combustion gas flow
outside tubes and heated the water when they come in the contact with the
internal surface of the tube all boiler used for propulsion plants water tube boiler.
BOILER AT BIN QASIM
The boiler for 210MW is Single DrumRadiant Water Tube Boiler “EL-PASO” Type
which has self-drainableheating surface. The unit is of pressurized furnacedesign
with two regenerative air heater, two FDFs, two GRFs(Gas Recirculation Fan). The
flue gases are discharged by one chimney, mounted on the boiler steel structure.
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Day 6th
Attend the Safety Hour In the Workshop. In which Briefed aboutthe
Environmental pollution.
Environmental pollution:
One of the greatest problems that the world is facing today is that
of environmentalpollution, increasing with every passing year and causing grave
and irreparabledamage to the earth. Environmentalpollution consists of Four
basic types of pollution are Following…
 Air Pollution
 Water Pollution
 Noise pollution
 Soil Pollution
Air Pollution:
Air pollution is by far the mostharmfulform of pollution in our environment. Air
pollution is cause by the injurious smokeemitted by cars, buses, trucks, trains,
and factories, namely sulphur dioxide, carbon monoxide and nitrogen oxides.
Evidence of increasing air pollution is seen in lung cancer, asthma, allergies, and
various breathing problem.
Water Pollution:
Water pollution caused industrialwasteproducts released into lakes, rivers, and
other water bodies, has made marine life no longer hospitable. Humans pollute
water with large scaledisposalof garbage, flowers, ashes and other household
waste.
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Noise pollution:
Noise pollution, soil pollution and light pollution too are the damaging the
environmentat an alarming rate. Noise pollution include aircraft noise, noise of
cars, buses, and trucks, vehiclehorns, loudspeakers, and industry noise, as well as
high-intensity sonar effects which are extremely harmfulfor the environment.
Soil pollution:
Soil pollution, which can also be called soil contamination, is a result of acid rain,
polluted water, fertilizers etc., which leads to bad crops.
In this safety Hour discuss aboutthe Basic types of pollution how it affects to our
health and if didn’tcontrol pollution, its increase and harmfull for our us and our
family members, and told how to controlpollution in our Environment for better
Life.
Unit # 3 Trip:
Yesterday Unit # 3 tripped because of the Leakage occurred in the Line of Boiler,
which resulted in stopping steam production. Sincesteam was not being
produced as per requirement, Turbine stop rotating and generation of electricity
was suspended. TheUnit was nonoperationalfor 24 hours. I observed thewhole
Process of the Unit startup in control Room.
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Day 7th
Description about the Steam generation Cycle.
ECONOMIZER
It is horizontal continuous tube type and located beneath horizontal section of
the primary super heater economizer is arranged for counter flow of gases and
water and flow of water in economizer to upper ward to the drum.
BOILER DRUM/STEAM DRUMS
It is pressed to full hemi spherical shape is placed and fusion welded to shell
The drum is provided with two main hole covers. Feed water pipes from the
economizer out let are connected with nozzles with both hands of the drum and
feed water is fed inside drum through hydro clone. The main function of the
steam drum is to separate completely water from mixture of the steam and water
through cyclone separator and scrubbers are installed inside the steam drum.
SUPER HEATER:
Most of the modern boilers are having super heater and reheater arrangement.
Super heater is a componentof a steam-generating unit in which steam, after it
has left the boiler drum, is heated above its saturation temperature. The amount
of superheatadded to the steam is influenced by the location, arrangement, and
amount of super heater surfaceinstalled, as well as the rating of the boiler.
REHEATER :
Some of the heat of superheated steam is used to rotate the turbine where it
loses some of its energy. Reheater is also steam boiler component in which heat is
added to this intermediate-pressuresteam, which has given up someof its energy
in expansion through the high-pressureturbine. The steam after reheating is used
to rotate the second steam turbine.
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PRIMARY SUPER HEATER
The primary super heater low temperature section is located in interstate of
boiler pass above the economizer and high temperature section above repeater
section and arranged for the counter flow.
SECONDARY SUPER HEATER
Secondary section is located in the furnace exit zone where gas temperature is
relatively high and arranged parallel flow.
TERTIARY SUPER HEATER:
Tertiary section is located between secondary and repeater section and arranged
parallel flow. Super heater is supported from the enclosure boiler tube wall
extended from the furnace wall with support lugs and spacers are constructed so
as to suitable fuel oil having appreciable vanadium content.
CONDENSER:
Steam after rotating steam turbine comes to condenser. Thesecondensers are
heat exchangers which convertsteam fromits gaseous to its liquid state, also
known as phasetransition. In so doing, the latent heat of steam is given out inside
the condenser. Wherewater is in shortsupply an air cooled condenser is often
used.
The purpose is to get the condensed steam in the form of pure water, otherwise
known as condensate, back to steam generator or (boiler) as boiler feed water.
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Day 8th
ACCESSORIES OF THE BOILER:
1. Electro I High Level:
They are used to indicate the level of boiler drum.
2. Safety Valves:
They are used to release excess steam pressure from the stream drum.
3. Pressure Gauges:
These are installed on the streamdrumto indicate the pressurein the
boiler.
4. Economizer:
Itis arrangementof the tubes installed up take surfaceof the furnace.
All water entering in the steam drum mustpass through the
economizer.
5. Boiler feed pump:
Three boilers feed pumps having 60% capacity each delivered water to
the boiler at 190 bars. Itis driven by 3965 KW motor of 1485 rpm. The
pump is coupled through geared fluid put speed enabling pump to run
at varying speed to achieve the efficient flow control it is manufactured
by Hitachi (Tokyo).
6. Super Heater:
Itis the partof boiler which is specifically designed to raise the
temperature of the saturated steam abovethe saturation point for
designed pressureof the boiler.
7. HP ByPass:
There are 2 HP Bypass areconnected to the boiler named by a and b.
they are used to operate Temperature & pressurecontrolduring the system
Startup.
8. Thermocouple:
A thermocouple is a temperature-measuring device consisting of two
dissimilar conductors that contact each other at one or more spots.
