internship at tuwairqi steel mills muhammad fasih waheed
DESCRIPTION
UIT students Fasih waheedSyed hayderSohaib ahmedTRANSCRIPT
2013
Muhammad Fasih WaheedSohaib AhmedSyed Hayder
Internship Report
ACKNOWLEDGMENT
An attempt over a period can be successful only with the advice and support of well
wishers. We take this opportunity to express our gratitude to all those who encouraged
and helped us to complete the tasks of this internship.
We are deeply indebted to Sir. MUHAMMAD JAMSHED and Sir FIDA HUSSAIN, for
our successful completion of internship.
We express our profound and sincere thanks to Miss ZEHRA who acted as mariner’s
compass and steered us throughout our internship journey through her excellent
guidance and constant inspiration.
We shall be failing our duty if we don’t acknowledge our debt to Mr. MUHAMMAD
TALHA, Mr. ASIM RAUF, Mr. KAPIL DAVE, for their valuable counseling and support,
which helped us giving a shape to our study.
We also extend our thanks to all other TSMLE members for their support and
encouragement.
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EXECUTIVE SUMMARY
This internship report consists of four sections; the first section is introduction to TSML
which include organization’s history, background, vision, mission Introduction of
TSMLE and TSMLE Solar. The second section covers assignments which include solar
cell types, working, construction, brief information about inverters, batteries and
mounting structures, Visuals are also included for better understanding. Third section
entirely consists of solar system designing according to the load. Fourth section discusses
the successful projects like SHADMAN MALL, BEACON HOUSE SCHOOL SYSTEM
LAHORE campus, the inverters, batteries and other equipments that were used in these
projects.
In the end handouts of PLC, Actuators, Thermocouple and RTD’s are attached and are
part of this report.
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Contents
ACKNOWLEDGMENT.....................................................................................................2
EXECUTIVE SUMMARY.................................................................................................3
ABOUT TSML....................................................................................................................5
TSML DEPARTMENTS.....................................................................................................6
TSML ENGINEERING KARACHI (TSMLE)...................................................................6
TSMLE SOLAR..................................................................................................................7
ASSIGNMENTS...............................................................................................................12
PHOTO VOLTAIC MODULES.......................................................................................12
MOUNTING STRUCTURES...........................................................................................14
INVERTERS.....................................................................................................................14
INVERTERS OFFERED BY TSMLE..............................................................................15
BATTERIES......................................................................................................................16
SOLAR SYSTEM DESIGNING.......................................................................................17
SOLAR PROJECTS..........................................................................................................18
1. 40 KW ROOF TOP SOLAR SYSTEM (SHADMAN SHOPPING MALL )...........18
SYSTEM RATINGS.........................................................................................................18
2. 10KW ONGRID SOLAR SYSTEM AT BEACON HOUSE CANAL CAMPUS LAHORE...........................................................................................................................19
IMPORTANT FORMULAE.............................................................................................20
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ABOUT TSML
AL TUWAIRQI holding is a prestigious Saudi Arabian industrial conglomerate, which
has interests in steel and engineering and ranked 26th among top hundred companies of
the kingdom with the rating of 2nd fastest growing group ATH’s core business include
iron and steel production, steel products manufacturing, electrical manufacturing, power
generation and engineering.
In engineering ATH has a strong presence in the region of KSA, UAE and Pakistan. The
group comprises five separate entities unified under one flag i.e. Al TUWAIRQI holding,
to form a resource pool, which offers multi dimensional services to our clients, TSMLE
Engineering Pakistan is one of them.
TSML DEPARTMENTS 1. Administration2. Finance department3. It department4. Procurement5. Electrical and instrumentation6. Mechanical engineering7. Process engineering8. Civil engineering9. Cad department10. Pmo department11. Sales and marketing
TSML ENGINEERING KARACHI (TSMLE)
TSMLE Karachi is an engineering company involved in engineering designs, fabrication
and erection of products related to oil and gas, fertilizers, petrochemicals, power
generation and process industry. TSMLE acts as a design engineering hub for the ATEG
and has to its major credit complete “out side the licensor scope” design and 50% of
fabrication of DRI plant, a state-of-the-art-steel manufacturing complex in Pakistan, at
Port Bin Qasim Karachi.
