INTERNSHIP REPORT

PAKISTAN STEEL

SUBMITTED TO : Incharge HRD

SUBMITTED BY : Hammad Mustafa
Saad Latif
Izhar Ahmed
Soban Umer Sheikh
Muhammad Osaf
TECHONOLOGY : Mechanical Engineering
NO. OF WEEK : Four (4)
PERIOD OF TRAINING FROM : 27-05-2019 TO 20-06-
2019
NAME OF UNIVERSITY : NED University of
Engineering & Technology
 PAKISTAN STEEL MILL

PREFACE
This report content the briefing of selected four departments namely MR&HT, MERS, PERS
and TPP, which we have visited for the purpose to understand the procedure which are follows
in this corporation to run the daily operation.
At the first part of this report, we address MRHT (Mechanical Repairing and Heat Treatment)
Department. In this department mechanical parts are repaired and manufactured. With the use
of different heat treatment process, we get the metal of our desired requirement. In this
department different machines carried out manufacturing and repairing like lathe machine,
drilling machines, welding machines, milling machines, planner, shaper etc.
Next department, which this report will discuss is MERS (Mechanical Equipment Repair Shop)
which plays a vital role in the Pakistan steel, which have two important role that is repair and
maintenance. It include maintenance, retrofitting, installation, engineering calibration,
fabricating, welding, balancing, vibration analysis. Alignment, plant relocations, inspection,
cleaning, cutting, hardening/annealing, soldering, brazing, staffing and testing. One of the main
purpose is maintenance, every department contains heavy machinery which has to be maintain
time to time to be work properly.
Third part of this report consists on PERS-M (Power Equipment Repair Shop) in which internal
Mechanical part of Power machine such as pumps, roller bearings are repaired. This department
Works along and adjacent to PERS-E (electrical), in which motor and electrical systems are
Repaired. There is a section in PERS-M called Babbitting section, where babbitting process is
applied on bearings. Babbitt is a process where metal alloys of Tin, Copper, Cadmium and
Lead are used as a sliding bearing material due to which material wear resistance increases.
At last, we describe the TPP (Thermal Power Plant) which is used for the generation of
electricity for Pakistan Steel. TPP consist of five sections namely Water chemical treatment
plant, Boiler, Turbine, Generator and Main switch gear room (MSGR). Due to this department,
Pakistan steel fills the requirement of energy for the industry as well as for the staff and the
remaining energy is given to K-Electric.

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ACKNOWLEDGEMENT

We are very thankful from the core of us to honorable Chief Executive Officer, Pakistan
Steel, for providing us opportunity for training and who’s intelligent, wise and sound leadership
has converted manpower into winning combination by this industry into a Gold mine.

We wish to express our deep gratefulness to Riaz Hussain Mangi, ADGM/ Incharge
(A&P/HRD) for his consideration and supervision. It was a memorable time in Pakistan Steel
due to his kind concern.

We are also thankful to Mr. Badaruddin Pirzada Incharge (HRD), & Mr. akhlaq Alam,
Section Head (IPD)HRD for his precious advice and for the great encouragement and
corporation because of which we have successfully completed u internship training at Pakistan
Steel, where we learned a lot.