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Thermocouples are a widely used type of temperature sensor for
measurement and control.
9. France Pressure Switch:
There are 3 pressureswitch connects to the boiler. Which show the
pressureof the boiler if the pressurehigh due to a certain value they trip, and
if 2 switch are trip boiler trip.
10. Force Draft (FD) Fan:
Forced Draft(FD) fans purposeis to providea positive pressureto a
system. This basic concept is used in a wide variety of industries but the term
FD Fans is most often found in the boiler industry. Fans for boilers force
ambient air into the boiler, typically through a preheated to increase overall
boiler efficiency. Inletor outlet dampers are used to control and maintain the
systempressure.
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Day 9th
& 10th
Attendthe Safety Hour. This Briefedabout the Personal ProtectiveEquipment
(PPE) training session.
Learning Outcomes
What is PPE?
Personalprotective equipment (PPE) refers to
protective clothing, helmets, goggles, or other garments or equipment designed
to protect the wearer's body from injury.
Protecting Employees from Workplace Hazards:
 Employers mustprotect employees fromworkplacehazards and dangerous
work procedures thatcan cause injury, illness and fatalities.
 Employers must:
• Use all feasible engineering and work practicecontrols to eliminate
and reduce hazards
• Then use appropriatePPE if these controls do not eliminate hazards
• Remember: PPE is the last control
Employee Responsibilities:
 You are responsiblefor attending all PPE training sessions
 You are responsiblefor wearing your assigned PPE
 Follow ALL Warnings and Precautions
 Listen and Follow Directions
• Listen and follow the directions that you may be given by your
supervisor or safety manager.
 Report
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• Report any and ALL unsafeconditions you may find in your work area
to your supervisor or safety manager.
Training
Employees required to use PPE mustbe trained to know at least the following
• When PPEis necessary
• What type of PPEis necessary
• How to properly put on, take off, adjust, and wear
• Limitations of the PPE
• Proper care, maintenance, usefullife and disposal
What type of PPE Use in Plant?
Eye and Face Protection:
 Safety Glasses
• much stronger and more resistantto impact and heat than regular
glasses
• equipped with side shields that give you protection fromhazards that
may not be directly in front of you
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 Goggles
• surround theeye area, they give you more protection in situations
whereyou might encounter splashing liquids, fumes, vapors,
powders, dusts, and mists
 Face Shields
• full face protection
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•
 Ear Plug:
Savefrom high noisewhich affects to ears.
 Welding Helmets
• provideboth face and eye protection
• use special absorptivelenses that filter the intense light and radiant
energy that is produced during welding operations
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Head Protection
Types of Head PPE
 Class A HardHats
• Protect you fromfalling objects
• Protect you fromelectrical shocks up to 2,200 volts
 Class B HardHats
• Protect you fromfalling objects
• Protect you fromelectrical shocks up to 20,000 volts
 Class C HardHats
• Protect you fromfalling objects
 Bump Caps
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• Bump caps are made from lightweight plastic and are designed to
protect you from bumping your head on protruding objects .
Hand Protection:
 Rubber gloves
• protect you when working around electricity.
•
Foot Protection:
 Electrostatic dissipating footwear
• Conducts static electricity to floors that are grounded.
 Electrical hazardfootwear
• Insulated with tough rubber to prevent shocks and burns from
electricity.
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Body Protection:
 InsulatedCoats and Pants
• Fire resistant
• Heat resistant
• Cold resistant
Attend training session On Programmable Logic Controllers (PLC’s)
Learning Outcomes
 A programmablelogic controller (PLC) is a digital computer, used for
automation of electromechanical processes.
o Central Processing Unit (CPU)  Processes data, carries out the logic
operations.
o InputModules  Takes input fromthe outside world (plant),
protects the CPU fromoutside world (Optical isolation).
o Output Modules  Provides outputto energize motor starters,
lights, coils, valves etc.
o Power Supply  For 24V dc voltage.
o Communication Interfaces  For programming and remote
monitoring.
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PLC ARCHITECTURE
REAL WORLD
ADDRESS
DATA
CONTROL
While Ladder Logic is the most commonly usedPLC programming language.
PROGRAM
MEMORY INPUT/OUTPUT
CENTRAL PROCESSING UNIT
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Day 11th
Attend training sessiononNetworking Topology &TransmissionNodes Basic
Hardware.
Learning Outcomes
What is Network?
A network is a collection of terminal nodes, links & any intermediate nodes which
are connected so as to enable telecommunication between the terminals.
What is Terminal?
A computer terminal is an electronic or electromechanical hardwaredevicethat is
used for entering data into, and displaying data from, a computer or
a computing system.
What is Node?
In communication networks, a node(Latin nodus, 'knot') is either a connection
point, a redistribution point or a communication endpoint (some terminal
equipment).
Types of Nodes:
Computer Network Nodes
Distributed System Nodes
End Node In Cloud Computing
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What is Network Topology?
In computer networking, topology refers to the layout of connected devices. This
article introduces the standard topologies of networking.
Topology in Network Design
 Bus Topology
A bus network is a network topology in which nodes are connected in a daisy
chain by a linear sequence of buses.
Howit works
The bus is the data link in a bus network. The bus can only transmit data in one
direction, and if any network segment is severed, all network transmission ceases.
Advantages
 Easy to connect a computer or peripheral to a linear bus
 Requires less cable length than a star topology
 Itworks wellfor small networks.
Disadvantages
 Entire network shuts down if there is a break in the main cable
 Terminators are required at both ends of the backbonecable
 Difficult to identify the problem if the entire network shuts down
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 Ring Topology
A ring network is a network topology in which each node connects to exactly two
other nodes, forming a single continuous pathway for signals through each node -
a ring. Data travel from nodeto node, with each node along the way handling
every packet.