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TSMLE is gearing up to market its engineering design and fabrication capabilities in
Pakistan, with objective to maintain a sustainable growth with one underlying principal;
to combine the multifaceted capabilities and energies of people, partners, entrepreneurs,
community and stakeholders, in order to form an alliance which one could create its own
excellence in the services spectrum. In Pakistan we have already developed business
relationship with prestigious names such as ENGRO, Bayer PHARMA, KPT, BYCO and
KSEW.
Besides providing design service to group, TSMLE ambitiously expending its operations
in Pakistan, with primary focus on prestigious customers who nurture quality.
AL TUWAIRQI engineering companies have strategy alliances with a number of
internationally renowned engineering companies operating in the region such as SACDO,
SPCEO and FL smith. Under these J-V agreements the partners would synchronize their
expertise to provide the best yet cost effective solution to our customers.
At group level our existing external customers include illustrious names such as Saudi
ARAMCO, Qatar Steel, SABIC, Saudi electricity company, WINDHOFF, ADNOC, and
ENGRO etc. At group level, we have provided complete EPC solution to our subsidiaries
in Saudi Arabia, UAE and Pakistan,
We are committed to set the high quality standards. The group already conforms to the
international quality management standards (ISO 9001:2008) , Hence begin capable of
meeting all quality marks and international standards.
TSMLE SOLARTSMLE SOLAR is a subsidiary of Tuwairqi Steel Mills Limited, TSMLE SOLAR is one of the largest Solar Systems integrators and services providers in Pakistan, with special expertise in design and installation of commercial solar systems. With its in-house mechanical fabrication facility, dedicated design and executions teams, a vast team of experienced professionals and technical personnel, Simulation and testing facilities, TSMLE SOLAR is dedicated to deliver best quality services and solutions to its customers. TSMLE SOLAR has been continuously working to develop innovative
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solutions to play its part in the collective effort to meet the ever increasing energy demands while constantly striving for nature and environment conservation by providing clean and green energy. TSMLE SOLAR is ISO 9001:2008 certified and believes in constant quality improvement and delivering the best quality of services to the utmost satisfaction of its clients.
TSMLE DESIGN ENGINERING SERVICES
TSMLE is capable of multidisciplinary and multidimensional design engineering services
in the core business sector like
Crude oil refining
Oil storage terminals
Natural gas processing
Fertilizer
Cement
Steel
Petrochemicals
Power generation
Process industry
TSMLE have multidisciplinary engineering teams, i.e. Process, Mechanical and piping,
civil and structure, E&I.
VISION
Our vision for TSMLE is its transformation into an international market leader equipment
manufacturing and multifaceted engineering service we envisage to grow as a company
which acquire a place among the best in the business and retains the place by
continuously delivering world class engineering services to the utmost satisfaction of our
valued customers, and at the same time bringing new technologies to our nation and
contribute to its economic growth.
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MISSION
Our mission of TSMLE is to transform it in one stock solution provider in design
engineering, Equipment manufacturing, construction, Fabrication and maintenance
services by offering best quality and optimal cost.
To accomplish our goals we are already geared; By inducting the best human resource,
providing rigorous professional training creating a conductive work environment and
establishing a culture where striving for the not lesser than the best is the order of every
day!
VALUESWe endeavor to be a respected world-class organization and the leader in Pakistan’s steel
industry by:
• Fostering teamwork
• Delivering premium products & services
• Nurturing talent
• Developing solutions based on cutting-edge technologies
• Respecting the environment
• Caring for our community
Demonstrating high ethical standards
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CORPORATE VALUES
SERVICES OFFERED:
Solar Module design and installation. Engineering design services. Direct Reduced Iron from DRI plant.
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ORGANOGRAM OF TSMLE ENGINEERING
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BASIC DESIGN
P&ID and Speciation’s
Instrument and device locations
Single line diagram
DCS Configuration design
Interconnection design
DETAIL ENGINEERING Load calculations and cable sizing
Switch gear selection instruments hook ups
Wiring diagrams and schematics
Earthling and grounding
Cable schedule and cable details
Equipment layout drawing
Electrical co ordinations and short circuit studies
TSMLE have multidisciplinary engineering teams, i.e. process, Mechanical and piping,
civil and structure, E&I These terms comply of individuals who blend extensive past
experience in designing and detail engineering of relevant fields, Exposure to
international engineering codes and practices and modern engineering tools, working
with renowned licensers and serving prestigious clientele.
