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Internship Report Department: Power Plant

Technical Report · February 2020

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 AL KARAM TEXTILE MILLS (PVT) LTD

Internship Report
Department: Power Plant
Muhammad Faizan Qureshi, Muhammad Athar, Hasnain Raza, Ahmed Raza
20-Feb-2020 to 09-Mar-20

University: Usman Institute of Technology

(Affiliated with NED University)
 In the name of
ALLAH
The Gracious and The Benevolent

1
Acknowledgment
First of all the whole praise to ALMIGHTY ALLAH, the creator of the universe and anything in
this universe. He made us super creature, blessed us to accomplish this work. We are very
thankful to Allah Almighty, Who has provided us such an opportunity to gain knowledge in
Alkaram Textile Mills. It was a great experience to do internship over here. We learnt many
things practically which we have learnt theoretically earlier. We also pay our gratitude to the
Almighty for enabling us to complete this Internship Report within due course of time.

The internship opportunity we have with Al Karam Textile Mills (Pvt) Ltd. was a great chance
for learning and professional development. Therefore, we consider ourselves very lucky as we
were provided with an opportunity to be a part of it. We are also grateful for having a chance to
meet so many wonderful people and professionals who led us through this internship period.

It is our radiant sentiment to place on record our best regards, deepest sense of gratitude to
Mr.Agha Wajih Uddin, [General Manager (Engineering)] who allow us to do internship in
Power House.

Bearing in mind previous we are using this opportunity to express our deepest gratitude and
special thanks to Mr. Syed Saad Ali [Manager (Engineering)] who in spite of being
extraordinarily busy with his duties, took time out to hear, guide and keep us on the correct path
at their esteemed organization and extending during the training.

We perceive this opportunity as a big milestone in our career development. We will strive to use
gained skills and knowledge in the best possible way, and we will continue to work on their
improvement, in order to attain desired career objectives. Hope to continue cooperation with all
of you in the future.

2
Contents
About Al Karam Textile Mills ......................................................................................................................... 5
Company Profile........................................................................................................................................ 5
History ....................................................................................................................................................... 5
Vision......................................................................................................................................................... 6
Mission ...................................................................................................................................................... 6
Values (V8) ................................................................................................................................................ 6
Production Process ....................................................................................................................................... 7
Spinning..................................................................................................................................................... 7
Weaving .................................................................................................................................................... 7
Weaving Capabilities ............................................................................................................................. 8
Yarn Dyeing ............................................................................................................................................... 8
Yarn Dyeing Capabilities........................................................................................................................ 8
Wet Processing/Finishing.......................................................................................................................... 8
Wet-Processing Capabilities.................................................................................................................. 9
Cutting & Stitching .................................................................................................................................... 9
Retail & Distribution ............................................................................................................................... 10
Power Plant ................................................................................................................................................. 11
List of Generator ..................................................................................................................................... 11
Gas Turbine ............................................................................................................................................. 11
Gas Engine Basics ........................................................................................................................................ 12
Jenbacher Gas Engines ................................................................................................................................ 13
Electrical Output Range .......................................................................................................................... 13
Power Production ................................................................................................................................... 13
Gas Engine Energy Balance ..................................................................................................................... 14
LEANOX® Combustion technology .......................................................................................................... 14
Features .............................................................................................................................................. 15
Gas Engines Offerings ............................................................................................................................. 15
Jenbacher Type 2 ................................................................................................................................ 15
Jenbacher Type 3 ................................................................................................................................ 17
Jenbacher Type 4 ................................................................................................................................ 19

3
 Jenbacher Type 6 ................................................................................................................................ 21
Power Generation Plan ............................................................................................................................... 24
Power Distribution Plan .............................................................................................................................. 25
Electric Power ............................................................................................................................................. 26
Definition ................................................................................................................................................ 26
AC Power ................................................................................................................................................. 26
Active Power ....................................................................................................................................... 26
Reactive Power ................................................................................................................................... 26
Apparent Power .................................................................................................................................. 26
Power Factor and PFI Plant ......................................................................................................................... 26
Disadvantages of low power factor .................................................................................................... 27
Causes of Low power factor ................................................................................................................ 27
Power Factor Improvement (PFI) Plant .................................................................................................. 27
Power Factor Improvement by static capacitors (capacitor banks) ................................................... 28
Conclusions ......................................................................................................................................... 29
Circuit Breaker & Its Types .......................................................................................................................... 29
Types of Circuit Breaker .......................................................................................................................... 29
Gas Engines vs. Gas Turbines ...................................................................................................................... 30
Gas Engines ............................................................................................................................................. 31
Gas Turbines ........................................................................................................................................... 32
Alternators .................................................................................................................................................. 33
Basics of Power Generation .................................................................................................................... 33
Types of Winding .................................................................................................................................... 33
Armature Winding .............................................................................................................................. 33
Field Winding ...................................................................................................................................... 33
Block Diagram ......................................................................................................................................... 33
Summing up ................................................................................................................................................ 34