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Contents
1. MECHANICAL REPAIRING AND HEAT TREATMENT (MRHT): ........................................................... 7
LATHE MACHINES: .............................................................................................................................. 7
DRILLING: ............................................................................................................................................ 7
TYPES OF DRILLS .............................................................................................................................. 7
RADIAL DRILLING MACHINES .......................................................................................................... 7
PILLAR DRILLING MACHINES ........................................................................................................... 8
DRILLING CUM MILLING MACHINES ............................................................................................... 8
WELDING:............................................................................................................................................ 8
WITHOUT APPLICATION OF HEAT: .................................................................................................. 8
WITH APPLICATION OF HEAT: ......................................................................................................... 8
GEAR MANUFACTURING:.................................................................................................................... 9
GEAR MILLING: ................................................................................................................................ 9
GEAR HOBBING: .............................................................................................................................. 9
GEAR SHAPING ................................................................................................................................ 9
BEVEL GEAR CUTTING ..................................................................................................................... 9
MILLING:............................................................................................................................................ 10
TYPES OF MILLING USED IN MRHT:............................................................................................... 10
PERIPHERAL MILLING: ................................................................................................................... 10
TYPES OF MILLING MACHINES: ......................................................................................................... 10
VERTICAL MILLING MACHINES ...................................................................................................... 10
HORIZONTAL MILLING: ................................................................................................................. 10
SHAPER MACHINE PROCESS ......................................................................................................... 10
PLANNER MACHINE: ..................................................................................................................... 11
HEAT TREATMENT:............................................................................................................................ 11
HEAT TREATMENT PROCESS: ............................................................................................................ 11
HARDENING: ................................................................................................................................. 11
ANNEALING: .................................................................................................................................. 11
NORMALIZING ............................................................................................................................... 12
TEMPERING ................................................................................................................................... 12
CARBURIZATION............................................................................................................................ 12
SURFACE HARDENING ................................................................................................................... 12
2. MECHANICAL EQUIPMENTS REPAIR SHOP (MERS): ..................................................................... 13
EQUIPMENT REPAIR: ......................................................................................................................... 13
PRODUCTS:........................................................................................................................................ 14

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Billets ............................................................................................................................................. 14
HOT ROLL PRODUCTS:................................................................................................................... 15
COLD ROLLED PRODUCTS: ............................................................................................................ 16
3. POWER EQUIPMENT REPAIR SHOP-MECHANCAL (PERS-M)......................................................... 17
4. THERMAL POWER PLANT AND TURBO BLOWER STATION (TPP-TBS)........................................... 18
WATER CHEMICAL TREATMENT PLANT (WCTP): .............................................................................. 18
TEMPORARY HARDNESS ............................................................................................................... 18
PERMANENT HARDNESS ............................................................................................................... 19
BOILER: .............................................................................................................................................. 19
BOILER PARTS:................................................................................................................................... 19
BURNER: ........................................................................................................................................ 19
BOILER DRUM: .............................................................................................................................. 19
IDF AND FDF: ................................................................................................................................. 20
TURBINE: ........................................................................................................................................... 20
TURBINE PARTS: ................................................................................................................................ 20
STOP VALVE................................................................................................................................... 20
REGULATOR:.................................................................................................................................. 20
GOVERNOR:................................................................................................................................... 20
SERVO MOTOR: ............................................................................................................................. 20
BEARING GEAR: ............................................................................................................................. 21
OIL PUMP: ..................................................................................................................................... 21
OIL: ................................................................................................................................................ 21
MAIN PARAMETERS OF TURBINE INTALLED IN TPP:......................................................................... 21
MAIN PARAMETERS OF COMPRESSOR INTALLED IN TPP: ................................................................ 22
GENERATOR: ..................................................................................................................................... 22
GENERATOR SPECIFICATIONS: .......................................................................................................... 22
...................................................................................................................................................... 23
GENERATOR COOLING: ................................................................................................................. 23
MAIN SWITCH GEAR ROOM (MSGR): ............................................................................................... 23
CONTROL ROOM: .......................................................................................................................... 23
DC BATTERIES: ............................................................................................................................... 23
ADVANTAGES AND DISADVANTAGES OF THERMAL POWER PLANT: ............................................... 23
ADVANTAGES: ............................................................................................................................... 23
DISADVANTAGES: .......................................................................................................................... 23
CONCLUSION:........................................................................................................................................ 24

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1. MECHANICAL REPAIRING AND HEAT TREATMENT (MRHT):

Abbreviation of MRHT is mechanical repairing and heat treatment here mechanical parts
are repaired and manufactured. With the use of different heat treatment process we get the
metal of our desired requirement.
Manufacturing and repairing works in this department is done with the help of different
machines. Major machines i.e. lathe machine, drilling machines, welding machines, gear
manufacturing machines, milling machines, planner, and shaper. This Department consist of
sections which are as Bay I, Bat II, Heat Treatment Section, and Tool Room & Assembly
Section.