The attitude of constant knowledge sharing and flexibility of technology adoption are
inherent of TSMLE team members who are constantly progressing towards gaining
expertise and utilizing the skills to the utmost in their respective fields of engineering.
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ASSIGNMENTS
PHOTO VOLTAIC MODULES
A complete PV (photo voltaic) Module consists of PV cells, Inverter, batteries, battery
charging circuitry and mounting structure. The PV cell converts photons produced by the
sun to electrons (electricity) on the basis of a simple process called “The photo electric
effect”. The inverter converts the DC signal produced by the panel to AC signal and in
some cases also acts as a charge regulator for batteries. A mounting structure mounts the
PV panel on a degree at which maximum Sun light is accessible.
CONSTRUCTION
PV cells are constructed of Silicon semi conductors. These silicon layers are sandwiched
between two protective layers and are bordered depending upon the power we would like
to extract from them. One side of the protective layer is transparent from which the
photons are allowed to enter. In the end set of these PV cells are connected in series or
parallel depending upon the requirement.
TYPES OF PV CELLSThere are two types of PV cells
Mono crystalline Poly crystalline
Mono Crystalline
Mono Crystalline consist of single crystal
Of silicon which is way more efficient and
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Harnesses more energy from the sun compared
To poly crystalline but is costly and lacks
Flexibility.
POLY CRYSTALLINE
Poly Crystalline cells are made up of millions
and billions of Silicon crystals that are combined
to form poly crystalline cell, It is cheap
and flexible to use but less efficient when it
comes to power output.
WORKING OF PV CELLS
As the photon from sun strikes to the surface of PV silicon cell. The barrier potential of
Silicon PN-junction is disturbed causing an imbalance in electrons and holes of upper
band and lower band of PV cell. This imbalance creates a potential difference across the
ends of PV cell hence delivering usable electricity.
MOUNTING STRUCTURESMounting structures are an essential part of a solar system; they hold the PV cells and tilt
them at the required angle to expose cells to maximum
Sunlight, Currently TSMLE Solar is working as a
Distributor of Solar world mounting structures.
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TYPES OF MOUNTING STRUCTURES Fixed Racks Horizontal one-axis tracking system Tilted one-axis tracking system Rail tracking system
INVERTERS
MODIFIED SIN WAVE INVERTER Modified sin wave inverters are cheap and common however
they have some strong drawbacks. Modified sin wave inverters
are able to run appliances like refrigerator, hand tools, computers
. But they fail to run gaming systems, plasma display and complex
scientific testing systems.
PURE SIN WAVE INVERTER
Pure sin wave inverters are way expensive as compared to modified sin wave inverters
but they are more efficient, they are able to produce pure sin wave and there efficiencies
are up to 98%. Pure sin wave inverters can run high end audio Ideal units, plasma
displays etc too without any problem.
HYBRID INVERTERS
An inverter is an electrical device that converts electricity derived from a DC (Direct
Current) source to AC (Alternating Current) that can be used to drive an AC appliance.
The theory of operation is relatively simple. DC power, from a hybrid battery for
example, is fed to the primary winding in a transformer within the inverter housing.
Through an electronic switch (generally a set of semiconductor transistors), the direction
of the flow of current is continuously and regular broken (the electrical charge travels
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into the primary winding, then abruptly reverses and flows back out). The in/out flow of
electricity produces AC current in the transformer's secondary winding circuit.
Ultimately, this induced alternating current electricity flows into--and produces power
in--an AC load (for example an electric vehicles (EV) electric traction motor). A rectifier
is a similar device to an inverter except that it does the opposite, converting AC power to
DC power.
INVERTERS OFFERED BY TSMLETSMLE is importing inverters from SMA and, Following are some main inverter types;
VOLTRONIC INVERTERS Axpert KS series
SMA INVERTERS
SUNNY MINI CENTRAL SUNNY TRIPOWER SUNNY ISLAND
BATTERIES
TYPES OF BATTERIES:1. VRLA Battery2. Gel type Battery3. Lead Acid Battery
GEL TYPE BATTERY
Gel type batteries are recommended to be used with Solar panels because of their longer
life, lesser danger and deep cycle properties.