4
Introduction
About Al Karam Textile Mills
Company Profile
The Alkaram group was founded in March 1986 with a vision to be a provider of innovative
textile solutions worldwide. We are a manufacturer and supplier of distinguished fabric for
apparel, home and industrial markets with clients all over the world. Our ability to create
forward-thinking solutions that give our clients a competitive advantage is what sets up apart.
Our core services include:

• Fiber manufacturing
• Spinning
• Weaving
• Knitting
• Dyeing and printing of woven and knitted fabrics Designing
• Cutting and Stitching

With a constructed area of over one million square feet, Alkaram has the capacity to fulfill small,
medium and large scale orders. We are one of the few vertically integrated operations in
Pakistan. Offering a diversified range of products, our customers can mix and match from a wide
variety of print, yarn dyed, solids, dobby and jacquard. We also deal in twill, sateen, basket
weave and percale, knitted to woven fabric; and thread counts ranging from 130 to 1000.

At Al Karam we also provide our customers with complete in-house design solutions. Our
creative center is equipped with state of the art designing and sampling equipment and skilled
textile artists.

History
The Group has its origins in the early 1900s when it started the trade of grains and oil in the
subcontinent. Entrepreneurial skills and acumen have always been the driving force behind the
success of the Group. Based in Karachi, the Alkaram Group has unfolded its vision of growth
and established its multifaceted concerns countrywide and abroad. Following opportunities in the
newly created state of Pakistan, the Group flourished in the fields of textiles, F & B, salt mining,
hospitality, trading and distribution.

A melting pot of skilled employees and advanced technology, Alkaram has been brushed upon
the wall of success using a simple formula; short lines of communication were kept, along with
consistently quick yet well thought-out decisions by managers that have been part of the
Alkaram mix since the start. In using this simple philosophy, we have ensured that the identity of

5
Alkaram has not been lost along the way and that the ladder of success we have been climbing
has been leaning against the right wall. Soon the Group became the largest business family of the
country by creating the most modern textile units that went on to become household names of the
country.

Vision
To be a global partner integrating vertical textile solutions with values and sustainability.

Mission
To be a leading competitive global textile company delivering improved Stakeholders' value by
being a Preferred Partner for our Customers, Suppliers and Society through Innovative and Cost
Efficient Quality products guided by Technology and Competitive Workforce in a Sustainable
manner through Continuous Improvement.

Values (V8)
• HONESTY
• TEAMWORK
• TRANSPARENCY
• PASSION
• LEADERSHIP
• POSITIVE MENTAL ATITUDE
• HUMBLENESS
• SIMPLICITY

6
Process Flow
Production Process
Every voyage has a start and an end. Even with the best laid plans, it is easy to lose direction
along the way and end up at a destination that is very different from what was planned. At
Alkaram, we ensure that our products never stray far from their goal. From the first step of their
journey, the creation of fibers via spinning, down to the last, of stitching the finished fabric, our
products are constantly checked to ensure they end up exactly how our customers want them.
Each step is carefully planned. We have a fully integrated services facility that uses the latest
technology across all parts of the products' voyage. For this reason, Alkaram products never lose
their way.

Spinning
The raw cotton arrives in the form of large bales. From here, the cotton goes to a machine which
cleans the cotton of any remaining dirt and separates the fibers. The cotton emerges in the form
of a thin blanket. The fibers are separated more completely. The output from these machines is
more like an untwisted rope than a blanket. This is carried out on a madiine called a 'draw frame'.
This further straightens the fibers. The yarn is further attenuated - i.e., it is stretched so that the
weight per unit length decreases further. The term 'spinning' is used to denote the process in the
production of the yarn. The thread is strengthened by adding a twist to it and then wound onto a
bobbin. Cleansing is required to remove the trash such as dirt, leaves, burrs and any remaining
seeds. 'Carding' is the initial straightening process which puts the fiber into a parallel lengthwise
alignment. This process untangles the tangled mass and molds it into a round, rope-like form
called 'sliver'. The sliver is then straightened again through a process called 'combing'. In it, fine-
toothed combs continue straightening the fibers until they are arranged in such a parallel manner
that the short fibers are completely separated from the longer ones. 'Drawing' pulls the staple
lengthwise over each other. As a result, longer and thinner slivers are produced. After several
stages of drawing-out, the sliver is passed to the spindles where it is given its first twist and then
wound on bobbins. 'Roving' is the final product of the several drawing-out operations. It is the
preparatory stage for the final insertion of twist. Till now, the fibers are given enough twist to
hold them together but they have no intense strength. They can break apart easily with a slight
pull. The 'roving', on bobbins, is placed in the spinning frame, where it passes through several
sets of rollers running at high speeds and finally the 'yam' is produced of the sizes desired.