LATHE MACHINES:
A lath Machine is used for cutting, drilling, knurling and other related machine operations.
Lath is one of the old machines that are used for cutting and knurling operations. This machine
has the property of producing a three-dimensional surface.

DRILLING:
Drilling the holes into solid materials like metal or wood
surfaces is a tough job and it takes a lot of time and efforts.
Therefore, for these tough jobs, a special type of machine used
called Drilling machine or Drill machine. Drill machine uses to
drill the holes into metal surfaces harder surfaces which is
impossible to do with manual force. Drill machine used in the
construction and some home repairing and improvement tasks.

TYPES OF DRILLS
Major types are listed below:
RADIAL DRILLING MACHINES
Radial drilling machine in which drilling head is fitted on the radial arm. The radial arm in
these machines can be rotated, raised as well as lowered as per the requirement

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PILLAR DRILLING MACHINES

Pillar drilling machines are offered in sturdy and economical formats. You can add advanced
technology features in these machines. Pillar drill machines are known for their higher
efficiency and precision in the tasks.
DRILLING CUM MILLING MACHINES
Drilling cum milling machines are the multi-functional devices. They can be used for both
drilling and milling works.

WELDING:
Welding is a process of permanently joining two metals together with the application of heat
which is used in assembly section for the purpose of Steel.

WITHOUT APPLICATION OF HEAT:

Cold Welding process which is completed with the help of pressure applied only. Generally
adopted for ductile and malleable metals of less thicknesses. Bonding is surface to surface
resulted due to exchange of molecules.

WITH APPLICATION OF HEAT:

 FUSION WELDING / NON-PRESSURE WELDING

The process deals with metals in molten state i.e. metal is heated up to molten state and then
solidification results the joining. Arc welding, TIG welding, MIG welding, submerged arc
welding, Flame welding etc.

 NON FUSION WELDING PROCESS/ PRESSURE WELDING PROCESS

The metal is in plastically molten state and joined with the help of pressure applied. All
resistance welding processes comes under this heading such as spot welding, seam welding,
projection welding etc.

 ADVANCED METHODS OF WELDING

Metals are heated with the help of non-conventional heating sources and then solidification
results the welds. Sources such as Laser Beam, Electron Beam, and Ultrasonic Mediums etc.
are used to generate the required heat for the welding processes.

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GEAR MANUFACTURING:
Gear manufacturing basically is categorized based on the type of gear to be manufactured.
The types of gears can be classified as follows:
1. Spur
2. Helical
3. Worm Gears
4. Bevel Gears
The manufacturing methodology involved for manufacturing of the above types of gears
defines the types of machines to be used. The various production methods for producing the
above mentioned gears by machining are as follows.

GEAR MILLING:
This method requires the usage of a milling machine. It is also to be noted that this method
can produce nearly all types of gears. The method involves the use of a form cutter, which is
passed through the gear blank to create the tooth gap.

GEAR HOBBING:
Gear Hobbing is a continuous generating process in which the tooth flanks of the constantly
moving work piece are formed by equally spaced cutting edges of the hob. The main advantage
of this process is its versatility to produce a variety of gears including Spur, Helical, Worm
Wheels, Serrations, Splines, etc.

GEAR SHAPING
Gear shaping is a generating process. The cutter used is virtually a gear provided with
cutting edges. The tool is rotated at the required velocity ratio relative to the gear to be
manufactured and any one manufactured gear tooth space is formed by one complete cutter
tooth. This method can be used to produce cluster gears, internal gears, racks, etc. with ease,
which may not have the possibility to be manufactured in gear hobbing.
BEVEL GEAR CUTTING
This involves a special type of machine for each variety of the bevel gear to be
manufactured. Some of the bevel gear types along with the type of machines required are
Gleason, Oerlikon, Hypoid, Zerol, etc. Each type of bevel gear is always manufactured only
on the corresponding type of machine against its name.

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MILLING:
Milling is a cutting process that uses a milling cutter to remove material from the surface of
a work piece.
TYPES OF MILLING USED IN MRHT:
FACE MILLING:

In face milling, the cutting action occurs primarily at the end corners of the milling cutter.
Face milling is used to cut flat surfaces (faces) into the work piece, or to cut flat-bottomed
cavities.

