INTERNSHIP REPORT

Prepared By: SARFARAZ AHMED

Mechanical Department
MEHRAN-UET JAMSHORO
Submitted to: ABDULLAH HUSSAIN
Assistant Manager Maintenance (COGEN)

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 ACKNOWLEDGMENT

No Doubt all praise belongs to Almighty Allah. First of all I am thankful to Allah
for granting me such a valuable chance of internship at LOTTE CHEMICAL
PAKISTAN. I would like to thank Human Resources Department for selecting
me to be the part of this organization. Special thanks to Mr. Abdullah Hussain for
enlighting me with complete insight of mechanical field in very friendly
environment and assigning me the tasks which were rich in learning and thanks
to Mr. Taha Siddiqui (Trainee Engineer) who also put efforts to enrich my
Practical knowledge and provided guidance with sincere dedications.
I am also thankful to management team who facilitate us during my
internship and lastly, I would like to thank my companions who accompanied me
on this internship and share their worthy concepts and ideas that refined my
knowledge.
My four weeks' internship at LOTTE CHEMICASL PAKISTAN was a
wholesome learning experience. I look forward to work with this company in the
future.

Regards,
SARFARAZ AHMED
DEPARTMENT OF MECHANICAL ENGINEERING
MEHRAN UNIVERSITY OF ENGINEERING AND TECHNOLOGY JAMSHORO

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 TABLE OF CONTENTS
About Lotte Chemical Pakistan..............................................................................

Safety Health and Environment.............................................................................

Employee's Safety.............................................................................................

Extra Safety..........................................................................................................

Overview Of Plant........................................................................................................

Core Area...............................................................................................................

Oxidation Area.........................................................................................
Purification Area.....................................................................................

Non Core Area....................................................................................................

Utility Area................................................................................................
Cogeneration Area.................................................................................

Mechanical Devices ....................................................................................................

Pump ......................................................................................................................

Valve........................................................................................................................

Bearing...................................................................................................................

Gear.........................................................................................................................

Mechanical Seal..................................................................................................

Heat Exchangers................................................................................................

Combustor............................................................................................................

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Cogeneration Area.......................................................................................................

Overview...............................................................................................................

Working Process................................................................................................

Major Plant Items..............................................................................................

Gas Turbine Generator (GTG)...........................................................
Heat Recovery Steam Generators (HRSG)...................................
Natural Gas Booster Compressors (NGBC).................................

Assignments...................................................................................................................

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 LOTTE Chemicals Pakistan Limited (LCPL)
LCPL stands strong as the only world-class manufacturer and supplier of Purified
Terephthalic Acid (PTA) in Pakistan with a capacity to deliver 500,000 tons of PTA annually
through its state-of-the-art plant situated at Port Qasim, Karachi. Although last year they
achieved a personal record of manufacturing above 6 million tons of PTA annually.
PTA is the primary raw material for producing Polyester fiber, Polyester filament yarn,
Polyester film and Polyethylene Terephthalate (PET). LCPL holds the foundation of the
polyester chain in Pakistan and retains its edge by being a local producer and key supplier
for the domestic Polyester and PET industries with short delivery, world class quality and
exceptional customer service.
For producing PTA LCPL imports their feedstock (Paraxylene) from reputable suppliers
based in Asia and Middle-East region. Their plant operates under a technology license with
IPT (Investa Performance Technologies) which is currently the leading global supplier of
PTA technology.
LCPL has also enabled expensive infrastructure development in Port Qasim area including
Chemical Jetty, raw water pipeline and production of industrial gasses through third party
contracts. This has started a new trend in industrial investments in Pakistan.
Besides enabling significant growth in downstream industries LCPL operations provide
significant foreign exchange savings in excess of USD 100 million annually for the country.

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 Health Safety& Environment
LOTTE Chemicals Pakistan is a responsible organization, governed by a safety, health and
environment (SHE) policy. This accords the highest priority to the safety and health of their
employees and the public.