Advantages
 Very orderly network whereevery device has access to the token and the
opportunity to transmit
 Performs better than a bus topology under heavy network load
 Does not require a central node to manage the connectivity between the
computers
Disadvantages
 Moving, adding and changing the devices can affect the network
 Communication delay is directly proportionalto number of nodes in the
network
 Bandwidth is shared on all links between device
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 Mesh Topology
A mesh network is a network topology in which each node (called a mesh node)
relays data for the network. All nodes cooperate in the distribution of data in the
network.
 Star Topology
Star networks areone of the most common computer network topologies. In its
simplest form, a star network consists of one central switch, hub or computer,
which act as a conduit to transmitmessages
Advantages
 Easy to detect faults and to remove parts.
 No disruptions to the network when connecting or removing devices.
 Installation and configuration is easy since every one device only requires a
link and one input/output port to connect it to any other device(s).
Disadvantages
 Failure of the central hub renders the network inoperable
 Communication between nodes must pass through the central hub. Therefore
if the central hub is compromised, so is all communication.
45 | P a g e
 Tree Topology
Alternatively referred to as a star bus topology, tree topology is one of the most
common network setups that is similar to a bus topology and a star topology. A
tree topology connects multiple star networks to other star networks. Below is a
visualexample of a simple computer setup on a network using the star topology.
Advantages:
 The topology makes it possibleto have a point-to-point network
 A tree network provides enough roomfor future expansion
Disadvantages:
 Dependence of the entire network on one central hub is a point of
vulnerability for this topology.
46 | P a g e
Day 12th
On this day a fire incident took place at Jamshoro Power plant, due to which
majority of the load was transferred through transmission lineto Bin Qasim
Power Plant. For the safety purposes, allthe 6 units were tripped respectively.
The plant was un-operationalfor 5 to 6 hours.
After the break in plants operations; plant was gradually broughtto its orthodox
operational condition. I observed the whole process with the team of I&C of unit
# 3.
Day 13th
On this day I visited electronic roomof unit # 3 with Mr. Imran Saeed (Sr.
Application Engineer at Solutions Engineering Private. Ltd) to check the Data
Aqusition System(DAS). I observed that image of DAS was created for backup in
case of any data loss.
As Eid holidays werestarting fromnext day, we inspected and inquired fromthe
control roomif any problemwas to be addressed; as unit 3 was to be shut down
at midnight.
Day 14th
On this morning unit 3 was again started after the gap of 1 week. I along with my
team was there in control roomto observeand contribute to smooth starting of
the unit in case any problem occurs. Weobserved the wholeprocess.
Start-up Time:
If the boiler has acquired the temperature required to startthe unit, then the
start-up time is 1-2 hours. Elseit takes around 6-7 hours.
47 | P a g e
Day 15th
This day I attended the “Safety Hour”. We were briefed about the Monsoon
weather. As this is the season when people working near electricity specially
power plants, have to be mostcareful about. A minor mistake could lead to
massiveHazards; both for the worker and also for others.
Some points we were briefed about are:
 Walk slowly.
 Do not work alone.
 Always makesurethat you have all the necessary stuff with yourself. For
Torch, Cell phone, etc.
 Make surethat your instruments areproper working condition and no
instrumentis likely to play partin damaging you or others.
 Always usePersonalProtective Equipment (Rain coat, gloves, and shoes).
 Do not walk to sensitive places like Degrer, CW pump, Boiler, etc.
unnecessarily.
As through Weather We haveto take care of our Instruments So We cleaned and
took the measures to protect our equipment fromwater.
Day 16th
There are total 12 burners for the boiler. 4 burners on each floor.
Burners have 3 main parts, namely;
 Main Gun
 Igniter Transformer
 Air Damper.
We were informed by the control roomthe Burner # 32 was constantly tripping.
We visited the burner with our team. There our senior technician inspected about
the rootcause of the problem and told us that there was problem in the Main
Gun. We informed the control roomas this was not concerned with our
department and mechanical team then dealt with this problem.
48 | P a g e
Day 17th
& 18th
Today I with Mr.Arif Mehmmod Visit to the CW Pump of Unit # 3.
CW Pump:
A pump is a specific type of pump used to circulate gases or liquids in a closed
circuit. They are commonly found circulating water in a cooling system. Because
they only circulate liquid within a closed circuit, they only need to overcomethe
friction of a piping system(as opposed to lifting a fluid froma point of lower
potential energy to a point of higher potential energy). Each Unit has 2CW Pump
if one of them is Un-operation so second Pump we used.
We attended the unit # 3 CW pump # 1 to address the complain of oil leakage in
sub unit hydrolic pump. With Mr.Arif I went on the location and checked Hydrolic
Pump, as per checked decided to firstcleaned it to solveproblem and Observed it
fromwhere Oil leakage present.
We received a complaint fromthe control roomthat the Minimum flow value
(MFV) close/open indicator switch of BFP#3 of unit #3 was not working properly. I
along with my team addressed checked the value. There our senior technician
inspected about the root cause of the problem and solved the problem

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LETTER OF AUTHORIZATION

  • 1. 1 | P a g e LETTER OF AUTHORIZATION Dear Reader, We are authorized by K-Electric limitedHumanResource, to preparea reporton “Internship atBin QasimPower Station-1,K-Electric Limited”. This is done in partial fulfillment of the Internship Program Sincerely, Moiz Akhter
  • 2. 2 | P a g e LETTER OF TRANSMITTAL K-Electric limited HR Subject: INTERNSHIP ATBIN QASIM POWER PLANT-1,K-ELECTRIC LIMITED Respected Sir/Ma’am, We are submitting our reportof “Internship”, theresultof our effort as well as our conclusion is embodied in the accompanying report. Your feedback is valuable to us. Regards, Moiz Akhter
  • 3. 3 | P a g e TABLE OF CONTENT S.NO TOPIC PAGE.NO 1 Letter of Authorization 2 Letter of Transmittal 3 Preface 4 Acknowledgement 5 Day 1st 6 Day 2nd 7 Day 3rd 8 Day 4th 9 Day 5th 10 Day 6th 11 Day 7th 12 Day 8th 13 Day 9th & 10th 14 Day 11th 15 Day 12th 16 Day 13th 17 Day 14th 18 Day 15th 19 Day 16th 20 Day 17th & 18th
  • 4. 4 | P a g e PREFACE Through different tasks and with great supportfromMr. Shams Tabrez Khan (Deputy General Manager –M I&C) wehave gained reasonableknowledge of in the field of Engineering Through this internship I have learned the useof many electronic components including switches and transducers. I havealso learned practical application of different principles. This internship also helped us getting profound knowledgeof Power Plant. Here we learned how to deal with different technical situations that can occur that usually are not part of our Academic Syllabus. This reportwill firstillustrate the basic knowledge aboutBQPS 1, and the task completed during internship, and the results shall be discussed and analyzed that our obtained.