PERIPHERAL MILLING:
In peripheral milling, the cutting action occurs primarily along the circumference of the
cutter, so that the cross section of the milled surface ends up receiving the shape of the cutter.
In this case the blades of the cutter can be seen as scooping out material from the work piece.
Peripheral milling is well suited to the cutting of deep slots, threads, and gear teeth.

TYPES OF MILLING MACHINES:

VERTICAL MILLING MACHINES
In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the
spindle and rotate on its axis. The spindle can generally be extended (or the table can be
raised/lowered, giving the same effect).
HORIZONTAL MILLING:
A horizontal mill has the same sort but the cutters are mounted on a horizontal spindle across
the table.
SHAPER MACHINE PROCESS

The shaper process can be defined as a process for removing metal from the surface in
horizontal, vertical and angular planes by the use of a single point cutting tool held in a ram
that reciprocates the tool in a linear direction across the work piece held on the table of the
machine.

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PLANNER MACHINE:
The planer machine is similar to a shaper machine. It intended to produce plane and flat
surfaces

HEAT TREATMENT:
Heat treatment is heating and cooling of metals to change their physical and mechanical
properties without letting it change its shape this is done to strengthen material but could also
be used to alter some mechanical properties such as improving formability, machining etc.

HEAT TREATMENT PROCESS:

HARDENING:
Hardening is a metallurgical metalworking process
used to increase the hardness of a metal. The hardness
of a metal is directly proportional to the uniaxial yield
stress at the location of the imposed strain. A harder
metal will have a higher resistance to plastic
deformation than a less hard metal.
ANNEALING:
In metallurgy and materials science, annealing is a
heat treatment that alters the physical and sometimes
chemical properties of a material to increase its ductility
and reduce its hardness, making it more workable. It
involves heating a material above its recrystallization
temperature, maintaining a suitable temperature for a
suitable amount of time, and then cooling.

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NORMALIZING:
Normalizing refers to a heat treatment process that is
used to regulate internal material stress. Normalizing
reduces the rate of corrosion that may be experienced by a
metallic surface and also increases the strength and
hardness of the steel.
TEMPERING:
Tempering is a process of heat treating, which is used to
increase the toughness of iron-based alloys.
CARBURIZATION:
Carburization is a heat treatment process in which iron or
steel absorbs carbon while the metal is heated in the
presence of a carbon-bearing material, such as charcoal or
carbon monoxide. The intent is to make the metal harder
SURFACE HARDENING:
In many engineering applications it is necessary to have
the surface of component hard enough to resist wear and erosion while maintaining ductility
and toughness to with stand impact and shock loading this can be achieved by local austenizing
and quenching and diffusion of hardening elements like carbon or nitrogen into the surface
.Process involved for the purpose are known as flame hardening nitriding and carbonitriding.
Heat treatment process are performed by using different furnaces.

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2. MECHANICAL EQUIPMENTS REPAIR SHOP (MERS):

MERS is one of the most important department which plays a vital role in the Pakistan steel
mill, which have 2 important role that is repair and maintenance.

EQUIPMENT REPAIR:
Repair and maintenance services for
mining, steel milling, and foundry equipment.
Capabilities include proactive, predictive, and
preventive maintenance, emergency on-site
repair, shutdown inspection, and outage work
services. Steel mill equipment repair
services. Capabilities include maintenance,
retrofitting, installation, design, building,
engineering, calibration, fabricating, welding,
and balancing and vibration analysis. Other
services include alignment, contracting, plant
relocations, inspection, machining, cleaning,
cutting, hardening/annealing, soldering,
brazing, staffing and testing.
Some of the machine trip or shutdown during the process so emergency team of MERS
went on the site and first check the problem that cause the shutdown and then starting them to
repair, some of the machine is not be shut down because it will damage the production rate so
it is to be repair in no time so it can be operate if the repair cannot be done on the sit then the
machine or the damaged part is move to MERS department by means of crane or carts.
One of the common part to be repair is gear. Some gears just cannot be properly repaired.
Cracks, for example, require complete removal. There are shops willing to repair weld teeth,
and while I salute them for their patience and artistry, I do not want to be associated with the
results. If you weld anything, even far away from the gear teeth, you have to do a thorough
check for cracks following the post-weld stress relief. Some of the gear cannot be repair so they
have to change it immediately.