Weaving
'Weaving', the second step of the vertical textile chain is the art of interlacing yarn to make a
piece of cloth/fabric. It involves taking two sets of formed yarn and interlacing them at right
angle. The lengthwise yarn is known as warp threads and the crosswise or filler yarn, weft
threads. Before the 'weaving' is done, there are a few preparatory processes involving 'warping'

7
(it is the process of creating the base yarn that runs from top to bottom on woven cloth), sizing
(the addition of starch to give strength to the yarn to avoid breakage) and then weaving.

Weaving Capabilities
• Complete Fabrication solution provider with largest shed of Wider Width High Thread
Counts, dobbies, Yarn Dyed, jacquards & over 400 looms.
• Simultaneous and multiple weft insertion capability; 4 color welt insertions and dobbies.
• Largest capacity to weave Yarn Dyed fabric in Pakistan.

Yarn Dyeing
Yarn Dyeing is a process of adding color to textile products like fiber and yarn. It is normally
done in a special solution containing dyes and particular chemical material. After dyeing, dye
molecules have an uncut chemical bond with the fiber molecules. The temperature and time
control are two key factors in dyeing. There are mainly two classes of dye, natural and man-
made. There are many forms of Yarn Dyeing, from which the package form is most commonly
used. The common dyeing process of cotton yarn with reactive dyes in the package form
involves the raw yarn being wound onto a spring tube to achieve a package suitable for dye
penetration. These softened packages are loaded onto a dyeing carrier's spindle, one on top of
another. The packages are pressed up to a desired height to achieve suitable density of packing.
The carrier is loaded on the dyeing machine and the yarn is dyed. After dyeing, the packages are
unloaded from the carrier into a trolley. Now the trolley is taken to hydro-extractor where water
is removed from them. The packages are hydro-extracted to remove the maximum amount of
water, thus leaving the desired color into the raw yarn. They are then dried to achieve the final
dyed package.

Yarn Dyeing Capabilities

• Capacity of 18 tons per day.
• All machines are air-packed.
• One-time dyeing capacity ranges from 2 lbs - 4000 lbs

Wet Processing/Finishing
If required, the created fabric is reduced in size by steeping it in diluted acid and then rinsing it.
Enzymes may also be used. 'This is known as 'de-sizing'. If the Fabric in question is cotton, then
it is chemically washed to remove impurities such as natural wax, non-fibrous impurities and any
dirt that may time been accumulated over the previous process. If reagents are incorporated
correctly into the process, the fabric becomes smaller in size. At the end of this 'scouring'
process, most cotton turns out to be yellowish, and then requires bleaching to make it white. For
cotton which will he dyed deeper shades later on, lower levels of bleach are used. The strength,
dye affinity and luster result from 'mercerizing' the fabric which involves treating it with caustic
soda to cause the fibers to swell.

8
The fabric then needs to be made smoother. By passing it over brushes, the fibers of the cloth are
raised. These fibers are then singed of by passing it over a heated plate. Depending on the fabric
type, the 'raising' process is applied, where the fabric surface is treated with sharp teeth,
imparting hairiness, softness and warmth. The fabric can then be 'calendared' by passing it
between heated rollers to increase the smoothness and polish it. It is then mechanically shrunk to
prevent shrinking after our consumers purchase it.

Finally, the fabric can by dyed by submerging it into a dye solution for a period of time.
Alternatively, or after dyeing, we then print our imagination onto the fabric. Textile printing is
the process of applying color to fabric in definite patterns or designs. In properly printed fabrics,
the color is bonded with the fiber, so as to resist washing and friction. Textile printing is similar
to dyeing in which the whole fabric is uniformly covered with one color. In printing, however,
one or more colors are applied to certain pans only and in sharply defined patterns.

