Tuwairqi Steel Mills

15 Days Internship Report

By Raheel (student of BE-Electrical)
From PNEC- NUST

+92-322-3374867
raheel.m.saleem@gmail.com

09
 Table of Contents
Preface…………………………………………………………………………………………………………….3
Acknowledgement…………………………………………………………………………………………..4
TSM
Ø Introduction…………………………………………………………………………………………..5
Ø Project Status…………………………………………………………………………………………6
DRI Process………………………………………………………………………………………………………9
Relevance of Work Experience to Studies
Ø Induction Motors and their Starting Methods………………………………………11
Ø Gas Turbine Generators…………………………………………………………………….…14
Ø CCPP…………………………………………………………………………………………………….16
Ø Buchholz Relays……………………………………………………………………………………18
Training………………………………………………………………………………………………………….21
Conclusion……………………………………………………………………………………………………..21

-2-|Page
 Preface

Over 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.

-3-|Page
 Acknowledgement

The 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 HOD Electrical

Mr. Zubair HOD Electrical @ SITE
Mr. Sajid Senior Engineer from Mechanical Department
Mr. Zahid Senior Engineer
Mr. Aamir Senior Engineer
Mr. Farrukh Engineer
Mr. Furqan Engineer
Mr. Zuhair Engineer
Mr. Naveed Engineer
Mr. Noman Engineer
Mr. Yasir Engineer (Intern Instructor)
Mr. Kamal 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.

-4-|Page
 Introduction

The 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 world’s 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.

-5-|Page
 Project Status
DRI 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.

-6-|Page
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.

-8-|Page
 DRI Process

-9-|Page
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 540 °C. The product from module is discharged as
COLD DRI and is sent to product silos for safe keeping and supply to Meltshop
for melting.

- 10 - | P a g e
 Induction Motor

The AC induction motor is a rotating electric machine designed to operate

from a three-phase source of alternating voltage. The stator is a classic three
phase stator with the winding displaced by 120°. The most common type of
induction motor has a squirrel cage rotor in which aluminum conductors or
bars are shorted together at both ends of the rotor by cast aluminum end
rings. When three currents flow through the three symmetrically placed
windings, a sinusoidally distributed air gap flux generating the rotor current is
produced. The interaction of the sinusoidally distributed air gap flux and
induced rotor currents produces a torque on the rotor. The mechanical angular
velocity of the rotor is lower than the angular velocity of the flux wave by so
called slip velocity.

In adjustable speed applications, AC motors are powered by inverters. The

inverter converts DC power to AC power at the required frequency and
amplitude. The inverter consists of three half-bridge units where the upper and
lower switch is controlled complimentarily. As the power device's turn-off time
is longer than its turn-on time, some dead-time must be inserted between the
turn-off of one transistor of the half-bridge and turn-on of it's complementary
device. The output voltage is mostly created by a pulse width modulation
(PWM) technique. The 3-phase voltage waves are shifted 120° to each other
and thus a 3-phase motor can be supplied.

- 11 - | P a g e
 Methods of Starting Induction Motor

As we know, once a supply is connected to a three phase induction motor a

rotating magnetic field will be set up in the stator, this will link and cut the
rotor bars which in turn will induce rotor currents and create a rotor field
which will interact with the stator field and produce rotation. Of course this
means that the three phase induction motor is entirely capable of self starting.

The need for a starter therefore is not, conversely enough, to provide starting
but to reduce heavy starting currents and provide overload and no-voltage
protection.

There are a number of different types of starter including ‘The Direct On-line
Starter’, ‘The Star- Delta Starter’, ‘and Auto-Transformer ’and‘ Rotor
resistance’.

Direct-on-Line Starter (DOL)

The DOL starter switches the supply directly on to the contacts of the motor.
As the starting current of an induction motor can be 6-8 times the running
current the DOL starter is typically only used for motors with a rating of less
than 5kW.

Star Delta starter

This is the most common form of starter used for three phase induction
motors. It achieves an effective reduction of starting current by initially
connecting the stator windings in star configuration which effectively places
any two phases in series across the supply. Starting in star not only has the
effect of reducing the motor’s start current but also the starting torque.
Once up to a particular running speed a double throw switch changes the
winding arrangements from star to delta whereupon full running torque is
achieved.
Such an arrangement means that the ends of all stator windings must be
brought to terminations outside the casing of the motor.