Employee’s Safety:
Lotte chemical Pakistan provides important safety to their employees as precaution to any
accident by providing specific equipment known as Personal Protective Equipments (PPEs).
The PPEs provided to each and every individual includes:

• Safety Goggles
• Light Eye Product (LEP)
• Safety Shoes
• Safety Helmet
• Ear plugs
• Ear muffs
Extra Safety:
Extra safety equipment includes:
• Safety harness
• PVC Gloves
• PVC suit
• Leather gloves
• Face shield
• Dust mask

Safety symbols include:

❖ Yellow line: Plant area

❖ Red & white boxes: High noise
❖ Green & white boxes: Chemical area
❖ Green & red: hazardous area

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 OVERVIEW
Lotte Chemical Pakistan is producing PTA from Paraxylene as a solute and acetic acid as a
solvent. Lotte consists of two areas:

1. Core Area:

2. Non Core Area

CORE AREA

OXIDATION PLANT:

Paraxylene, acetic acid, and catalyst (Cobalt Manganese Bromide), are mixed to create a
feed which goes to the oxygen reactor to react with compressed air (18 bar). The major
portion of Terephthalic Acid produced is precipitated to form slurry in the reactor. This slurry
is than passed through crystallizer where it is cooled to form crystals. It then goes to the
ROVAC (Rotary Vacuum Filter), where it is filtered. After filtration the product, it is dried in
the dryer to produce crude Terephthalic Acid (CTA) which is 99.7% pure. The Residue is
treated in Catalyst Recovery Unit (CRU) to recover Acetic acid for reusing it in the reaction.
The waste water is sent to Effluent Treatment Plant (ETP).

PURIFICATION PLANT:

In pure the CTA which contains few impurities is purified, resulting in PTA which is 99.98%
pure product. The most problematic impurity is 4-formylbenzoic acid (commonly known in
the field as carboxybenzaldehyde) which is removed by hydrogenation of a hot aqueous
solution of terephethalic acid. This solution is then passed to crystallizers where it is cooled
to crystallize. Next it passes through the PTA drier where it is dried to yield the final product,
Purified Terephethalic Acid (PTA).

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 NON CORE AREA

UTILITIES:

It consists of Effluent treatment plant (ETP), Cooling Towers, Based Load Generators,
Emergency Diesel Generators, Boilers, Reverse Osmosis Plant. Utilities also provide raw
materials used in the production of PTA, which are Paraxylene, Acetic Acid, Catalyst, Diesel,
Demin Water, Fuel Oil and Caustic.

CO-GENERATION (COGEN):

This plant generates electricity and steam hence known as C0-Gen started from August
2012, Before C0-Gen electricity was taken from K-Electric and steam was taken from the
Boilers (which used natural gas as a fuel). The total power needed to run the plant is about
25-26MW and the steam needed is approximately 50 tons/hours. After Co-Gen, electricity is
produced by the Gas Turbine generator (GTG) and steam is generated by using the
Exhaust heat of the turbine.

MECHANICAL DEVICES

PUMP
Pump is a mechanical device which converts mechanical energy into kinetic and pressure
energy of fluid as a result the pressure of fluid rises.

TYPES:
1. Positive Displacement Pump.
2. Centrifugal Pump.

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 Position Displacement Pump:
Positive displacement pump or PDP is a type of pump in which a certain amount of fluid is
captured inside the cavity, and then discharges the same. This displacement of fluid takes is
done by plunger, piston, diaphragm etc. depending on the type of the pump.

Reciprocating:
In this type of pump, the reciprocating part (which moves backward and forward) helps the
fluid to move forward from the reservoir. The reciprocating parts can be a plunger, piston or
diaphragm.

Rotary:
In this type, the fluid is moved with the help of a rotary. The rotation of the rotary displaces
the fluid from the reservoir to the discharging pipe.

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 Centrifugal pump:

A centrifugal pump is a mechanical device designed to move a fluid by means of the

transfer of rotational energy from one or more driven rotors, called impellers. Fluid enters
the rapidly rotating impeller along its axis and is cast out by centrifugal force along its
circumference through the impeller’s vane tips. The action of the impeller increases the
fluid’s velocity and pressure and also directs it towards the pump outlet. The pump casing
is specially designed to constrict the fluid from the pump inlet, direct it into the impeller and
then slow and control the fluid before discharge
Following are types of centrifugal pump.
1. Axial
2. Radial.

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 VALVE

A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids,
fluidized solids) by opening, closing, or partially obstructing various passageways.
• TYPES:
Gate Valve:
Gate valve is a sliding type of valve. In gate valves,
the closing member is a metal gate. The gate slides
down to close the valve. In fully open conditions, the
flow area is equal to the area of the pipe and hence,
there is negligible pressure drop across the valve.
Gate valve is used as on-off valve.