  • 5. 5 | P a g e Acknowledgement This internship has only been successfulbecauseof the help of some people. First and foremost, I would like to thank our DGM of training Sir: SALEEM SAJJID for giving me this opportunity fromwhich I could learn many things and also for guiding me whenever his guidance was necessary. Next, I would like to thank the following withoutwhosehelp and supportI can’t able to learn anything.  Mr. Shams Tabrez Khan  Mr. Farooq-e-Azam  Mr. Arif Mehmood  Mr.Ali Raza I also wish to express my gratitude to the officials and other staff members of “Instrument And control Depart” of K-Electric who rendered their help during the period of Internship. Lastbut not least I wish to avail myself of this opportunity, express a senseof gratitude to my beloved Parents for their manual support, strength, and help and for everything. Duration of Internship Startdate: 8th July, 2014 End Date: 15th August, 2014
  • 6. 6 | P a g e Day 1st Introduction I was informed to report at K-Electric BQPS-1, Bin QasimTown HR Office reception at 7:00 am. Firstly we were briefed about policies and were given guide lines for our stay at Power Station. They provided me Apron Card & safety Hamlet. There our attendance was marked, DGM of training SALEEM SAJJID allocated me to Instrumentation & ControlDepartment. Orientation of Plant: I was briefed about Bin QasimThermalPower Station by Mr. Shams and visit the Plant under the supervision of Mr. shukat BIN QASIM’S HISTORY This plant is the biggest in Karachiand its construction is started in 1979. Initially the projects wereapproved for the installations of 6 units of 210 MW each with different phases. Hereare some important events in the history of this plant. SPECIFICATION OF THE DIFFERENT UNITS BQPS-1 has 6 Boiler Turbine Generation Units, which has a maximum capacity production of 1260 MW. The specification of each element is: Boiler: 530 C, 140 bar steam, 680 t/h Turbine: 525 C steam inlet, 3000 rpm Generator: 3000 rpm, 3 phase, 210 MW The Boiler could work on Gas and Oil both. However the overall always process remains the same. UNIT NO MANF. BOILER MANF. TURBINE MANF. GENERATOR INSTALL CAPACITY PRESENT CAPACITY COMN DATE 1 Hitachi Hitachi Hitachi 210 190 1983 2 Hitachi Hitachi Hitachi 210 180 1984 3 Deutche Ansaldo Ercolemarelli 210 120 1989 4 Deutche Ansaldo Ercolemarelli 210 150 1990 5 Hitachi Hitachi Hitachi 210 200 1991 6 Hitachi Hitachi Hitachi 210 195 1997
  • 7. 7 | P a g e Units 1,2,5,6 areconstructed by the collaboration of Japanese companies and Japanese labor while units 3,4 were installed by Italian company Ansaldo. OPERATING PRINCIPLE OF BIN QASIM POWER PLANT According to the laws of magnetic field: “A moving conductor inthe presence of magnetic fieldhas a voltage inducedin it this is the basis of generator action.” This means we need to rotate the turbine blades by means of any force,now this forcewhich is required to turn the turbine blades is the difference between different power plants. Hydrogen Plant: Hydrogenproduction is the family of industrialmethods for generating hydrogen. Currently the dominant technology for direct production is steam reforming from hydrocarbons. Many other methods areknown including electrolysis. Hydrogen is used as a coolant in generators of Bin Qasimpower plant. This type of cooling increases the efficiency by decreasing the heat which can melt the insulation, the hydrogen is kept on cooling by hydrogen coolers. WORKSHOP: Various kind of machines are present in the workshop including: 1. Lathe machine 2. Milling machine 3. Drilling Machine 4. Rolling machine 5. Welding machine 6. Electrical Furnace Parts which are fabricated mostly include sleeves. Argon welding is mostly carried out to weld parts.
  • 8. 8 | P a g e WATER TREATMENT PLANT Before the water is fed to the boiler it is treated to removeall impurities and to dematerialize it i.e. to make it dematerialized water. TRANSFORMERS USED IN BIN QASIM POWER STATION Different types of Transformers being used in Bin QasimPower Station:  6 Main Transformer(1 for each unit)  6 Auxiliary Transformer(1 for each unit)  3 Startup Transformer (1 for 2 units)
  • 9. 9 | P a g e
  • 10. 10 | P a g e Day 2nd The variety of different departments in the Plant includes:  Instrumentation & Control  Mechanical- Boiler  Mechanical- Turbine  Electrical  Electrical HVAC  Balance of Plant (B.O.P)  Operations  Civil Instrumentation & Control  Instrumentation is an art and science using instruments in a control process for the purposeof observation, measurementand control.  Instruments can beused to measureweight, density, thickness, flow, temperature, force, humidity, current, voltage, horsepower, phaseangle, power- factor, frequency, etc.  Process Control- Activities involved in ensuring a process is predictable, stable, and consistently operating at the target level of performancewith only normalvariation. There are two types of control systems: 1. Pneumatic Control Systems  Pneumatics is a section of technology that deals with the study and application of pressurized gas to produce mechanical motion.  Mechanisms which use air pressureto apply mechanical forceand displacement (work). Applications: a. Gear Shifters. b. Lifters. c. Brakes.
