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Internship by Raheel from PNEC, NUST

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Tuwairqi Steel Mills

15 Days Internship ReportBy Raheel (student of BE-Electrical)From PNEC- NUST +92-322-3374867 raheel.m.saleem@gmail.com

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Table of ContentsPreface.3 Acknowledgement..4 TSM Introduction..5 Project Status6 DRI Process9 Relevance of Work Experience to Studies Induction Motors and their Starting Methods11 Gas Turbine Generators.14 CCPP.16 Buchholz Relays18 Training.21 Conclusion..21

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PrefaceOver the summer of 2009, I was granted the unique opportunity to be employed by Tuwairqi Steel Mills as an Internee. Under the supervision of Electrical and Instrumentation department, I was lucky enough to undertake 15 days internship that expanded my horizons and my way of thinking. Tuwariqi Steel Mills is a project of Al-Tuwariqi Group of Saudi Arabia. It is being set up over an area of 220 acres at Bin Qasim, Karachi with a production capacity of one million tons. The capacity can be expanded to three million tons. Themills will start functioning soon. My main project was based within the Electrical discipline and primarily involved practical understanding basic theories under the supervision of concerned Engineers.

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AcknowledgementThe whole praise is to almighty Allah, creator of this universe. Who made us the super creature with great knowledge and who able me to accomplish this work, I feel great pleasure in expressing my deepest appreciation and heartiest gratitude to the staff of Tuwairqi Steel Mills (TSM) for their guidance and great help during the internship period. I would like to express my deepest affection for my parents and my friends who prayed for my success and encouraged me during this internship period. I appreciate and acknowledge the patience, understanding and love provided by employees of TSM. A token of special thanks to the following people who had been very friendly, co-operated with me throughout my internship period in E & I department and made it possible for me to learn and gather information. These are the people who in spite of their busy scheduling took time out to explain to me the procedures and mechanics of work in the organization. Mr. Jamshed Mr. Zubair Mr. Sajid Mr. Zahid Mr. Aamir Mr. Farrukh Mr. Furqan Mr. Zuhair Mr. Naveed Mr. Noman Mr. Yasir Mr. Kamal HOD Electrical HOD Electrical @ SITE Senior Engineer from Mechanical Department Senior Engineer Senior Engineer Engineer Engineer Engineer Engineer Engineer Engineer (Intern Instructor) Engineer (Intern Instructor)

I would like to express my deepest thanks to Mr. Kamal and Mr. Yasir, who really gave their best of time to me and I really learned a lot from them in a very short period.

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IntroductionThe Altuwairqi Group of Companies {ATG} one of the leading business concerns in the Kingdom of Saudi Arabia and the largest private sector steel producer, is in the process of setting up a steel making plant in Karachi Pakistan. The project namely Tuwairqi Steel Mills Limited (TSML), Whose foundation stone was laid by the president of Pakistan General Pervez Musharraf on the 30th of March, 2006, spreads over 220 acres and has a strategic location at Port Qasim Karachi. TSML shall be a state-of the-art steel making complex becoming the biggest steel producing project in Pakistan. The plant shall have a capacity of 1.28 million tons per annum using the worlds most advanced DRI {direct reduced iron} technology of the MIDREX process which uses natural gas to convert iron ore into Direct Reduced Iron. The process uses both lump iron ore and iron pellets as the raw material and recycles the used gas. The process lowers both energy consumption and environmental impact, making it an environmentally friendly process. Along with an Intermediary Phase which includes the setting up of an Induction Furnace to produce 0.5 million tons of billets per annum is also being executed. The Intermediary Phase will be completed close to the completion of DRI Plant. Phase II of the project consists of installation of an Electric Arc Furnace and continuous caster to produce 1.28 million tons high quality billets.

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Project StatusDRI PLANT For the overall DRI Plant, the engineering portion of the Core Plant is complete and 98 % of the structure fabrication, erection and equipment purchases have been finalized with approximately 70% of equipment purchased and delivered at site. Fabrication and construction is proceeding in earnest with the Core Plant, Water Treatment, Material Handling and associate infrastructure which have emerged on the ground and are in view.

DRI FURNACE All piling and foundation work has been completed and second phase of the structural erection is in progress. As the fabricated steel is arriving from the fabricator (HMC in Taxila) it is being promptly put in place and bolted to the previous members.