Maintenance:
One of the main purpose is maintenance, every department contains heavy machinery
which has to be maintain time to time to be work properly. The use of condition monitoring
in steel plants can turn more of the critical unknowns into known.

The production of steel and other sheet and rolled metals (e.g. iron) in plants / mills relies
upon heavy plant equipment operating under extreme conditions. This means that the
lubricants used in these circumstances require constant monitoring and maintenance. Such
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monitoring techniques have moved from being viewed as an extravagance, to their new
position as relevant and necessary tools.

Vital parameters to be monitored in steel plants and steel mills include:

 Quality control of roll plate surfaces, providing a quantitative analysis of debris on
adhesive sample tape surfaces

 Maintenance and monitoring of ferrous debris in quench lines for rolling mills

 The continuous monitoring of metal particle levels and sizes in stainless steel quench
oil can improve production quality and reduce waste, resulting in higher profits

By the collaboration of other departments time table is made, and then the time table is given
to the different department in which the date and time of the maintenance id given so the
department have to shortly stop to the machine to be maintain.

PRODUCTS:
Billets
Pakistan Steel billets are produced to
tight tolerances, high surface finish and
superior quality. Pakistan Steel's high
quality billets are used for
Manufacturing plain, deformed, twisted
and ribbed bars. Manufacturing steel
sections via, rails, angles, joints,
channels, squares, flat bars, rods, wire
rods, bailing hoops, tees and chains etc.
Manufacturing seamless pipes.
Manufacturing of machine components.
Forging and stamping. Manufacturing of spring steel flat bars.

SIZES & TOLERANCES

Hot Rolled Steel Billets

Size Of Square Length Radius Of Round Tolerance Limit From

Ends Side Of The Square
50mm up to 6 meters 7mm ±1.2mm
65mm up to 6 meters 9mm ±1.6mm
75mm up to 6 meters 12mm ±2.0mm
100mm up to 6 meters 15mm ±2.4mm

60, 80 and 90mm Square Billets and 50, 56, 60 and 75mm Round Bars can also
be produced if ordered in substantial quantity.

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Cast Steel Billets

Size Of Square Tolerance

80mm ±2.0%
100mm ±2.0%
125mm ±1.75%
150mm ±1.50%

HOT ROLL PRODUCTS:

Hot rolled carbon steel coils, sheets, strips and plates are produced at our 1700mm Hot
Rolling Strip Mill.

Uses.
Seam Welded Pipes for Gas/Water/Oil. Storage Tanks, Vessels, Containers.
Ships/Barges, Launches & Floating Structures. Fabricated Sections/Structures. General
Purpose Sheets/Plates. Wheel Rims. Formed Sections, Steel Flooring and Cold Rolled
Products

Standard Sizes Of Hot Rolled Sheets As Rolled Edges In (mm)

Thickness (mm) Min. & Max. Sheet Lengths per Width (W)

1000 (W) 1220 (W) 1500 (W)

1.6, 2.0 2440 2440 -
2.35 - 2440 -
2.65, 2.90 2440 2440 -
3.25, 3.65 2440 2440, 6000 2440, 3000, 6000

3.90, 5.0, 6.0 2440, 6000 2440, 6000 2440, 3000, 6000

7.0, 8.0, 9.0, 10.0, 12.0 2440, 6000 2440, 6000 2440, 3000, 6000

Standard Sizes Of Hot Rolled Coils

Width As Rolled Thickness Of Hot Rolled Coils (mm)
(mm)

1000 & 1220 1.6, 2.0, 2.35, 2.65, 2.90, 3.25, 3.65, 3.9, 4.0, 4.5, 5.0, 6.0,
6.5, 7.0, 8.0, 9.0, 10.0, 12.0

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1500 2.90, 3.25, 3.65, 3.9, 4.0, 4.5, 5.0, 6.0, 6.5, 7.0, 8.0, 9.0,
10.0, 12.0