  • 11. 11 | P a g e 2. Electronic Control System An electronic systemis a systemthat employs electronic signals to control devices. The input of an electronic systemis provided by electronic signals. Electronic devices include semi-conducting diode, transistors, and capacitors thatthey are usually welded onto electronic circuit boards. The control systemis sub divided into open loop and closed loop system.  Open loop Control Systems: When an input signal directs the controlelement to respond, an output will be produced  Closedloopcontrol system: Compares the output with the expected resultor command status, then it takes appropriatecontrolactions to adjustthe input signal. CONTROL ROOM  Visited electronic roomand controlroom of unit 3. Each unit has its own control room.  The control systemcontrol temperature, pressureflow, level of boiler and burner etc.  If any problem in boiler for Eg : high or low of temperature, pressure, level, flow then L.E.D glow in controlroom according to their requirement
  • 12. 12 | P a g e ELECTRONIC ROOM  Each unit has its Electronic room. Electronics deals with electrical circuits that involve active electrical components such as diodes, transistor integrated circuit etc.  Electronic room is generally solid state wherethe wired networks of relays are replaced by softwarelogic running on special-purposecontrol hardware.  The fact that the logic is implemented by softwarerather than hard-wired circuitry greatly facilities the ability to make modification when needed by reprogramming rather than rewiring. Electronic  Systemoperates in 24 v dc and 4-20 mA. How signal operate in electronic room? LOCAL/FIELD MARSHALLING TURBINE CONTROL BMS ANALOG BINARY CLOSED LOOP CONTROL ROOM TRANSMITTER OPEN LOOP
  • 13. 13 | P a g e
  • 14. 14 | P a g e Day 3rd I was simply briefed about Thermal Cycle. Thermal CYCLES: Following are three main cycles that are occurring in the main cycle: 1. Condensate cycle 2. Feed water cycle 3. Steam Generation cycle Condensate cycle:  The steam from LP Turbine condenses into condenser and stores in Hot- well.  Now, condensate cycle starts fromHot-well.  Fromhot-well, we havethree suction lines for our condensate pumps (CPs). Condensate pumps aredouble stage pump.  FirstCP Main pump takes suction fromHot-well  Then condensate goes through CP second stage or CP booster pump.  Now we have three low pressureheaters (LPHs) which areused to preheat the condensatefromLP Turbine extractions.  Finally fromall these heaters, condensate is delivered to De-aerator where condensatecycle ends and after removalof dissolved gases, water is stored in feed water tank and feed-water cycle starts. Note that we have a back-up reservoir, Cold Condensate Tank (C.C.T) which stores the water and delivers it where it is required.
  • 15. 15 | P a g e
  • 16. 16 | P a g e FEED WATER CYCLE:  The feed water systemreceives condensatefromdearator storagetank.  Then pumps the feed water tank to reducehardness of water.  Through feed water high-pressureheaters 5 and 6.  Finally to the economizer inlet of the boiler, the feed water heated in the HP heaters by extraction steam and high-pressurecondensatedrains.  Suring this process the feed water is feed water systemsupplies water to cold reheat and super heater attemperators to control the steam temperature. THE FEED WATER CYCLE BFP 1, 2, 3 HP heater 5 HP heater 6 Economizer Feed Water tank De-aerator
  • 17. 17 | P a g e BOILER DRUM CONDENSER PRIMARY SUPER HEATER LP TURBINE SECONDARY SUPER HEATER TERTIARY SUPER HEATER HP TURBINE REHEATERIP TURBINE STEAM CYCLE:
  • 18. 18 | P a g e
  • 19. 19 | P a g e Day 4th TRANSFORMERS USED IN BIN QASIM POWER STATION. I was briefed about Transformer used in Bin Qasim Power Station by Mr. Shams. Different types of Transformers being used in Bin QasimPower Station:  6 Main Transformer(1 for each unit)  6 Auxiliary Transformer(1 for each unit)  3 Startup Transformer (1 for 2 units)  6 Excitation Transformer(1 for each unit)  42 Service Station Transformer(6 connected to each auxiliary and 2 connected to each startup transformer) MAIN TRANSFORMER The purpose of Main Transformer is to Step-up the generating voltage from 18KV/21KV to 220KV so that it can be used for transmission purpose. The voltage which is generated by generator is only upto 18KV/21KV since this voltage is not enough for transmission so it is step-up by Main Transformer upto 220KV which is eligible enough to transmit. 21 KV-------------->220KV------------->Transmission line The ratings are as under: HV LV Rated Power 148/247 MVA 148/247 MVA Rated Voltage 220 kV 21 kV Rated Current 389/648 A 4075/6791 A
  • 20. 20 | P a g e AUXILIARY TRANSFORMER Auxiliary Transformers areused in order to run auxiliary (big) motors like Boiler Feed Pump (BFP) and several different motors used in turbine/Boilers/Generators. The primary voltage of Auxiliary Transformer is 21KV which is step down to 6.6KV.Theconnection is given such that Auxiliary Transformer is given a supply from21KV Generated Voltage line which steps it down to 6.6KV thus enabling to operate Auxiliary Motors.