REFORMER All foundations are complete. Fabrication and the erection of the Reformer is in full swing.

The Lower Feed Gas Ducts and the main support structural steel frames have been installed, while the floor and roof panel installation is in progress. Reformer area piping has been contracted out (ICC).

HEAT RECOVERY

The fabrication and erection of the boxes and the stack of the Heat Recovery are near completion and the refractory work is almost complete.

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WATER TREATMENT

The construction of Clarifier and Cooling tower is almost complete, whereas the construction of Reservoir is in process.

BUILDINGS

Control Building: Construction is in progress. The ground floor and rough building structure have been completed. Installation of Bentley Controller is also in progress Analyzer building: Construction of the rough building and roof has been completed. Termination of the gas pipes is also in progress. ELECTRIC POWER PLANT

Layout / demarcation of the 35MW Combined Cycle Power Plant has been completed. Excavation for Gas Turbines has been started.

REVERSE OSMOSIS (RO) PLANT (FOR CONSTRUCTION PURPOSE)

The 500 CUM/day capacity RO plant for the general site services was completed by mid-2007 and has been providing potable water for the construction activities. The water is obtained from the wells drilled for this purpose.

NG METERING STATION

The natural gas supply line has been completed by SSGC but the Metering Station by them is to be installed. However, purchase order of Metering Station for DRI (to be installed by TSML) has been placed.-7-|Page

CONCRETE BATCH PLANT

The Batch Plant had been completed by mid-2007 and has been fully functional and providing ready-mixed concrete to the DRI project. With the only exception of the furnace foundation where very large amount of concrete was required to make a continuous pour, the TSM Batch Plant has provided all concrete for the DRI Project and for all the general civil works.

TSM FABRICATION SHOP (CMD)

The CMD Fabrication Shop has been constructed and outfitted with Machine Shop and fabrication equipment. There is a current effort to upgrade the shop with higher production equipment to increase the quantity of steel fabrication. As a temporary step a local Pakistani fabricator has been contracted to utilize the TSM fabrication facilities and equipment. Fabrication is currently being done both by TSML and the fabrication subcontractor.

WATER SUPPLY SYSTEM

Survey and design of 18 Km Water Supply Line have been completed. The job is in the process of being contracted out. Design of 36000 CUM potable Water Reservoir completed. Excavation and construction by civil contractor has been undertaken.

RO PLANT (FOR DRI PLANT)

The civil design of the RO plant for the DRI Plant is now in process and the site has been cleared and ready for the start of the civil work. Treated Water Tanks are under designing by the consultants.

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DRI Process

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A MIDREX (tm) Direct Reduction Plant is composed of two main facilities: the Shaft Furnace, where iron ore is reduced, and the Reformer which generates the reforming gas to be charged into the Shaft Furnace. The MIDREX DR Process is able to use both lump and pellet as the raw material and recycles the used gas. Therefore the process has both low energy consumption and low environmental impact, making it an environmentally friendly process. The direct reduction of the oxide is carried out on a continuous basis. The Iron Oxide fed to the top of the shaft furnace flows downward under gravity and is discharged from the bottom in the form of direct reduced iron. The shaft furnace has two main gas circuits. In the upper circuit, iron oxide is preheated and reduced by counter flowing reducing gas consisting of predominantly Hydrogen and Carbon Monoxide. The lower circuit introduces a mixture of reducing gas and natural gas for the purpose of carburizing the direct reduced iron. The reducing gas is generated in the reformer by catalytically reforming a mixture of fresh natural gas and recycled top gas from the shaft furnace. The reformer is a refractory lined furnace containing alloy tubes filled with a Nickel based catalyst. The feed gas mixture flows upward through the catalyst bed where it is heated and reformed. The reducing gas leaves the reformer at near equilibrium conditions, containing 90 to 92% Hydrogen and Carbon Monoxide. The gas is then directly conveyed to the shaft furnace. The thermal efficiency of the reformer is greatly enhanced by the heat recuperator. This unit consists of two shell and tube type heat exchangers in the flue gas duct coming from the reformer. The heat exchangers recover the sensible heat from the reformer flue gas to preheat combustion air (used in the Reformer Burners) to 640 C and to preheat the process gas (mixture of top gas and natural gas fed to the reformer tubes) to 54