Firstly, we would like to thank Almighty ALLAH who is the creator and master of this universe and

everything in it. After that we would like thank IBRAHIM FIBRES ltd. for this learning and
developmental opportunity in our career.
We are thankful to Mr. Fahmeed and Mr. Amir Hashim for helping in Polymer utilities. A thanks to
Mr. Omer Khan and Mr. Hammad for watching over us in polymer Instruments. We are also
grateful to Mr. Naeem for guidance and supervision in spinning & fiber line instrumentation. We
would also like to thank Mr.Amanullah and Mr. Imad for helping us in power generation. We are
also grateful to the co-operative and helpful staff of IFL that helped us in our learning.

Power Generation
Ibrahim Fibres Limited – Power Generation Plants
Power Generation Plants of Ibrahim Fibres Limited consist of three production
plants; Power Generation Plant – I , Power Generation Plant – II and Power
Generation Plant – III. Total power generation capacity of these plants is 73.3
MW. These Plants are for the sole objective of catering to the requirements of
the company’s industrial operations for uninterrupted and stable power supply.

Power Generation Plant – I

Power Generation Plant – I started its operations in January 1994 with power
generating capacity of 31.8 MW. The plant comprised of 6 furnace oil
generating sets, each having a capacity to produce 5.3 MW, supplied by Niigata
Engineering Company, Japan. During 1996, after the installation of Polyester
Plant – I two more engines were added to meet the additional power
requirement. Primarily all these engines were based on heavy fuel oil but to
remain competitive in the ever changing market the Company has converted its
operations to 60% heavy fuel oil and 40% natural gas.

With the recent expansion of polyester plant

from 596 ton per day to 1,116 ton per day of
PSF, power requirement has further
increased by approximately 10.4 MW which is
now being fulfilled by installation of five new
furnace oil generating sets, each having a
capacity to produce 5.3 MW, supplied by
Niigata Engineering Company, Japan. These
Engines with total power generation capacity
of 26.5 MW along with steam generation
capacity of 11 tons per hour have started
their generation from May 2013.
Power Generation Plant – II

During 2007 the Company signed an agreement with Turbomach, Switzerland

for the engineering supply and supervision of installation/commissioning of gas
power generation plant, having a power generation capacity of 15 MW along
with steam generation of 25 tons per hour as a by-product. This plant started
its operations during 1st half of 2009. The installation of this plant has not only
reduced the power generation cost but has also resulted in a saving of fuel cost
which was incurred for steam generation.

……………………….

Gas Turbine

Gas turbine is the main component of utility. This section of utility is also called PG-II. Gas turbine
operates on Bryton Cycle which is ideal thermodynamic cycle. Bryton cycle is composed of four ideal
processes:

a. Isentropic compression (Compressor)

b. Constant pressure heat addition (Combustion Chamber)

c. Isentropic expansion (Turbine)

d. Constant pressure heat rejection (Atmosphere)

These process are clearly explained by the schematic diagram and P -V diagram.
 Fig. : Schematic and P-V diagram of Ideal Bryton cycle

Gas turbine of IFL utility section has 14 stages of compressor with intercooling between the stages to
decrease the temperature of compressed air and increase the efficiency of gas turbine. The combustion
chamber is pilot type burner where natural gas at 25 bar pressure is used as fuel. This compressed
natural gas and compressed air mixed at the ratio of 1:16 (by mass) and burned to give high pressure
and high temperature gasses. These gases are expanding on 3 stage turbine. The turbine uses the
enthalpy of hot gasses in its reaction stages to extract useful work out of it.

This gas turbine has 11197 rpm. A gear reducer is connected between turbine and generator so that
generator is rotated at 1500 rpm giving the power output of 15.3 MW. The hot gasses leaved the
turbine at about 490-520°C and is used in HRSG as discussed above.

POWER GENERATION I (PG - I)

Oil Circulation
Two types of oil i.e. Heavy Furnace Oil (HFO) and Diesel oil are circulated to engines using pumps.
Storage tanks are present to store oil. Three comparatively large tanks are present to store HFO oil while
one tank is available to store diesel oil. From storage tanks HFO circulates to the settling tanks where
the impurities or sludge present in it settles down. The temperature of oil in this tank is about 80-85C.
From settling tank, oil moves to purifiers. The impurities that are left behind are filtered by passing the
oil through purifiers. Purifiers consist of three filters primary filter, secondary filter and fine filter. After
passing through these filters, oil comes into the cleaning tank where the temperature of oil is about 90-
95c. From here the oil finally moves to the engines or prime movers. Fuel service oil tanks and Diesel
service oil are present under the motor controlling lube oil circulation that stores lube oil. The
specifications of each tank and filter are mentioned below:

Engine Auxiliary Motors:

Cooling tower:
It is used to provide cool water to PG-1 area so that engines can work in the limited temperature
without overheating. The hot water that comes from engine is treated here so that is can go there again
to decrease the temperature of engine.