Allowable Telescopicity In Hot Rolled Coils

Thickness(mm) Width Telescopic Value
up to & Incl. 2.5 up to & Incl. 800 50
over 800 100

Over 2.5 up to & Incl. 800 35

70

COLD ROLLED PRODUCTS:

Thickness 0.3 to 2.5mm
Width 700 to 1500mm
Lengths 1 to 4 meters
Coil Inner Diameter 600mm
Coil Outer Diameter 1800mm (max)
Max. Coil Weight 14.5 tons
Min. Pack Weight 5.0 tons

Standard Sizes Of Cold Rolled Sheet & Coils With Tempered (Trimmed) Edges
Thickness, mm 0.45, 06, 08, 10, 12, 16, 20, 25
Width, mm 915, 950, 1220, 1250
Sheet length per width, mm 1830, 2440

Standard Thickness Tolerances For Cold Rolled Sheets/Coils (values in mm)

Specifi Thickness tolerances, over and under for specified thickness

ed Upto & Over Over Over Over Over Over Over
Widths Includi 0.4 0.6 0.8 1.0 1.2 1.6 2.0
ng Upto & Upto & Upto & Upto & Upto & Upto & Upto &
0.4 Includi Includi Includi Includi Includi Includi Includi
ng ng ng ng ng ng ng
0.6 0.8 1.0 1.2 1.6 2.0 2.5
600 0.07 0.08 0.09 0.1 0.12 0.14 0.16 0.18
upto
and
includi
ng
1200
Over 0.08 0.09 0.1 0.11 0.13 0.15 0.17 0.20
1200

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upto
and
includi
ng
1500
Over - 0.1 0.11 0.12 0.14 0.17 0.19 0.22
1500

3. POWER EQUIPMENT REPAIR SHOP-MECHANCAL (PERS-M)

PERS-M is a department in PSM where internal mechanical part of
Power machine such as pumps, roller bearings are repaired. This
department works along and adjacent to PERS-E (electrical), in the
latter department motor and electrical systems are repaired.
There is a section in PERS-M called Babbitting section, where
bearings whose Babbitt linings are worn out, babbitting process is
applied on it. Babbitt is a process where metal alloys of Tin, Copper,
Cadmium and Lead are used as a sliding bearing material. Its
advantages consist of low friction coefficient, wear resistance and
real part protection.
The most commonly used Babbitt material is Tin Babbitt, the alloy
contain more than 80% Tin and the rest is Antimony and Copper.
The Alloy completely melts at 400 to 420 degree Celsius and it
pouring temperature is 450 to 480 degree Celsius.
The Re-heating furnace is used to melt the babbitting material. Its maximum temperature is
1300 degree Celsius. Its maximum discharging rate is 120 tons per hour and its gas
consumption is 6000 to 8000 cubic meter per hour. Air is blasted at 400 degree Celsius and the
fuel to air ratio is 1: 10.
The molten metal is then poured onto a mold which is semi-cylindrical in shape so that it can
be fitted inside the bearing. The radius of casted material is always less than the inner radius of
the bearing, because the Babbitt has to be machined before it is fitted to give smooth surface
finish. Other processes of repairing are also done in the PERS-M. There is a machine to align
and balance shafts. There is a torch repair shop and a cutting tool to cut thick metal sheets and
punch.

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4. THERMAL POWER PLANT AND TURBO BLOWER STATION (TPP-TBS)

TPP stands for thermal power plant which is used for the generation of electricity for Pakistan
Steel Mills. TPP is broadly divided into following 5 sections:
1. Water chemical treatment plant (WCTP)
2. Boiler
3. Turbine
4. Generator
5. Main switch gear room (MSGR)

WATER CHEMICAL TREATMENT PLANT (WCTP):

Before supplying water to boiler, it is chemically treated to remove impurities from raw water.
Impurities present in raw water are called total dissolve solid (TDS), which is broadly divided
into three types:
1. Organic impurities
2. Inorganic impurities
3. Bio impurities