In printing, engraved plates, rollers or silk screens are used to place colors on the fabric.
Colorants contain dyes thickened to prevent the color from spreading beyond the limits ol the
pattern or design by capillary attraction.

Wet-Processing Capabilities
• Vats, reactives, pigments, Disperse/ Reactive, Disperse/Vat and woven & knitted fabrics
printing and dyeing.
• Huge capacity of Flannel Production.
• Largest producer of Yarn Dyed fabric in Pakistan.
• Specialized finishing capability according to our customers' requirements.
• Flannels and brushed twills printing and dyeing. Once the cloth is ready in its final form,
it is cut and stitched by advanced automatic cutting and sewing machines.

Cutting & Stitching

The finished fabric will now be changed into products. It goes through the process of cutting and
stitching, where one of numerous techniques may be applied depending on which type of product
is required. Our capabilities and capacities include: latest folding machines range with wrapping
facility; 125,000 meters CMT; production of 15,000 woven sheet sets and quilt covers per day;
production of 10,000 jersey sheet sets per day; more than 900 stitching machines with the
capacity of producing various kinds of stitching items and different hem treatments; 1,200 per
day Bed in a Bag, plus Room in a Bag with complete filling solutions; up to 1 million Fabric
Warehousing Facility in finished form; up to 1.5 million Fabric Warehousing Facility in Greige
form. The facility has the capability of various stitching techniques at the highest production
level and of producing all kinds of Applique; made-ups of all types i.e., bed linen, quilt covers,
sheet sets and pillow cases; garments for men and women's night wear and fashion wear; curtains
and kitchen linen. Alkaram Textile, in collaboration with the Ministry of Textiles, the
Government of Pakistan has embarked on a training project for the development of a skilled

9
work force. For this purpose, we have designed an in-house systematic training system for a
cutting & stitching skilled labor force.

Retail & Distribution

Once our creations of imagination are ready to wrap themselves around our stylish customers or
decorate their welcoming homes, they are taken to one of our various distribution centers. By
creating a retail network where each shop is specialized to suit a certain type of customer,
Alkaram focuses on satisfying each customer via ease of access and the widest ranges.

• Alkaram fabric is distributed throughout Pakistan via a distribution network of

independent retail outlets and fabric stores.
• Alkaram Studio is a retail chain that specializes in providing classy attire for men and
women, from local to international styles of clothing.

Distribution- A vast network of dealers, whole sellers, and retailers, our products reach more
than 200 outlets nationwide.

10
Power Generation
In recent years, the local providers of electricity have faced several issues in generating sufficient
quantities of power for the country. Alkaram has helped to overcome any shortages in electricity
by generating its own power so that our work never stops, whilst simultaneously lessening the
load on electricity providers.

Power Plant

Figure 1: Jenbacher Type-6 Engine 620

Alkaram has installed its in-house co-generation plant capable of generating 25MW of electricity
to drive the whole industry. Currently, the power house is consisting of engines and two gas
turbines supplying the electricity to the load of 22MW.

List of Generator
Following are the generators that are installed in Alkaram:

• Jenbacher Type 6 Engine 620

• Jenbacher Type 4 Engine 420
• Jenbacher Type 3 Engine 320
• Rental Generators (Orient, CAT etc.)

Gas Turbine
• Turbo Machinery Gas Turbine (Not Operational)

11
Gas Engine Basics
The image below shows the basics of a stationary gas engine and generator used for the
production of power. It consists of four main components - the engine which is fueled by
different gases. Once the gas is burnt in the cylinders of the engine, the force turns a crank shaft
within the engine. The crank shaft turns an alternator which results in the generation of
electricity. Heat from the combustion process is released from the cylinders. This must be either
recovered and used in a combined heat and power configuration or dissipated via dump radiators
located close to the engine. Finally and importantly there are advanced control systems to
facilitate robust performance of the generator.

Figure 2: Gas Engine Basic Components

12
Jenbacher Gas Engines
Jenbacher gas engines give you a power range of 200 kW to 10 MW with fuel flexibility to run
either on natural gas or a number of other gases. Jenbacher gas engines are manufactured in the
town of Jenbach, Austria in the Tyrol. They furnish onsite power, heat and cooling for a variety
of commercial, industrial and municipal applications – particularly renewable and waste-to-
energy, industrial power generation and cogeneration/CHP (combined heat and power), and
oilfield power generation. More than 48,000 Jenbacher gas engines have been delivered in 100-
plus countries.