  • 21. 21 | P a g e Generated voltage -----------------> Auxiliary Motors (21 KV) (6.6 KV) HV LV1 LV2 MVA Ratings ONAN 21.6 10.8 10.8 ONAF 36 18 18 Voltage Ratings 21000 6600 6600 BIL (kV) Line 125 60 60
  • 22. 22 | P a g e START-UP TRANSFORMER Start-up Transformer is used when there is a total shutdown of plant i.e. neither of the units is being able to generate the supply. Now there is only the Start-up transformer which is the solution to this failure. Since the bus bar in operation have both the incoming and outgoing possibility so in case of complete shutdown of all units within Bin Qasim Power Station, the emergency bus bar will import a 220KV supply from outer stations which in turn provides a supply to Start-up Transformer that steps it down to 6.6KV so that Auxiliary Motors which requires 6.6KV to run the necessary motors could be restarted, thus enabling the unit to restart its operation inspite of the failure occurrence. Bus Bar Line ----------> Start-up Transformer ------------> For Auxiliaries (220 KV) (6.6 KV) HV LV1 Lv2 MVA Ratings ONAN 26.4 13.2 13.2 ONAF 44 22 22 Voltage Ratings 220 kV 6.6 kV 6.6 kV BIL (kV) LINE 950 60 60 NEUTRAL 150 - -
  • 23. 23 | P a g e EXCITATION TRANSFORMER Excitation Transformer steps down the generated voltage i.e. 21kV to 0.47kV. This 0.47kV is converted into DC by using Thyristor stacks and then feed to the rotor of the generator for excitation so the generator could start. The ratings are as under. LV HV 470 V Rated Voltage 21000 V 2580 A Rated Current 57.7 A SERVICE TRANSFORMER Itfurther steps down 6.6 KV into 400 V for lighting and for general purposebut very important small motors like gear motor, motors used for lubrication purpose etc. Rated Power 1600 KVA Rated Voltage: 6.6/0.4 KV Rated Current: 139.9/2309.4 A
  • 24. 24 | P a g e Day 5th BOILER A boiler is a strong metal tank or vessel composed of tubes, drums and header in which water is heated by the gases of combustion from steam. Boiler is a steam generator gets input as Air, Water, Fuel and some source to Burn the Fuel and outputs Steam and Flue Gases Each Boiler has 12 burners. 4 burners at Each Floor. CLASSIFICATION OF BOILER There are two types of boiler: FIRE TUBE BOILER In this type, the combustion gases flow thought the tube and water remains outside of the tubes. Some auxiliary boilers are example of fire type boiler.
  • 25. 25 | P a g e WATER TUBE BOILER In the type of boiler water remain inside the tube while combustion gas flow outside tubes and heated the water when they come in the contact with the internal surface of the tube all boiler used for propulsion plants water tube boiler. BOILER AT BIN QASIM The boiler for 210MW is Single DrumRadiant Water Tube Boiler “EL-PASO” Type which has self-drainableheating surface. The unit is of pressurized furnacedesign with two regenerative air heater, two FDFs, two GRFs(Gas Recirculation Fan). The flue gases are discharged by one chimney, mounted on the boiler steel structure.
  • 26. 26 | P a g e Day 6th Attend the Safety Hour In the Workshop. In which Briefed aboutthe Environmental pollution. Environmental pollution: One of the greatest problems that the world is facing today is that of environmentalpollution, increasing with every passing year and causing grave and irreparabledamage to the earth. Environmentalpollution consists of Four basic types of pollution are Following…  Air Pollution  Water Pollution  Noise pollution  Soil Pollution Air Pollution: Air pollution is by far the mostharmfulform of pollution in our environment. Air pollution is cause by the injurious smokeemitted by cars, buses, trucks, trains, and factories, namely sulphur dioxide, carbon monoxide and nitrogen oxides. Evidence of increasing air pollution is seen in lung cancer, asthma, allergies, and various breathing problem. Water Pollution: Water pollution caused industrialwasteproducts released into lakes, rivers, and other water bodies, has made marine life no longer hospitable. Humans pollute water with large scaledisposalof garbage, flowers, ashes and other household waste.
  • 27. 27 | P a g e Noise pollution: Noise pollution, soil pollution and light pollution too are the damaging the environmentat an alarming rate. Noise pollution include aircraft noise, noise of cars, buses, and trucks, vehiclehorns, loudspeakers, and industry noise, as well as high-intensity sonar effects which are extremely harmfulfor the environment. Soil pollution: Soil pollution, which can also be called soil contamination, is a result of acid rain, polluted water, fertilizers etc., which leads to bad crops. In this safety Hour discuss aboutthe Basic types of pollution how it affects to our health and if didn’tcontrol pollution, its increase and harmfull for our us and our family members, and told how to controlpollution in our Environment for better Life. Unit # 3 Trip: Yesterday Unit # 3 tripped because of the Leakage occurred in the Line of Boiler, which resulted in stopping steam production. Sincesteam was not being produced as per requirement, Turbine stop rotating and generation of electricity was suspended. TheUnit was nonoperationalfor 24 hours. I observed thewhole Process of the Unit startup in control Room.
  • 28. 28 | P a g e Day 7th Description about the Steam generation Cycle. ECONOMIZER It is horizontal continuous tube type and located beneath horizontal section of the primary super heater economizer is arranged for counter flow of gases and water and flow of water in economizer to upper ward to the drum. BOILER DRUM/STEAM DRUMS It is pressed to full hemi spherical shape is placed and fusion welded to shell The drum is provided with two main hole covers. Feed water pipes from the economizer out let are connected with nozzles with both hands of the drum and feed water is fed inside drum through hydro clone. The main function of the steam drum is to separate completely water from mixture of the steam and water through cyclone separator and scrubbers are installed inside the steam drum. SUPER HEATER: Most of the modern boilers are having super heater and reheater arrangement. Super heater is a componentof a steam-generating unit in which steam, after it has left the boiler drum, is heated above its saturation temperature. The amount of superheatadded to the steam is influenced by the location, arrangement, and amount of super heater surfaceinstalled, as well as the rating of the boiler. REHEATER : Some of the heat of superheated steam is used to rotate the turbine where it loses some of its energy. Reheater is also steam boiler component in which heat is added to this intermediate-pressuresteam, which has given up someof its energy in expansion through the high-pressureturbine. The steam after reheating is used to rotate the second steam turbine.
  • 29. 29 | P a g e PRIMARY SUPER HEATER The primary super heater low temperature section is located in interstate of boiler pass above the economizer and high temperature section above repeater section and arranged for the counter flow. SECONDARY SUPER HEATER Secondary section is located in the furnace exit zone where gas temperature is relatively high and arranged parallel flow. TERTIARY SUPER HEATER: Tertiary section is located between secondary and repeater section and arranged parallel flow. Super heater is supported from the enclosure boiler tube wall extended from the furnace wall with support lugs and spacers are constructed so as to suitable fuel oil having appreciable vanadium content. CONDENSER: Steam after rotating steam turbine comes to condenser. Thesecondensers are heat exchangers which convertsteam fromits gaseous to its liquid state, also known as phasetransition. In so doing, the latent heat of steam is given out inside the condenser. Wherewater is in shortsupply an air cooled condenser is often used. The purpose is to get the condensed steam in the form of pure water, otherwise known as condensate, back to steam generator or (boiler) as boiler feed water.