Globe Valve:
Globe valve is a linear motion type of valves and is
typically used in both on-off and throttling applications.
In globe valves, the flow of the fluid through valve
follows an S-path. Due to this, the flow direction
changes twice which results in higher pressure drops.
Due to other advantages offered by them, they are
widely used in applications where pressure drop
through the valve is not a controlling factor.

Disc Check Valve:

Disc check valves, also called as non-
return valves allow the flow to pass
through them in only one direction
and stop the flow in reverse direction.

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Diaphragm Type Check Valve:
This kind of check valves uses diaphragms
arranged in such a way that that open to
allow the flow only in forward direction. When
flow comes from the reverse direction, the
diaphragms remain closed.

Butterfly Valve:
A butterfly valve is a type of flow control device,
typically used to regulate a fluid flowing through a
section of pipe. The valve is similar in operation to a
ball valve. A plate or disc is positioned in the center of
the pipe. The disc has a rod through it connected to
an actuator on the outside of the valve. Rotating the
actuator turns the disc either parallel or perpendicular
to the flow. Unlike a ball valve, the disc is always
present within the flow; therefore a pressure drop is
always induced in the flow, regardless of valve
position. It is a quarter turn valve and suitable for low
pressure service. It can be used for throttling as well
and has a positive shut-off and Provides little resistance to flow.

Ball Valve:
Ball valve is a quarter turn operated valve. The closure
member is a spherical plug with a through hole. When the
valve is in open state, the through hole is in-line with the
fluid flow and hence, the fluid passes through it. The valve
is closed by rotating the globe by 90 Deg. such that the hole
now becomes perpendicular to the flow and hence, stops
the flow.

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 Plug Valve:
Similar to ball valves, plug valves are also
quarter turn type of valves. This valve consists of
a plug which can be either cylindrical or conical
in shape. The plug has a through slit which
remains in-line with the flow in the open
condition. When the plug is turned by 90 Deg.,
this slit becomes perpendicular to flow and the
valve gets closed.
Plug valves are well suited to handle fluids with
suspended solids, slurries etc.

Bearing
Bearing is a machine element that have constrained relative motions and used to reduce
friction between moving parts of machine to obtain desired motion. For example to stop
deviation in a shaft of a machine while rotating, a bearing is used. The main functions of
bearings are

▪ To reduce friction between moving rotator parts.

▪ To support rotating parts of a machine.
▪ To bear radial and thrust load.

TYPES:

Friction Bearing:
As the name implies, in this bearings the bearing surface is in contact with moving surface
or the shaft which produces more friction. Lubricant is used for slow moving and heavy
weighted running on shaft. Friction bearing are also subdivided into following types:

(A.)Solid Bearings:
It is a simplest hole made in cast iron to support the shaft and
form running fit. These are made up of cast iron or bronze in
the form of bush and press-fitted in fabricated or cast iron
housings. This is used for small and light shafts moving at low
speed. A hole is provided on its face of lubrication.

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(B.)Split Bearings:
Split bearings are same like solid bearings but have an
arrangement of split. Split bearings are made in halves and
assembled in special plumber blocks. It has collar on its external
surfaces and also made in two parts as shown in figure.

Anti-Friction Bearing:
The main purpose of these bearings is to minimize the friction in bearing. Due to this
reason, the speed of an object increases and friction and temperature decreases. Such
bearing have long life. These bearing also sub-divided into following categories.

Ball Bearings:
A ball bearing is a rolling element bearing that uses ball to maintain the separation between
the bearing races. The width of these bearing is smaller than the bore diameter or ball. On
the basis of load and groove cut, ball bearings are classified in the following types.

A) Deep Groove Ball Bearing:

• Capable of operating at high speed.
• Have Simple Design.
• Can withstand moderate radial and axial load.
• Have low friction and high precision.

B) Angular Contact Ball Bearing:

• It has line contact.
• Can withstand axial and radial load.
• have inner and outer ring raceways that are displaced
relative to each other in the direction of the bearing axis.
• These bearings are designed to accommodate combined
loads, i.e. simultaneously acting radial and axial loads.

C) Self Aligning Ball Bearing:

• Permit angular miss alignment
• Have two rows of Balls.
• These bearings can withstand with journal loads
.

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Roller Bearings:
Roller bearings are available with the grooved race in the outer and inner members. Roller
bearings are capable of carrying the journal (radial) loads. It can work with greater load than
ball bearings. To use this bearing, race is required to be locked. On the basis of uses, roller
bearings are classified in following types.