Jenbacher has led the way in gas engine innovation over the last 50 years with developments
including:

• The LEANOX control philosophy

• The world's first 20 cylinder gas engine
• The world's first 24-cylinder gas engine
• The world's first twin-turbocharger gas engine
• The high-efficiency 4-series concept

Electrical Output Range

The gas engine generators cover an electrical output range from 249 to 9,500 kW:

1. Type 2 (249-330kWe)
2. Type 3 (499-1,063kWe)
3. Type 4 (844-1489kWe)
4. Type 6 (1,600-4,400kWe)
5. Type 9 (9,500kWe) (Not Explain in this report)

Power Production
Jenbacher gas engines can be configured to produce:

• Electricity only (base-load generation)

• Electricity & heat (cogeneration / combined heat & power - CHP)
• Electricity, heat and cooling water (trigeneration / combined heat, power & cooling -
CCHP)
• Electricity, heat, cooling and high-grade carbon dioxide (quadgeneration)
• Electricity, heat and high grade carbon dioxide (greenhouse cogeneration)

Gas engines are typically applied as stationary continuous generation units but can also operate
as peaking plants & in greenhouses to meet fluctuations in local electricity demand. They can
produce electricity in parallel with the local electricity grid, in island mode operation, or for
power generation in remote areas.

13
Gas Engine Energy Balance

LEANOX® Combustion technology

LEANOX is a lean-mixture combustion control. It was developed by Jenbacher and has been
patented worldwide.

The system ensures the correct air to gas ratio under all operating conditions. This has the benefit
of minimizing exhaust gas emissions whilst maintaining stable engine operation.

14
Features
The LEANOX system uses a special combustion chamber configuration for more efficient
combustion and directly links power output, boost pressure, fuel temperature and nitrogen oxide
emission. This eliminates the need to monitor oxygen in the exhaust using a Lambda probe.

The LEANOX control system corrects engine parameters to ensure the engine permanently
meets the required nitrogen oxide emission level.

Gas Engines Offerings

Jenbacher Type 2
Introduced in 1976, INNIO's Jenbacher Type 2 gas engine offers high efficiency in the 250 to
350 kW power range with a robust design. The stationary engine concept provides excellent
durability, while enhanced components and a proven control and monitoring model give the
Type 2 engine outstanding reliability.

Figure 3: Jenbacher Type 2 Engine

TOTAL FLEXIBILITY RELIABILITY FOR ALL COMPLETE EFFICIENCY

SCENARIOS
Depending on customer needs, The Jenbacher Type 2’s Enhanced combustion
the Type 2 can use a variety of turbocharger bypass is able to provides maximum efficiency,
gas types to increase compensate for extreme no matter how it’s being used
efficiency levels and reduce operating conditions. or what fuel is desired.
industrial emissions.

With their durability, reliability, and fuel flexibility, Jenbacher Type 2 gas engines have an
unmatched worldwide reputation of getting the job done.

15
 ➢ High-performance long-life spark plug for reliable operation.
➢ Applicable heat sources include engine cooling water, oil, mixture gas, and exhaust gas.
➢ Applicable gas types include:
o natural gas
o associated petroleum gas (flare gas)
o propane
o biogas
o sewage gas
o landfill gas
o coal mine gas
o other special gases (e.g. coke, wood, and pyrolysis gases)

Technical Specs

16
Jenbacher Type 3
Technical maturity and a high degree of reliability make INNIO’s Jenbacher Type 3 gas engines
a leader in their range i.e. 500 to 1,100kW. Long service intervals, a maintenance-friendly engine
design, and low fuel consumption ensure maximum efficiency, while enhanced components
prolong service life—even when employing non-pipeline gases such as landfill gas.

Figure 4: Jenbacher Type 3 Engine

PROVEN TECHNOLOGY EXCELLENT RELIABILITY THE FLEXIBILITY TO DO

The world-renowned Type 3
claims more than 220 million
operating hours of experience,
with over 8,000 engines
delivered since 1988.
MORE
Its high degree of The Type 3 is fuel-flexible
availability—up to 98%—and and solution-flexible—it can
its longer service intervals be installed in a container, as
mean the Type 3 is as reliable part of a generator set, or even
as it is durable. a CHP setup.

Jenbacher Type 3 engines offer proven savings on service and fuel consumption, offering
customers excellent efficiency.