  • 30. 30 | P a g e
  • 31. 31 | P a g e Day 8th ACCESSORIES OF THE BOILER: 1. Electro I High Level: They are used to indicate the level of boiler drum. 2. Safety Valves: They are used to release excess steam pressure from the stream drum. 3. Pressure Gauges: These are installed on the streamdrumto indicate the pressurein the boiler. 4. Economizer: Itis arrangementof the tubes installed up take surfaceof the furnace. All water entering in the steam drum mustpass through the economizer. 5. Boiler feed pump: Three boilers feed pumps having 60% capacity each delivered water to the boiler at 190 bars. Itis driven by 3965 KW motor of 1485 rpm. The pump is coupled through geared fluid put speed enabling pump to run at varying speed to achieve the efficient flow control it is manufactured by Hitachi (Tokyo). 6. Super Heater: Itis the partof boiler which is specifically designed to raise the temperature of the saturated steam abovethe saturation point for designed pressureof the boiler. 7. HP ByPass: There are 2 HP Bypass areconnected to the boiler named by a and b. they are used to operate Temperature & pressurecontrolduring the system Startup. 8. Thermocouple: A thermocouple is a temperature-measuring device consisting of two dissimilar conductors that contact each other at one or more spots.
  • 32. 32 | P a g e Thermocouples are a widely used type of temperature sensor for measurement and control. 9. France Pressure Switch: There are 3 pressureswitch connects to the boiler. Which show the pressureof the boiler if the pressurehigh due to a certain value they trip, and if 2 switch are trip boiler trip. 10. Force Draft (FD) Fan: Forced Draft(FD) fans purposeis to providea positive pressureto a system. This basic concept is used in a wide variety of industries but the term FD Fans is most often found in the boiler industry. Fans for boilers force ambient air into the boiler, typically through a preheated to increase overall boiler efficiency. Inletor outlet dampers are used to control and maintain the systempressure.
  • 33. 33 | P a g e Day 9th & 10th Attendthe Safety Hour. This Briefedabout the Personal ProtectiveEquipment (PPE) training session. Learning Outcomes What is PPE? Personalprotective equipment (PPE) refers to protective clothing, helmets, goggles, or other garments or equipment designed to protect the wearer's body from injury. Protecting Employees from Workplace Hazards:  Employers mustprotect employees fromworkplacehazards and dangerous work procedures thatcan cause injury, illness and fatalities.  Employers must: • Use all feasible engineering and work practicecontrols to eliminate and reduce hazards • Then use appropriatePPE if these controls do not eliminate hazards • Remember: PPE is the last control Employee Responsibilities:  You are responsiblefor attending all PPE training sessions  You are responsiblefor wearing your assigned PPE  Follow ALL Warnings and Precautions  Listen and Follow Directions • Listen and follow the directions that you may be given by your supervisor or safety manager.  Report
  • 34. 34 | P a g e • Report any and ALL unsafeconditions you may find in your work area to your supervisor or safety manager. Training Employees required to use PPE mustbe trained to know at least the following • When PPEis necessary • What type of PPEis necessary • How to properly put on, take off, adjust, and wear • Limitations of the PPE • Proper care, maintenance, usefullife and disposal What type of PPE Use in Plant? Eye and Face Protection:  Safety Glasses • much stronger and more resistantto impact and heat than regular glasses • equipped with side shields that give you protection fromhazards that may not be directly in front of you
  • 35. 35 | P a g e  Goggles • surround theeye area, they give you more protection in situations whereyou might encounter splashing liquids, fumes, vapors, powders, dusts, and mists  Face Shields • full face protection
  • 36. 36 | P a g e •  Ear Plug: Savefrom high noisewhich affects to ears.  Welding Helmets • provideboth face and eye protection • use special absorptivelenses that filter the intense light and radiant energy that is produced during welding operations
  • 37. 37 | P a g e Head Protection Types of Head PPE  Class A HardHats • Protect you fromfalling objects • Protect you fromelectrical shocks up to 2,200 volts  Class B HardHats • Protect you fromfalling objects • Protect you fromelectrical shocks up to 20,000 volts  Class C HardHats • Protect you fromfalling objects  Bump Caps
  • 38. 38 | P a g e • Bump caps are made from lightweight plastic and are designed to protect you from bumping your head on protruding objects . Hand Protection:  Rubber gloves • protect you when working around electricity. • Foot Protection:  Electrostatic dissipating footwear • Conducts static electricity to floors that are grounded.  Electrical hazardfootwear • Insulated with tough rubber to prevent shocks and burns from electricity.
  • 39. 39 | P a g e Body Protection:  InsulatedCoats and Pants • Fire resistant • Heat resistant • Cold resistant Attend training session On Programmable Logic Controllers (PLC’s) Learning Outcomes  A programmablelogic controller (PLC) is a digital computer, used for automation of electromechanical processes. o Central Processing Unit (CPU)  Processes data, carries out the logic operations. o InputModules  Takes input fromthe outside world (plant), protects the CPU fromoutside world (Optical isolation). o Output Modules  Provides outputto energize motor starters, lights, coils, valves etc. o Power Supply  For 24V dc voltage. o Communication Interfaces  For programming and remote monitoring.