A) Cylindrical:
• High load carrying capacity.
• Accommodates heavy radial load at high speed.
• Small cylinder type roller is used.

B) Tapered:
• Accommodate axial and radial load.
• but accommodate axial load in one direction.
• For axial load in both direction it is used in matched
pair.

C) Spherical:
• Have two rows of roller inclined at an angle.
• Self Aligning.
• Accommodate radial and axial in both direction.
• High load carrying capacity.
• lower operating temperature.

GEARS

A device used to transmit power from one shaft to another or used to increase and
decrease the rpm and torque of shaft.

TYPES:

HELICAL GEAR:
• Gears cut at angles and make gradual contact between teethes.
• It is used for high speed applications.
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 • It is less noisy and high efficient.
• It is also can be used to adjust the rotation angle by 90
degree.
• It is used to generate large amount of thrust and use bearing
to support thrust load.

SPUR GEAR:
• Straight gear, very noisy and causes vibration.
• It is used where low speed and high torque output is
required.
• It is very prone to wear.
• used in series for large gear reduction.

BEVEL GEAR:
• It may have straight and spiral teeth.
• It is mainly used in right angle application.
• They are cone shaped gears.

WORM GEAR:
• It is used where high speed with high load is
required.
• It is used where high shock loads are
available.
• Low noisy, maintenance free, and very less
efficient.
• Used at right angle configuration.

MECHANICAL SEAL:
Mechanical seals are used to prevent leakage of gases
and liquids in rotating shaft applications that exceeds the
capabilities of radial lip shaft seals and packing. In a
simple mechanical seal the rotary sealing face acts as
the primary sealing ring and stationary sealing face as
mating ring. The primary seal ring is flexibly mounted in
the seal head assembly which rotates with shaft and the
mating ring is mounted on the pump gland plate.

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Mechanical Seal Components:
The Basic components in a mechanical
seals include the following
1. A stationary sealing face
2. A Rotating sealing face
3. A Static secondary seal for stationary
face
4. A Static secondary seal for rotating
face
5. A spring or a bellow to press the
sealing faces together.
6. A system to flush seal area.
A multiple seal may be mounted as double – Back to back, double – face to face or tandem
arrangement.

HEAT EXCHANGERS

Heat exchangers are devices that facilitate the exchange of heat between two fluids that are
at different temperatures while keeping them from mixing with each other whether the both
fluids are in direct contact or indirect.

CLASSIFICATION

• On the basis of fluid relative direction:

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Parallel Flow: When both the hot and cold fluids enter the heat exchanger at the same
end and move in the same direction.

Counter Flow: When both the hot and cold fluids enter the heat exchanger at the opposite
end and move in the opposite direction.

Cross Flow: When both the hot and cold fluids enter the heat exchanger and flows
perpendicular to each other.

• On the basis of Design & Construction:

Shell & Tube Heat Exchangers: Heat transfer takes place as one fluid flows inside the
tubes while the other fluid flows outside the tubes through the shell. Baffles are commonly
placed in the shell to force the shell-side fluid to flow across the shell to enhance heat
transfer and to maintain uniform spacing between the tubes.

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Plate & Fin Heat Exchangers: It is a type of heat exchanger design that uses plates and
finned chambers to transfer heat between fluids. Heat is transferred from one stream
through the fin interface to the separator plate and through the next set of fins into the
adjacent fluid. The fins also serve to increase the structural integrity of the heat exchanger
and allow it to withstand high pressures while providing an extended surface area for heat
transfer.

Plate Type Heat Exchangers: A plate exchanger consists of a series of parallel plates
that are placed one above the other so as to allow the formation of a series of channels for
fluids to flow between them. The space between two adjacent plates forms the channel in
which the fluid flows. Inlet and outlet holes at the corners of the plates allow hot and cold
fluids through alternating channels in the exchanger so that a plate is always in contact on
one side with the hot fluid and the other with the cold

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 COMBUST0RS

Can type Combustor:

A combustor, or burner section, of a gas turbine engine made up of several individual cans.
These cans are long and cylindrical and consist of an outer casing within which there is a
stainless steel combustion chamber liner, or inner liner. These combustors are arranged
radial around the engine axis. Compressed gases from the compressor flow through the
cans, where fuel is sprayed and burned to add energy. Cooling air flows between the
housing and the inner liner and through holes in the inner liner to keep the temperature of
the can slow enough to avoid any damage.