Cooling Water:
This water is used for cooling purpose of engine so that its temperature can be maintained. Motor used
here is also part of engine auxiliary motor.

Lube oil Priming Pump:

It is used for the lubrication purpose of prime mover till it gets 30 percent speed of its rated.

Fuel oil feed pump motor:

It is used to feed fuel either hfo or diesel in engine depending upon the instruction given to it.

GLC Motors:
It is used for the lubrication of shaft and bearings between engine and motor i-e in between generator
and motor.
Synchronous Generators:
Synchronous generators or alternators are synchronous machines used to convert mechanical
power to an ac electrical power. In synchronous generators dc current is applied to rotor
winding, which produces rotor magnetic field. The rotor of generator is then turned by a prime
mover, producing rotating magnetic field within the machine. This rotating magnetic field
induces a three phase set of voltages within the stator windings of the generator. Synchronous
Generators are called synchronous because the electrical frequency produced synchronized
with the mechanical rate of rotation of the generator. The rate of rotation of rotors magnetic
field is related to the electrical frequency produced is given by

F = np/120
Where n is the rotating speed, p is the number of poles and f is the electrical frequency produced the
stator winding. Electrical power is generated at 50 Hz so generators must rotate with constant Phase-
1 (HFO 4 Engines Niigata 4* 5.3=21.3MW) installed in 1993.

 Phase-2 (HFO 2 Engines Niigata 2*5.3=10.6 MW) installed in 1997

 Bi-fuel in 2006 of 6 Engines.
 Phase-3 (HFO Engines Niigata 5*5.3=26.5MW) in 2012/13
 Total Engines capacity=11*5.3=58.3MW

The total power generation of both GT and PG-1 add up to a total capacity of 58.3+15=73.3 MW. All of
these engines operate on Diesel Cycle.

Diesel Engine Cycle:

The diesel engine cycle is shown in the figure. A complete cycle has four processes:


Isentropic Compression

Heat addition at constant pressure

Isentropic Expansion

Constant volume heat removal

All the engines at the PG – I are also have turbocharging. All the phase III engines have HRSG
system installed that used the exhaust heat to generate steam that is further used in the PP
plants.
Engine Specifications:
 Cylinder Bore =320 mm

 Clearance volume = 10.1mm

 Swept Volume =463 L
 Compression ratio = 13.6
 Air fuel ratio = 1:31
 Maximum Power = 5.3 MW
The principle of cooling tower has already been described in polymer section. There are total of 11
cooling towers. Phase 1 and 2 cooling towers are of induced draft fan type counter flow cooling towers.
The phase 3 engines cooling towers are of cross flow type.

HRSG (Heat Recovery Steam Generator):

HRSG system is installed at the exhaust of the Phase 3 engines in which the energy at the exhaust of the
engines is utilized to convert water into steam that is used in Polyester Plant. The technical
specifications of HRSG are given as under:

Produces 2.8 ton/hr of saturated steam at 10bar and 191ºC.


Exhaust gas inlet temperature 345o C
Maintenance Work at PG – 1 Plant:
PG-I have a huge mechanical system for power generation which required regular maintenance for
smooth operation. These engines are mostly used for providing power to the polyester plant because it
cannot afford any shut down. Thus schedule maintenance is very necessary for the smooth operation of
polyester plant. Maintenance of engines are planned according to running hours of engines as described
below:

500 hours
Following maintenance operation are performed at each 500 hour of running of engine since last

MOH.

1000 hours
At each multiple of 1000 hour of running of engine since last MOH.

2500 hours
At each multiple of 2500 hour of running of engine since last MOH.


Major Overhauling (MOH)

After the each 8000 hours of running of engine, major overhauling engine is done.

Conclusion:

Internship is a platform for fresh students who have completed 2nd year or 3rd year which helps us to
transform theoretical knowledge or bookish knowledge that we have gained during our university life
into practical form. Internship in any industry provides us industrial exposure and opportunity to learn
practical things, helps us in polishing our skills and smoothen our ways, how can we become good
professional engineers by providing a well- oriented environment of skilled employees and workers. We
have learnt the complete processes of IFL in Electrical point of view. Discussion on motors, DCS and PLC
systems , and instrument clusters cleared our concepts and our syllabus was being revised during
discussion, as well as it helped us to visualize how things worked actually. This internship was a great
practical experience for us and during this internship we have improved many areas in which we lacked
and it helped us to identify the deficiencies and weaknesses. Engineers helped and guided us how could
we fill these deficiencies and built up our weaknesses over there. All these things will help us in our
career to terminate weaknesses that we felt there during internship.