- 12 - | P a g e
Auto-Transformer Starting
This method of starting reduces the start current by reducing the voltage at
start up. It can give lower start up currents than star-delta arrangements but
with an associated loss of torque. It is not as commonly utilized as other
starting methods but does have the advantage that only three connection
conductors are required between starter and motor.

Rotor Resistance Starter

If it is necessary to start a three phase induction motor on load then a wound
rotor machine will normally be selected. Such a machine allows an external
resistance to be connected to the rotor of the machine through slip rings and
brushes. At start-up the rotor resistance is set at maximum but is reduced as
speed inceases until eventually it is reduced to zero and the machine runs as if
it is a cage rotor machine

- 13 - | P a g e
 Gas Turbine
A gas turbine, also called a combustion turbine, is a rotary engine that extracts
energy from a flow of combustion gas. It has an upstream compressor coupled
to a downstream turbine, and a combustion chamber in-between. (Gas turbine
may also refer to just the turbine element.)

Energy is added to the gas stream in the combustor, where air is mixed with
fuel and ignited. Combustion increases the temperature, velocity and volume
of the gas flow. This is directed through a nozzle over the turbine's blades,
spinning the turbine and powering the compressor.

Energy is extracted in the form of shaft power, compressed air and thrust, in
any combination, and used to power aircraft, trains, ships, generators, and
even tanks.

Theory of Operation

Gas turbines are described thermodynamically by the Brayton cycle, in which

air is compressed isentropically, combustion occurs at constant pressure, and
expansion over the turbine occurs isentropically back to the starting pressure.

In practice, friction and turbulence cause:

1. non-isentropic compression: for a given overall pressure ratio, the

compressor delivery temperature is higher than ideal.
2. non-isentropic expansion: although the turbine temperature drop
necessary to drive the compressor is unaffected, the associated pressure

- 14 - | P a g e
 ratio is greater, which decreases the expansion available to provide
useful work.
3. pressure losses in the air intake, combustor and exhaust: reduces the
expansion available to provide useful work.

As with all cyclic heat engines, higher combustion temperature means greater
efficiency. The limiting factor is the ability of the steel, nickel, ceramic, or other
materials that make up the engine to withstand heat and pressure.
Considerable engineering goes into keeping the turbine parts cool. Most
turbines also try to recover exhaust heat, which otherwise is wasted energy.
Recuperators are heat exchangers that pass exhaust heat to the compressed
air, prior to combustion. Combined cycle designs pass waste heat to steam
turbine systems. And combined heat and power (co-generation) uses waste
heat for hot water production.

Mechanically, gas turbines can be considerably less complex than internal

combustion piston engines. Simple turbines might have one moving part: the
shaft/compressor/turbine/alternative-rotor assembly (see image above), not
counting the fuel system. However, the required precision manufacturing for
components and temperature resistant alloys necessary for high efficiency
often make the construction of a simple turbine more complicated than piston
engines.

More sophisticated turbines (such as those found in modern jet engines) may
have multiple shafts (spools), hundreds of turbine blades, movable stator
blades, and a vast system of complex piping, combustors and heat exchangers.

As a general rule, the smaller the engine the higher the rotation rate of the
shaft(s) needs to be to maintain top speed. Turbine blade top speed
determines the maximum pressure that can be gained,this produces the
maximum power possible independent of the size of the engine. Jet engines
operate around 10,000 rpm and micro turbines around 100,000 rpm.

Thrust bearings and journal bearings are a critical part of design. Traditionally,
they have been hydrodynamic oil bearings, or oil-cooled ball bearings. These
bearings are being surpassed by foil bearings, which have been successfully
used in micro turbines and auxiliary power units.