The main concern is with inorganic impurities (Ca, Mg) which cause hardness of water.
Hardness is of two types:

1. Temporary hardness
2. Permanent hardness

TEMPORARY HARDNESS
Temporary hardness of water is caused by the presence of dissolved bicarbonate minerals.
When dissolved, these minerals yield Calcium and magnesium cat ions (Ca2+, Mg2+),
Carbonate and bicarbonate anions (CO3 2- , HCO3 -). To remove temporary hardness raw
water is passed through;

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1. Clarifiers
2. Line coagulated water storage
3. Mechanical filters

PERMANENT HARDNESS
Permanent hardness of water is caused by the presence of dissolved sulfates and/or chlorides.
When dissolved, these minerals yield Calcium and magnesium cations (Ca2+, Mg2+), Sulfate
and chloride anions (SO4 2-, Cl-). Permanent hardness cannot be removed by boiling. After
removing temporary hardness, permanent hardness is removed from water by passing the water
through:
1. Primary H-cation exchangers
2. Primary anion exchangers
3. Decarbonizers
4. Decarbonized water storage
5. Secondary H-cation exchangers
6. Secondary anion exchangers

After passing through these stages, hardness is completely removed from water and
demineralized water is achieved. Treated water output from water chemical treatment plant is
230 tons/hour.

BOILER:
The water from WCTP passes through different stages before reaching boiler:
1. Condensate pump
2. Low pressure heaters
3. Deviators
4. Boiler feed pump
5. High pressure heaters.

After passing through these stages water reaches the four boilers in TPP, whose working
pressure is 100kg/cm2 and temperature of water is 215°C

BOILER PARTS:
BURNER:
TPP consists of 4 burners, in which different fuels are burnt to convert water into steam. In 2
burners, natural gas and coal tar is burnt. In 2 burners, BF gas (obtained from blast furnace)
and coke oven gas is burnt.
BOILER DRUM:
In boiler drum, the temperature of steam is 320°C, which is in saturated form; the steam is then
passed through super heaters, which increase the temperature of steam up to 540°C.

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IDF AND FDF:

FDF (force draught fan) sucks air from environment and passes it to the burner for combustion
of fuels producing the flue gases (flue gas refers to the exhaust gas produced at power plants).
Its composition depends on what is being burned, but it usually consists of nitrogen(typically
more than two-third) derived from the combustion air, carbon dioxide (CO2), and water vapor
as well as excess oxygen (also derived from the combustion air) are passed through
recirculating air heaters, release heat here and goes out in environment through IDF (induced
drought fan). After passing through super heaters steam moves out of the boiler at 100kg/cm2,
steam temperature 535°C and enters turbine.

TURBINE:
There are three turbines in TPP:
1. Turbine-1 is double cylinder type coupled with Generator 1
2. Turbine-2 and Turbine-3 are single cylinder type coupled with Generator 2 and
Generator 3 respectively. These turbines are impulse type and have 22 stages.

TURBINE PARTS:
STOP VALVE:
It is used for emergency tripping to stop the supply of steam to the generator.
REGULATOR:
Regulators are used to control the amount of steam supplied, i.e. depending on the demand of
steam, regulators are opened or closed.
GOVERNOR:
Governor gives instruction to regulator valves to open or close and provide steam to serve load.
SERVO MOTOR:
The servo motor is an amplifier which amplifies the order of the governor.

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BEARING GEAR:
Bearing gear is used to initially move a rotor to remove distortion, it is switched on before
turning the turbine on.
OIL PUMP:
Oil pump is used for pumping the oil.
OIL:
Oil is used for lubrication of bearings and governor control. The temperature of drain oil is
65°C, the oil cooler drops the temperature of oil up to 40°C.