• Two-stage mixture cooling enables high flexibility

• Turbocharger bypass evens out extreme operating conditions
• LEANOX* lean burn control ensures minimal emissions

17
A range of applicable gas types increases efficiency levels and reduces industrial emissions. Gas
types include:

• natural gas
• associated petroleum gas (flare gas)
• propane
• biogas
• sewage gas
• landfill gas
• coal mine gas
• Other special gases (e.g., coke, wood, and pyrolysis gases)

Technical Specs

18
Jenbacher Type 4
Based on the proven design concepts of Type-3 and Type-6, the modern Type-4 engines in the
800-1,500kW power range are characterised by a high power density and outstanding efficiency.
The optimised control and monitoring provides easy preventative maintenance and maximum
reliability and availability.

Figure 5: Jenbacher Type 4 Engine

PROVEN EFFICIENCY THE FLEXIBILITY TO DO RELIABILITY YOU CAN COUNT

Offering superior efficiency
with an innovative engine
concept, Type 4 engines save
on fuel without sacrificing
flexibility or reliability.
MORE
The Type 4 is available in 50
and 60 Hz and features fuel
and solution flexibility—
making it an excellent choice
for more than 10 different
applications.
ON
With their reliability,
dependability and high degree
of availability, it’s easy to see
why over 2,000 Type 4
engines have been delivered.

19
Jenbacher Type 4 engines have the same design, emissions control, and waste gas-to-energy
capabilities as their Type 2 and Type 3 counterparts, plus high power density and outstanding
efficiency in their power range.

• High-power turbocharger allows optimal operation at higher air intake temperature and
altitude.
• Four-valve cylinder head features enhanced swirl and channel geometry using advanced
calculation and simulation methods, resulting in optimal cooling and combustion
conditions.
• The Type 4’s crack connecting rod reduces bearing wear and is easy to maintain.

Technical Specs

20
Jenbacher Type 6
Continuously refined on Jenbacher’s extensive experience, the Jenbacher type 6 engines are
reliable, advanced products serving the 1.8 to 4.5 MW power range. Its 1,500 rpm engine speed
results in a high power density and low installation costs. The type 6 pre-combustion chamber
achieves maximum efficiency with low emissions. Proven design and optimized components
enable a service life of 60,000 operating hours before the first major overhaul.

Figure 6: Jenbacher Type 6 Engine

21
 FEATURES THAT IMPRESS LOWERED EMISSIONS PROVEN RELIABILITY
The Type 6’s pre-combustion With features like LEANOX* Type 6 engines’ enhanced
chamber achieves maximum lean burn control and an components and 60,000-hour
efficiency. enhanced steel piston, Type 6 service life continue
engines provide betters Jenbacher’s legacy of quality
emission reductions than ever. and reliability.
Type 6 engines are loaded with features that enhance heat recovery, assure stable combustion,
reduce emissions, and increase efficiency—taking the Jenbacher line to new levels of
performance.

• A centrally-located purged pre-combustion chamber helps provide optimal ignition

conditions.
• The spark plug ignition energy is amplified in the pre-combustion chamber, facilitating
stable and reliable combustion.
• Miller valve timing creates reduced compression temperature and increased safety margin
to knocking limits, providing improved ignition timing and high efficiency.

Company also provides a variety of upgrades to help maximize performance of the Jenbacher
Type 6 gas engine.

Technical Specs

22
23
 Power Generation Plan
Alkaram’s in-house co-generation plant is capable of generating 25MW of electricity to drive its
load that is around 22MW. The generation takes place in two categories i.e. HV and LV, with
different gas engines and turbines. Currently the power house is comprised of:

• Two Jenbacher 620 Gas Engines => 2*3MW => 6MW or 6,000kW at 11KV (HV)
• Two Jenbacher 420 Gas Engines => 2*1.4MW => 2.8MW or 2,800kW at 400V (LV)
• Four Jenbacher 420 Gas Engines (under commissioning)
• Three Jenbacher 320 Gas Engines => 3*900kW => 2.7MW or 2,700kW at 400V (LV)
• Six Rental Generators (Orient, CAT etc.) => 6*800kW => 4.8MW or 4,800kW at 400V
(LV)
o Note: [These generator will be remove after the commissioning of Jenbacher
420 Gas Engines]
• Two Gas Turbines (Not Operational) => 2*3.5MW => 7MW or 7,000kW at 11kV (HV)

Power Generation

High Voltage Generation at 11kV Low Voltage Generation at 400V

Two Gas Turbines Two Jenbacher 620

(Not Operational) Engines

Six Three Six Rental

Jenbacher Jenbacher Generators
420 Engines 320 Engines (Will
(Four under remove
Commission) soon)

24
Power Distribution Plan

25
Electrical Theory (Industrial Based)
Electric Power
Definition
The rate at which the work is being done in an electrical circuit is called an electric power. In
other words, the electric power is defined as the rate of the transferred of energy.