- 15 - | P a g e
 CCPP (Combined Cycle Power Plant)
Introduction
a. Definition. In general usage the term ‘ ‘combined cycle power plant”
describes the combination of gas turbine generator(s) (Brayton cycle) with
turbine exhaust waste heat boiler(s) and steam turbine generator(s) (Rankine
cycle) for the production Of electric power. If the steam from the waste heat
boiler is used for process or space heating, the term "cogeneration” is the
more correct terminology (simultaneous production of electric and heat
energy).
b. General description.
(1) Simple cycle gas turbine generators, when operated as independent electric
power producers, are relatively inefficient with net heat rates at full load of
over 15,000 Btu per kilowatt-hour. Consequently, simple cycle gas turbine
generators will be used only for peaking or standby service when fuel
economy is of small importance.
(2) Condensing steam turbine generators have full load heat rates of over
13,000 Btu per kilowatthour and are relatively expensive to install and operate.
The efficiency of such units is poor compared to the 8500 to 9000 Btu per
kilowatt-hour heat rates typical of a large, fossil fuel fired utility generating
station.
(3) The gas turbine exhausts relatively large quantities of gases at
temperatures over 900 “F, In combined cycle operation, then, the exhaust
gases from each gas turbine will be ducted to a waste heat boiler. The heat in
these gases, ordinarily exhausted to the atmosphere, generates high pressure
superheated steam. This steam will be piped to a steam turbine generator. The
resulting “combined cycle” heat rate is in the 8500 to 10,500 Btu per net
kilowatt- hour range, or roughly one-third less than a simple cycle gas turbine
generator.
(4) The disadvantage of the combined cycle is that natural gas and light
distillate fuels required for low maintenance operation of a gas turbine are
expensive. Heavier distillates and residual oils are also expensive as compared
to coal.

- 16 - | P a g e
 STACK

- 17 - | P a g e
 Buchholz Relay

A Buchholz relay is a gas and oil operated device installed in the pipework
between the top of the transformer main tank and the conservator. A second
relay is sometimes used for the tapchanger selector chamber. The function of
the relay is to detect an abnormal condition within the tank and send an alarm
or trip signal. Under normal conditions the relay is completely full of oil.
Operation occurs when floats are displaced by an accumulation of gas, or a flap
is moved by a surge of oil. Almost all large oil-filled transformers are equipped
with a Buchholz relay, first developed by Max Buchholz in 1921.

- 18 - | P a g e
Conditions Detected
A Buchholz relay will detect:

Ø Gas produced within the transformer

Ø An oil surge from the tank to the conservator

Ø A complete loss of oil from the conservator (very low oil level)

Fault conditions within a transformer produce gases such as carbon monoxide,

hydrogen and a range of hydrocarbons. A small fault produces a small volume
of gas that is deliberately trapped in the gas collection chamber (A) built into
the relay. Typically, as the oil is displaced a float (B) falls and a switch operates
- normally to send an alarm. A large fault produces a large volume of gas
which drives a surge of oil towards the conservator. This surge moves a flap
(D) in the relay to operate a switch and send a trip signal. A severe reduction
in the oil level will also result in a float falling. Where two floats are available
these are normally arranged in two stages, alarm (B) followed by trip (C).

Gas and Oil Flows

Buchholz relays are equipped with a number of gas and oil inputs and outputs,
including test and sampling facilities

Gas sampling - a graduated sight glass provides an indication of the volume of

gas that has accumulated, typically 100-400cm3. After an alarm or trip signal
has been received this must be collected and analysed before the transformer
is returned to service. Gas collection can be done at the relay, or at ground
level if suitable arrangements exist. Clearly the latter is a safer and more
convenient option.

- 19 - | P a g e
Functional Tests - a test petcock enables dry air to be admitted into the relay
to check correct operation. A trickle of air is equivalent to a gradual
accumulation of gas. A blast simulates an oil surge. These tests are sometimes
referred to as 'blowing the Buchholz'. On completion it is important that the
relay is bled to remove the air that has been introduced.

Draining - a valve in the bottom of the relay enables an oil sample to be taken
or the relay to be drained. As with gas sampling, this facility can be brought
down to ground level for enhanced operator safety and convenience.

- 20 - | P a g e
 Training
I received no formal training as such in terms of my individual project. It was
my responsibility to become familiar with the system and the development
platform.

However, in this internship program, I learned ‘team building’ exercises. Here I

studied how different ‘types’ of people in the workplace interacted. For
example, we discovered firsthand how my ‘type’ (Creator-Innovator) clashed
with the ‘Thuster-Organiser’ type and how to organize types of people to build
an effective and balanced team.

Conclusion
I have learned how science and engineering can interact in useful ways and
how remarkable research can occur even when it is ‘profit driven’.

I was lucky enough to work with a group of enthusiastic and communicative

people, who for whatever reason share in enjoying what they are doing; the
atmosphere at TSML is unique and hope that it stays that way.

It has been a unique opportunity and one that I will not soon forget. My time
there has been eye opening and I thoroughly recommend the experience to
any other student who is thinking of applying.

Raheel

- 21 - | P a g e