LEAD-ACID BATTERYLead Acid Batteries are avoided to be used because of the danger level and poor deep cycle properties.
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VRLA (Valve Regulated) batteryVRLA batteries are being used in solar modules for safer operation. They work on the
basis of LI-Ion batteries
SOLAR SYSTEM DESIGNING
DESIGN OF A SYSTEM CONSIDERING FOLLOWING LOADS:
1. 75 watt fan running for 8 hours2. 20 watt bulb running for 4 hours3. 200 watt TV running 4 hours4. 100 watt computer running 3 hours
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TO CALCULATE WH/DAY
(75*8) + (20*4) + (200*4) + (100*3)
600 + 80 + 800 + 300
1780 * 1.3
2314 Wh/day
PEAK RATING OF PV MODULE
2314/3.43
674.635
NO. OF MODULE
674.635/255 (available solar panel=255 watt)
2.645
3 panels each of 255 watt required
INVERTER SIZING
Total watt = 75+20+200+100 = 395 Watt
395 * 1.3 (for any possible losses)
513.5
600 Watt Inverter
SOLAR PROJECTS
1. 40 KW ROOF TOP SOLAR SYSTEM (SHADMAN SHOPPING MALL )
Client: Ghani Global Groups
SUMMARY
As per drawing we are using 60 PV-modules connected with 3 Sunny mini Central
Inverters to extract power and convert to AC from sun Also we are using 3 sunny island
inverters each connected with set of 24 batteries, these inverters act as a battery backup
system. SMC inverters are synchronized with main AC grid where solar power is given
priority to drive the load.
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SUNNY MINI CENTRAL:
These inverters are connected to PV modules on its DC input channel and to main power
grid on its AC side. It is synchronized with grid and supplies electricity to the load, Here
SMC is given priority to drive the load.
SUNNY ISLAND INVERTER:
Sunny island inverter is a multipurpose inverter, It supplies power from AC to the level
batteries can be charged in DC, Also it converts DC to AC so charged batteries could
supply power to the load.
SYSTEM RATINGSSunny mini Central
11KW, 230V, 50Hz
Sunny Island inverter
5KW, 230V, 50Hz
Switch box
125Ampere and 12 Ampere fuse
2. 10KW ONGRID Solar system at beacon house canal campus Lahore
Client: Beacon House
SUMMARY:
AS per drawing we are using 10KW, 400V, 50 HZ sunny tripower inverter which is
connected with eight PV modules connected in series/parallel connections. The
connections of PV panels and inverters are protected with fuses of 10 Ampere each,
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Sunny Tripower inverter is synchronized with AC, Solar panels output are given priority
to supply electricity to the load.
For a backup system we have three sunny Island inverters which are 2.2 KW, 230 V
50Hz each connecting 24 batteries each rated 300Ah 2V, These batteries are also
protected by 100 A fuses, The sunny Island inverter is directly connected with grid to
charge the batteries.
PROCEDURE
42 of modules are connected with Sunny Tripower Island inverters when the photon
strikes with the surface of the PV modules it produces DC electricity which is inverted in
3 Phase by Inverter and synchronize with main grid, which enable us to maintain stable
voltage. In this system we are given advantage by three phase c1 connector, If we want to
disconnect the grid we can do it.
Backup system consist of batteries which are connected with three Sunny Island system
these connections are protected by 3(100 A) fuses each these sunny Island inverters
perform multiple tasks it not only converts AC to DC but also DC to AC.
Sunny Island systems are directly connected to the grid to charge the batteries.
When switch on C2 three phase connector it makes sure to disconnect the C1 It helps to
prevent the system from damaging.
IMPORTANT FORMULA E
SOLAR PANEL ENERGY OUTPUT FORMULA
E=A*r*H*Pr
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Where,
A=Area
r=Solar panel yield
H=annual average solar radiation on tilt panel
Pr=Performance ratio (0.5-0.9) avg =0.75
BATTERY CHARGING AND DISCHARGING FORMULA
T= Ah of battery/Ampere of supplyWhere,
T= time in hours
Ah= Ampere hour
Annexure
Presentations attached
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