Submitted By:

Mr. ASIF ALI (K13EL-49)

Mr. ALI MUHAMMAD (K13EL-19)

Mr. MOUZAM ALI (K13EL-37)

MEHRAN UNIVERSITY OF ENGINEERING TECHNOLOGY SZAB CAMPUS KHAIRPURMIR’S

(15 DAYS INTERNSHIP REPORT)

ACKNOWLEDGMENT

‘In the name of Allah, the most Gracious, the most merciful’

“All praises for Almighty Allah, who guides us in darkness and helps us in difficultiesand due respect for Holy Prophet (Peace be upon him) who enables us to recognize ourcreator.”

First, we would like to thanks Almighty Allah who gave us strength to completechallenging tasks & His blessings that He provided me confidence, guidance & strengthto complete this report. The journey has not finished yet and we pray to Him to show usthe straight path & help us more in future as we nothing without His blessings.Writing an internship report appeared to be a great experience for us. It added a lot to usknowledge. Completion of internship report is not an easy task. It requires continuoushard work. Completion of this report would have not been possible without the support ofall staff of HR department to whom I interacted and concerned field department. We would like to thanks especially Mr. MUZAMIL SALEEM (GM), Mr. ANWER SAHB (DPM) Mr. FARHAN AHMED (senior plant manager) , Mr. AB,RAZAQUE (senior power house manager) and other engineers and field workers to their practical guidance and personal interest by which we become able to complete this task.Very special thank to all our dear teachers that build our personality and enable us to dosome creative work be a successful person in practical life. We are responsible for errors and mistakes presented in the report and a positive and constructive criticism will always be greeted warmth.

SECTION NO: 01 WARPING

SECTION: 02 SIZING

SIZING

SECTION: 03 WEAVING

WARPING

SECTION WARPING &SIZING (H-SHAPPED CRIAL) & 800 SPEED

DIRECT WARPING

(H-SHAPPED CRIAL)

BENGER WARPING (1200 SPEED)

CHINNA WARPING (700 SPEED)

KUCUKER WARPING (1200 SPEED) BEST AUTOMATIC SYSTEM

SIZING

KUCKER SIZING BEN SIZING

Weaving is a method of textile production in which two distinct sets of yarns or threads are interlaced at right angles to form a fabric or cloth. Similar methods are knitting, felting, and braiding or plaiting. The longitudinal threads are called the warp and the lateral threads are the weft or filling. In Afroze there are 72 looms are used each having same working.

LOOM:

A loom is a device used to weave cloth and tapestry. The basic purpose of any loom is to hold the warp threads under tension to facilitate the interweaving of the weft threads. The precise shape of the loom and its mechanics may vary, but the basic function is the same Toyota 710 loom used in an industry.

SENSORS USED IN LOOM:

Different sensors are used in loom as,

(1) Feeler sensor: which sense when thread breaks.(2) Metal sensor: which sense beam if it will be in front of it then it sense in working

condition otherwise not.(3) Proximity sensor: it counts number of turns.(4) Balloon sensor: it sense how much thread is used.

MOTORS USED IN LOOM:

(1) induction motor 1pahse and 3phase(2) Servo motor(3) Stepper motor

(1) Induction motor:Introduction;One of the most common electrical motor used in most applications which is known as induction motor. This motor is also called as asynchronous motor because it runs at a speed less than its synchronous speed.Induction motors are easier to maintain and cheaper.

Working principle:It has two main parts stator and rotor, stator is stationary part where rotor is rotating part also stator having thin lamination, when a AC supply is provided to stator of I.M a rotating magnetic field produces which cuts rotor, according to faradays law an emf induces in rotor loop which produces its own field so, both stator and rotor field interacts with each other and force produces which moves it. Where rotor speed is less then stator speed.

Applications in textile:Used in different places such as, in loom to drive it, drier etc.

(2) Servo motor:

This is nothing but a simple electrical motor , controlled with the help of servomechanism. If the motor as controlled device, associated with servomechanism is dc motor, then it is commonly known DC Servo Motor. If the controlled motor is operated by AC, it is called AC Servo Motor.

Servomechanism:A servo system mainly consists of three basic components

(1) A controlled device

(2) An output sensor

(3) A feedback system

This is an automatic closed loop control system. Here instead of controlling a device by applying the variable input signal, the device is controlled by a feedback signal generated by comparing output signal and reference input signal. When reference input signal or command signal is applied to the system, it is compared with output reference signal of the system produced by output sensor, and a third signal produced by a feedback system. This third signal acts as an input signal of controlled device.

Advantages:

Works on some angle Good accuracy Works both reverse and forward Servo amplifier also used High frequency on stator side

2. Stepper motor:A stepper motor is a type of DC motor that rotates in steps. When electrical signal is applied to it, the motor rotates in steps and the speed of rotation depends on the rate at which the electrical signals are applied and the direction of rotation is dependent on the pattern of pulses that is followed. A stepper motor is made up of a rotor, which is normally a permanent magnet and it is, as the name suggests the rotating component of the motor. A stator is another part which is in the form of winding.

(a)Humidity plant:

ROOM AIR (Return fan) AIR PASS (Shivering room) WEAVING (through supply fan having 26 to 27 degree cooling according to need)

4. PROCESSING:

(a) Bleaching:

There are 4 washing chambers in each portion has powder ,soap and detergents mixture which is used for cleaning purpose ,after that it will be washed and then it move to drier portion where inside it there is hot steam used. Where also flow sensors are used to sense flow of water inside washing portion.