MAIN PARAMETERS OF TURBINE INTALLED IN TPP:

Turbine TYPE ΠT-60-90/13
Two extraction 10-16 ata & 1.5-3 ata
Rated output 60, 000 kW (60 MW)
Speed 3, 000 rpm (50 Hz)
Live steam pressure after emergency 90 Kg/Cm2 (85-95)
stop value
Live steam temperature emergency stop 535°C
valve
Frequency (50 Hz)
Cooling water flow passing through 8000 m3 /Hour
condenser
Cooling water inlet temperature 28°C

Max. steam flow @ nominal conditions 402 t/hour

comprises respectively
Production extraction pressure 13 ± 3 kg/cm2

District heating extraction pressure 1.2 kg/cm2,

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 PAKISTAN STEEL MILL

Pressure control within 0.7-2.5 Kg/cm2

Normal parameters of live steam, 8000 m2 /hr.

cooling water flow
Normal parameters of live steam cooling 28°C
water flow Temperature
The load up to 75 MW Pressure

maximum steam flow to condenser 170 t/hr.

Oil temperature after oil cooler 40°C

Oil temperature from Bearing drains not 65°C

more than
Bearing pressure 1.01 - 1.03 Kg/cm2 (1.15 - 1.2 Kg/cm2
)

MAIN PARAMETERS OF COMPRESSOR INTALLED IN TPP:

COMPRESSOR Type K-3250-42-1
Pressure 3.5 Kgf/cm2 (Gauge Pressure)
Flow rate 2100 M3/hour
Minimum Speed 3250 rpm
Oxygen enrichment 30%
Cooling Seawater 500 M3 /hour
Critical speed 1600 rpm
Casing Cast Iron
Diaphragms Cast Iron
Rotor Steel
Weight of Compressor 77 Tones
Weight of heavier part 23 Tones
Maximum allowable Pressure inside air 3Kgf/cm2
Column
GENERATOR:
TPP has three turbo generators of 55 MW each coupled with steam turbines to serve the load
of Pakistan Steel Mills. Two of these generators are usually in working conditions while the
third generator is kept in reserve. Pakistan Steel Mills is also connected with KESC through
two interconnected transformers which steps up the voltage from 11kV to 132kV for
transmission.

GENERATOR SPECIFICATIONS:
Rated voltage. 11.5kV
Speed 3000 rpm
Power factor 0.8
Stator current 3460A
Rotor current 1280A
Hydrogen pressure 196 kPa
Rated power 68750 kVA

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 PAKISTAN STEEL MILL

GENERATOR COOLING:
Hydrogen gas is used as a cooling medium in turbo generators. The use of gaseous hydrogen
as a coolant is based on its properties as follows;
1. Low density
2. High specific heat
3. Highest thermal conductivity (at 0.168 W/(m·K))

Among all gases Hydrogen gas is 7-10 times better at cooling than air. Another advantage of
hydrogen is its easy detection by hydrogen sensors. A hydrogen-cooled generator can be
significantly smaller, and therefore less expensive, than an air-cooled one.

MAIN SWITCH GEAR ROOM (MSGR):

CONTROL ROOM:
The control circuit is controlled through DC supply so that the protective system remains
unaffected in the absence of AC supply from the generators.
DC BATTERIES:
There are 130 batteries of 2V each and current capacity of 1250 A/hr.106 batteries are currently
working while 24 batteries are in spare. These are lead acid batteries in which sulfuric acid is
used as an electrolyte.

ADVANTAGES AND DISADVANTAGES OF THERMAL POWER PLANT:

ADVANTAGES:
 Fuel is cheaper
 Smaller space is required as compared to hydro power plants
 Economical initial cost as compared to hydro power plants
 Can be placed near load centers, unlike hydro and nuclear power plants

DISADVANTAGES:
 Requires higher maintenance and operational cost

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 PAKISTAN STEEL MILL

 Causes air pollution

 Requires the abundant amount of water
 Efficiency is less i.e. 30-35%.

CONCLUSION:
It was a great experience for us and we admit that I learnt a lot from Pakistan Steel Mill. All
the staffs of all departments were very cooperative and humble our interaction with people here
has indeed helped us enhance our communication skills and public relation skills. Things we
learnt from here will not only help us in polishing our studies, we have learnt so far, but also
will benefit us in our practical life. As an engineers it was a great opportunity for us and with
the fun we learnt a lot from here. Overall, this four weeks experience will remain etched in our
memory and we do look forward to perhaps being a part of Pakistan Steel Mill in the future.

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