  • 40. 40 | P a g e PLC ARCHITECTURE REAL WORLD ADDRESS DATA CONTROL While Ladder Logic is the most commonly usedPLC programming language. PROGRAM MEMORY INPUT/OUTPUT CENTRAL PROCESSING UNIT
  • 41. 41 | P a g e Day 11th Attend training sessiononNetworking Topology &TransmissionNodes Basic Hardware. Learning Outcomes What is Network? A network is a collection of terminal nodes, links & any intermediate nodes which are connected so as to enable telecommunication between the terminals. What is Terminal? A computer terminal is an electronic or electromechanical hardwaredevicethat is used for entering data into, and displaying data from, a computer or a computing system. What is Node? In communication networks, a node(Latin nodus, 'knot') is either a connection point, a redistribution point or a communication endpoint (some terminal equipment). Types of Nodes: Computer Network Nodes Distributed System Nodes End Node In Cloud Computing
  • 42. 42 | P a g e What is Network Topology? In computer networking, topology refers to the layout of connected devices. This article introduces the standard topologies of networking. Topology in Network Design  Bus Topology A bus network is a network topology in which nodes are connected in a daisy chain by a linear sequence of buses. Howit works The bus is the data link in a bus network. The bus can only transmit data in one direction, and if any network segment is severed, all network transmission ceases. Advantages  Easy to connect a computer or peripheral to a linear bus  Requires less cable length than a star topology  Itworks wellfor small networks. Disadvantages  Entire network shuts down if there is a break in the main cable  Terminators are required at both ends of the backbonecable  Difficult to identify the problem if the entire network shuts down
  • 43. 43 | P a g e  Ring Topology A ring network is a network topology in which each node connects to exactly two other nodes, forming a single continuous pathway for signals through each node - a ring. Data travel from nodeto node, with each node along the way handling every packet. Advantages  Very orderly network whereevery device has access to the token and the opportunity to transmit  Performs better than a bus topology under heavy network load  Does not require a central node to manage the connectivity between the computers Disadvantages  Moving, adding and changing the devices can affect the network  Communication delay is directly proportionalto number of nodes in the network  Bandwidth is shared on all links between device
  • 44. 44 | P a g e  Mesh Topology A mesh network is a network topology in which each node (called a mesh node) relays data for the network. All nodes cooperate in the distribution of data in the network.  Star Topology Star networks areone of the most common computer network topologies. In its simplest form, a star network consists of one central switch, hub or computer, which act as a conduit to transmitmessages Advantages  Easy to detect faults and to remove parts.  No disruptions to the network when connecting or removing devices.  Installation and configuration is easy since every one device only requires a link and one input/output port to connect it to any other device(s). Disadvantages  Failure of the central hub renders the network inoperable  Communication between nodes must pass through the central hub. Therefore if the central hub is compromised, so is all communication.
  • 45. 45 | P a g e  Tree Topology Alternatively referred to as a star bus topology, tree topology is one of the most common network setups that is similar to a bus topology and a star topology. A tree topology connects multiple star networks to other star networks. Below is a visualexample of a simple computer setup on a network using the star topology. Advantages:  The topology makes it possibleto have a point-to-point network  A tree network provides enough roomfor future expansion Disadvantages:  Dependence of the entire network on one central hub is a point of vulnerability for this topology.
  • 46. 46 | P a g e Day 12th On this day a fire incident took place at Jamshoro Power plant, due to which majority of the load was transferred through transmission lineto Bin Qasim Power Plant. For the safety purposes, allthe 6 units were tripped respectively. The plant was un-operationalfor 5 to 6 hours. After the break in plants operations; plant was gradually broughtto its orthodox operational condition. I observed the whole process with the team of I&C of unit # 3. Day 13th On this day I visited electronic roomof unit # 3 with Mr. Imran Saeed (Sr. Application Engineer at Solutions Engineering Private. Ltd) to check the Data Aqusition System(DAS). I observed that image of DAS was created for backup in case of any data loss. As Eid holidays werestarting fromnext day, we inspected and inquired fromthe control roomif any problemwas to be addressed; as unit 3 was to be shut down at midnight. Day 14th On this morning unit 3 was again started after the gap of 1 week. I along with my team was there in control roomto observeand contribute to smooth starting of the unit in case any problem occurs. Weobserved the wholeprocess. Start-up Time: If the boiler has acquired the temperature required to startthe unit, then the start-up time is 1-2 hours. Elseit takes around 6-7 hours.
  • 47. 47 | P a g e Day 15th This day I attended the “Safety Hour”. We were briefed about the Monsoon weather. As this is the season when people working near electricity specially power plants, have to be mostcareful about. A minor mistake could lead to massiveHazards; both for the worker and also for others. Some points we were briefed about are:  Walk slowly.  Do not work alone.  Always makesurethat you have all the necessary stuff with yourself. For Torch, Cell phone, etc.  Make surethat your instruments areproper working condition and no instrumentis likely to play partin damaging you or others.  Always usePersonalProtective Equipment (Rain coat, gloves, and shoes).  Do not walk to sensitive places like Degrer, CW pump, Boiler, etc. unnecessarily. As through Weather We haveto take care of our Instruments So We cleaned and took the measures to protect our equipment fromwater. Day 16th There are total 12 burners for the boiler. 4 burners on each floor. Burners have 3 main parts, namely;  Main Gun  Igniter Transformer  Air Damper. We were informed by the control roomthe Burner # 32 was constantly tripping. We visited the burner with our team. There our senior technician inspected about the rootcause of the problem and told us that there was problem in the Main Gun. We informed the control roomas this was not concerned with our department and mechanical team then dealt with this problem.
  • 48. 48 | P a g e Day 17th & 18th Today I with Mr.Arif Mehmmod Visit to the CW Pump of Unit # 3. CW Pump: A pump is a specific type of pump used to circulate gases or liquids in a closed circuit. They are commonly found circulating water in a cooling system. Because they only circulate liquid within a closed circuit, they only need to overcomethe friction of a piping system(as opposed to lifting a fluid froma point of lower potential energy to a point of higher potential energy). Each Unit has 2CW Pump if one of them is Un-operation so second Pump we used. We attended the unit # 3 CW pump # 1 to address the complain of oil leakage in sub unit hydrolic pump. With Mr.Arif I went on the location and checked Hydrolic Pump, as per checked decided to firstcleaned it to solveproblem and Observed it fromwhere Oil leakage present. We received a complaint fromthe control roomthat the Minimum flow value (MFV) close/open indicator switch of BFP#3 of unit #3 was not working properly. I along with my team addressed checked the value. There our senior technician inspected about the root cause of the problem and solved the problem