(b)Drier:

It is used to dry product after bleaching and washing ,cylinder drier (beneger company) ,it has four zones ,having steam pressure of 4bar,and temperature of 100 degree C, in which total 25 induction motors used from which 23 are 0.75 KW and 2 motors are 5.5kw ,where dancer

(potentiometer) is used to balance speed of motors. Also invertors are used for 0.75 KW motors as easily rotate them forward and reverse.

5. POWER PLANT:

There are four alternators are used each having rating of one MW.

(a):

Step no: 01 In fuel there is mixture of 20% of natural gas and 80% of air.

20% natural gas

80% Air

Pressure of gas is used in current is 1513 mbar. Mbar meter is also used to measure actual pressure.

Step no:02 Union valve:

Is used to control the flow of fuel, also flinch used to connect valve on both sides of pipes.

Step no: 03 Filter: are used to make fuel pure from dust and other particles.

Mbar Step no: 04 Gas pressure gauge

Psi

Step no: 05 Fuel pressure filter: It is used to finally measure pressure of fuel. Then move through flexible pipes.

Step no: 06 Turbo charges: (mixture) It used to make mix natural gas and air properly then make equal distribution of fuel (gas) in pipes to Alternator; also it performs the function of exhaust.

(1) Power mode:individually each generator(2) Sink mode:all generators equal distribution of load Step no: 07 Starting of Engine : Initially what happens generator is moved through starting motor ( through a 12v battery source) when its speed reached to 150 t0 200 rpm’s then motor is removed and fire or ignition is provided to burn fuel (10000v are needed to start fire),and generator starts.

MODES OF OPERATION

(b) :Cable rating :

Qno: If power is 1KW then what will be the rating of cable?Ans: by using the real power formula we can find the carrying capacity of cable P=VICOSⱺ I=P/VCOSⱺ

=1000/400*0.85

I=1.8 Aand cable rating will be 1mm =1.8 ladder tray

(c) Power Tray

Pufrated tray

These trays are used to carry cables where ladder tray is used in open environment as rain water does not stop upon it, where ladder tray is used in closed environment.

(d) Switch gear:

One of the basic functions of switchgear is protection, which is interruption of short-circuit and overload fault currents while maintaining service to unaffected circuits. Switchgear also provides isolation of circuits from power supplies. it is designed on basis of ampere rating. then in last it is distributed in different sections of textile where it is required.

(e) Cooling of generator:

cooling is provided to generator through water. where water pumps are used to circulate water through it ,where it takes heat from different portions of generator and then that hot water goes to heat exchanger and becomes cool so, such process continue.

Figure: block diagram power plant.

FIRE ALARAM SYSTEM

A fire alarm system is number of devices working together to detect and warn people through visual and audio appliances when smoke, fire, carbon monoxide or other emergencies are present. These alarms may be activated from smoke detectors, and heat detectors.

Types of fire alarm system

(1) Conventional fire alarm systems:Conventional fire alarm systems and its components are all wired to the same cable that connects them to a fire alarm control panel that displays a signal when one of the components is activated. These types of systems are inexpensive and work well in small facilities. The main problem with conventional fire alarm systems is that when a fire alarm component produces a signal and it appears on the control panel there is no way to know which component it is in the building.

(2) Addressable fire alarm system: Addressable fire alarm systems are the most modern type of system and its components have individual unique identifiers. When one of the system’s components is initiated it displays a signal on the fire alarm control panel that indicates the component’s address. Large facilities are typically equipped with these systems because they can quickly pinpoint the address of the fire alarm component that sent the signal. This saves a lot of time because it eliminates the need to search for the component that produced the signal.In each zone there are 18 devices used total 42 zones , each operates on 24.5V ,where 16-20 ft distance between each alarm and having height of 15ft.

Conclusion:

We had a great learning and training experience at Afroze Textile Industries for our academic program of Electrical ENGINEERING at MEHRAN UNIVERSITY of Engineering And Technology SZAB CAMPUS KHAIRPURMIR’S

We physically visited industrial utilities like steam boiler, RO plant, oil boiler, power house, air compressor, chiller plant which work on those basic thermodynamics principles and laws which we have studied in theories,

Working on them physically on the industrial scale was really so demanding for us.

We had a real world working and have work from, experiences which we had never been exposed to, in our isolated academic life at university.

We learned the coordination in planning of production order of different buyers to make the buyers happy and how to take the necessary steps in modifying the machines to cover any halts in the machines during a run.

We learned that how electrical engineers do take actions in maintaining a harmonious flow in the production line by the properly govern the maintenance of

machines and by designing new efficient plants and by modifying the existing plants to reduce the time consumption, cost, break downs of the production line.

They also increase by the same way the quality, and more diversified product which can change the market.

We learned how to work in a team and how to work under the higher authorities.

SUGGESTIONS:

We saw that Afroze Textile Industry has to depend upon the water tankers a little bit which are expensive, not a true solution, dealing with them is nasty.

1. We suggest that they should consider reconfiguring the waste water plant RO, which has the water storage capacity of 500,000 gallons, this will eventually be good for environment, production, and profitable I guess.

ENERGY CRISIS:In spite of having fully owned 3MWatt power plant a froze is still facing power shutdown on Sundays due to natural Gas strike by the govt. this cause an effective loss to the production and profit of the industry.

1. We recommend the industry to install solar power system on the roofs and make use of it in conjunction with N.gas power plant.

2. We also recommend that industry should encourage the govt. for the use of Thar coal in producing energy for the betterment of this sector.

3. We also recommend that industry should overcome power losses in terms of power efficient machines and good lubrication and insulations of machines.