The classification of the electric power depends on the nature of the current. The electric power
is divided into two types:

• AC power
• DC power (Not Explain in this report)

AC Power
The AC power is mainly classified into three types:

• Active power / Real Power

• Reactive power
• Apparent power

Active Power
The power which is actually consumed or utilized in an AC Circuit is called True power or
Active Power or real power. It is measured in kilo watt (kW) or MW. It is the actual outcomes of
the electrical system which runs the electric circuits or load.

Reactive Power
The power which flows back and forth that means it moves in both the direction in the circuit or
reacts upon itself, is called Reactive Power. The reactive power is measured in kilo volt ampere
reactive (kVAR) or MVAR.

Apparent Power
The product of root mean square (RMS) value of voltage and current is known as Apparent
Power. This power is measured in kVA or MVA.

Power Factor and PFI Plant

The power factor is defined as the ratio of the active power (P) and volt-amperes. The active
power is the real power which is assumed in an AC circuit, whereas volt-amperes is the apparent
power which is produced in the circuit. For sinusoidal waveforms, the power factor is the cosine
of the angle (phase angle) between voltage and current.

26
Equation (1) shows that the current is affected by the power factor. Hence, for a given power P
by the load, the current I, taken by the load vary inversely as the load power factor cosΦ. Thus, a
given load takes more current at a low power factor than it does at a high power factor.

Disadvantages of low power factor

The undesirable effect of operating a low load at a low power factor is due to the large current
required for a low power factor. The important disadvantages of low power factor are

• Higher current is required by the equipment, due to which the economic cost of the
equipment is increased.
• At low power factor, the current is high which gives rise to high copper losses in the
system and therefore the efficiency of the system is reduced.
• Higher current produced a large voltage drop in the apparatus. This results in the poor
voltage regulation.

Since both the capital and running cost are increased, the operation of the system at low power
factor (whether it is lagging or leading) is uneconomical from the supplier’s point of view.

Causes of Low power factor

The usual reason for the low power factor is because of the inductive load. The current in the
inductive load lag behind the voltage. The power factor is therefore lagging. The important
inductive loads responsible for the low power factor are the three-phase induction motors (which
operate at a 0.8 lagging power factor), transformer, lamps and welding equipment operate at low
lagging power factors. Power factor improvement methods are used for improving the value of
power factor in a power system.

Power Factor Improvement (PFI) Plant

If the power factor is low or poor, it is necessary to improve or correct it. It may be improved by
injecting a leading current into the circuit so as to neutralize the effect of lagging current. The
power factor may be improved by using static capacitors (capacitor banks) or synchronous
motors.

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Power Factor Improvement by static capacitors (capacitor banks)
Consider an inductive load consisting of a resistor R and an inductor L connected to an AC
supply. The circuit and phasor diagrams are shown in the figure.

Let,

• V – Supply voltage.
• I1 – Load current
• φ1 – phase angle by which the current I1 lags behind the voltage
• cosφ1 – original power factor

Let the capacitor C be placed in parallel with the load. It will take a leading current Ic from the
supply. The circuit and phasor diagrams are shown in the figure.

The total I2 drawn from the supply will be equal to the phasor sum of I1 and Ic that is:

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Conclusions

• The phase angle of I2 is φ2. It is seen from the phasor diagram that the φ2 is less than φ1, and
hence, cosφ2 is greater than cosφ1. In other words, the power is improved from cosφ1 to
cosφ2.
• The new current supply from the supply is less than the load current I1, i.e., I2> I1. The new
current is given by the equation

• By connecting a capacitor in parallel with an inductive load, the power factor is improved,
and the current from the supply is reduced without altering either current or power taken by
the load.

This relation shows that the power taken from the supply has not altered.

Circuit Breaker & Its Types

A circuit breaker is a switching device that interrupts the abnormal or fault current. It is a
mechanical device that disturbs the flow of high magnitude (fault) current and in additions
performs the function of a switch. The circuit breaker is mainly designed for closing or opening
of an electrical circuit, thus protects the electrical system from damage.

Types of Circuit Breaker

There are several methods of classification of circuit breakers. The most general way of the
rating of a circuit breaker is by the arc extinction medium. The arc extinction can easily be done
by using the different medium like air, insulator, gas, vacuum, dielectric, etc.