Annular Combustor:

An annularcombustion chamber is in the shape of a ring or a cylinder and the whoe of the
annulus between the compressor and the turbine is used for combustion. There is a space
between the flame tube and the outer casing for secondary and tertiary airflowprior to entry int
o the flame tube. This type of combustion chamber is lighter; but control of airflow is difficult
as are repairs.

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 CO-GENERATION AREA

Overview:
In this area two types of generation is there as power or electricity by GTG and steam by
heat exchange from exhaust flue gases hence it is known as co-generation.

Working Process:
In this area power is generated by converting energy of flue gases into mechanical and
electrical energy. Atmospheric air is filtered from air filter and then compressed from
compressor that results in high pressure which leads to combustion chamber while natural
gas as fuel is also compressed by NGBC and sent to combustion chamber for combustion.
Exhaust gases are passed from turbine to produce power output.

Steam is generated by heat exchanging of flue gases with water in HRSG which
consist of evaporator and economizer. Flue gases are passed from both of them that results
in steam generation from water used in evaporator and economizer.

Major Plant Items:

Gas Turbine Generator:

It works on the principle of Brayton Cycle and consists of LP and HP compressor,
combustion chamber and LP and HP Turbine attached with generator. In this natural gas is

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used as a fuel and atmospheric air is used for combustion. It converts energy of fluid into
mechanical and then electrical energy. LM6000 PD sprint is used in Co-generation area.

Main Components:
1. LP and HP Compressor.

2. Variable Bleeding Valve.

3. Triple Annular Combustor.

4. LP and HP Turbine.

5. Hydraulic Starter

6. Generator

7. Gear Box

Working:
Atmospheric air is filtered from air filter then inters into LP Compressor having 5 stages and
then Hp compressor having 14 stages from which 6 stages have variable guide vanes, the
pressure of air is increased up to 46 bar and then air leads to combustion chamber. The
compressed natural gas from NGBC is also brought to combustion chamber in pre mixture
then injected to combustor. In LM6000 triple annular combustion chamber is used having 3
pre mixer hence called triple annular and 30 nozzles. In combustor spark ignition takes
place and combustion of fuel results in flue gases that flue gases enters the LP turbine of
two stages where expansion takes place and then further expanded in LP turbine that
results in power output. Gear box is attached to LP shaft which converts 3600 rpm to
3000rpm and gearbox is connected to Generator which converts mechanical energy into
electrical energy.

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 HEAT RECOVERY STEAM GENERATOR
In HRSG heated water is converted into steam by heat exchanging with flue gases
exhausting from Turbine. It consists economizer, evaporator, drum and stake. In this
process 48 tons of steam is generated at 100 bars and 310C. It is a horizontal type and
increasingly area type HRSG.

Working:
Exhaust Flue gases are passed through HRSG and water is sent to economizer then water
is pre heated and sent to Drum and from that it leads to Evaporator where flue gases
evaporates the water by exchanging its heat and steam is generated which again sent to
drum and further supplied where it is needed and the exhaust flue gases are sent to
atmosphere through stake after filtering.

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 NATURAL GAS BOOSTER COMPRESSOR
NGBC is a triple stage positive displacement compressor each stage connected to
intercoolers where natural gas is compressed and its pressure rises from 2 bar to 46 bar
then sent to GTG. There are two Compressors one is working and other is at stand by. To
increase discharge volume of natural gas double acting compressor is used.

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 Assignment
Question: Why separate oil system is used for generator and turbine?

Answer: B/c the temperature in generator section is low as compared to turbine section and hence it
requires low quality oil which is suitable to use in that temperature and requires larger amount of oil.

Question: How can we increase pressure by compressor at constant discharge volume and increase
volume at constant temperature?

Answer: Pressure is increased by increasing number of stages of compressor at constant discharge

volume while volume is increased by using double acting compressor instead of single acting.

Question: What is turbocharger?

Answer: It is a device used to increase the power output of engine. It consist of compressor wheel and
turbine wheel connected with same shaft. It takes exhaust flue gases of engine to rotate turbine wheel
which cause rotation in compressor wheel that suck larger amount of ambient air in compressor as result
air is very denser and has high temperature and then sent to intercooler to make more denser. This air is
sucked by engine that allows more efficiently burning of fuel and operation of engine and results in high
output power.

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