By the arc extinction medium, the circuit breaker is categorised into four types. They are the air
break circuit breaker, air blast circuit breaker, sulphur hexafluoride circuit breaker and vacuum
circuit breaker. The classification of the circuit breaker is shown in the figure below.

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Gas Engines vs. Gas Turbines
Gas turbines have conventionally been the sole technology of choice for larger sized heat and
power projects. If you ask any industry expert, the situation could slowly but remarkably be
changing, owing to the greater flexibility exhibited by engines. As the tradition in power plants is
tested, let’s compare the two types of power plants (gas turbine and gas engine), giving the pros
and cons of each.

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Gas Engines
This refers to an internal combustion engine that relies on fuels such as natural gas, blast furnace
gas and producer gas. This equipment is often associated with Dr. Otto, the famous scientist who
improved the original work of the Frenchman called Lenoir.

The gas engine is based on the Otto Cycle. Unlike the diesel cycle, the Otto Cycle does not
undergo what is referred to as auto-ignition. Instead, a spark plug initiates the ignition of the air-
fuel mixture.

Figure 7: GE's Gas Engine

Like a motorcar engine, a gas engine power plant is characterized by a four-stroke cycle. The
major difference is that the fuel is natural gas or others. Another difference would be that the
engine runs constantly once the operator has set the required capacity.

The engine connects to a generator for electricity generation. Similar to a car engine, this engine
warms up and produces waste heat. The sources of the heat include:

o Exhaust gas
o Gas mixture production
o Hot lubricating oil

In the power plant setting, you will find several gas engines interconnected to form generating
sets. However, every engine connects to its shaft that connects to an electric generator. The sets
are available in standardized sizes of up to 20 MW.

Other technologies may encounter higher costs and problems when required to adjust load to
actual demand, but engine power plants play this role very effectively. Even if the power plant
carries more than 20 such engines, starting and stopping them within minutes to match demand is
not an issue.

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Modularity and high cost-efficiency give gas engines provide an optimal solution for steady
power requirements in any place. You can easily install a small or medium sized power plant on
the roof or in the basement. You could even containerize it. These and other characteristics are
summarized below.

Advantages
High power efficiency over a wide range
Wide range of unit sizes
Fast startup - as fast as 15 seconds
Can operate with low pressure gas (1 bar)
Part load operation flexibility
Real multi-fuel capability
Disadvantages
Must be cooled
Lower power to weight radio
Requires substantially strong foundations
High levels of low frequency noise
High maintenance costs

Gas Turbines
A gas turbine, the brain of the power plant, is a combustion engine that converts liquid fuels,
especially natural gas, into mechanical energy. This energy powers a generator that in turn
produces electricity.

Figure 8: Industrial Gas Turbine

Within the gas turbine, there is a fuel-air mixture being heated at extremely high temperatures.
This causes the turbine blades to spin fast. The market for gas turbines is growing steadily, the
prediction being that the trend will continue into 2020. It is easy to understand why this is the
case if you look at the advantages outlined below.

Advantages Disadvantages
No cooling water required Lower mechanical efficiency than engines
Low emissions High noise levels
High power to weight radio Poor efficiency at low load
Wide fuel range capability Output affected by ambient temperature
High reliability May need long repair periods

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Alternators
Alternators produce AC power through electromagnetism formed through the stator and rotor
relationship.

Basics of Power Generation

• If we place a rotating conductor in a constant magnetic field then there is an induced EMF in
conductor.
• If we place a steady conductor in a rotating magnetic field then there is an induced EMF in
field winding.

Types of Winding
Armature Winding
The winding from which the voltage should extract is said to be Armature Winding. This
winding can be done on both stator and rotor.

Field Winding
The winding on which the field is created is said to be Field Winding. This winding can be done
on both stator and rotor.

Block Diagram

Exciter/Mini Alternator Main Alternator

(Stator- Field, Bridge Rectifier (Stator- Armature,
Rotor- Armature) Rotor- Field)

Automatic Voltage
Regulator

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 Closing Words
Summing up
Overall internship is really a good experience and recommended to my follow friends. It helps to
enhance and develop my skills, abilities and knowledge. Alkaram Textile Mills is also a good
place to do the internship since it provides numerous benefits and advantages to the practical
trainees. I am grateful and thankful to my supervisor Mr. Syed Saad Ali [Manager
(Engineering)] and whole team for the experiences and tutoring.

The End

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