1

PEOPLE STEEL MILLS

Summer Internship Program

Duration: 2 weeks from 22-06-09 to 03-07-09

Name: Muhammad Mehdi

PAKISTAN NAVY ENGINEERING COLLEGE

(NUST) Karachi Campus.
 2

CONTENTS

 INTRODUCTION

 PLANTS

 TESTING OF TRANSFOMER

 CRAIN INSTALLATION
 3

INTRODUCTION:

People Still Mills (PSM) is the only facility of its kind in Pakistan engaged in the
development and productions of alloys and special steels.

PSM is located about 20 km north of Karachi on manghopir road and is spread

over an area of 254,960 sqm.

PSM is headed by a Chairman and the Head Office is situated in Islamabad.

GM: Eng. Mr. Ali Asad

DGM: Eng. Mr. Dilawar Amjad

AM: Eng. Mr. Ali Subhani (Assistant Manager Q-Shop)

 4

PLANTS:
We have different plants in PSM that are labeled as Shops.

Q-Shop:
Also known as Electrical Shop. It comprises of two sections

i- Control Section (Room). ii- Production Section(Plant).

Control Section (Room):

In control section we have Control Center, Control Panel,

Transformer and AC and DC Motors of different ratings.

Control Centre:
Control Centre is based on Relay Logic mechanism which controls
the speed and Process Flow of “Production Plant” through
contactors and inverters.

Control Panels:
Control Panels are used to derive and control the speed of the motors
placed inside the control room and are connected to the Bar Rolling
placed inside the Production Plant.

Transformer:
A 3-Phase step down transformer having power rating of 500 KVA
is used to reduce the voltage level coming from main supply to 3.3
KV.

Motors:
AC and DC motors of different ratings are used to drive the Bar
Rollings.
We have 3 main motors in control room.
 5

A Wound Induction motor and two Separately Excited DC motors.

- Wound Motor:

Ratings: 750 KW, 350 A, 600 V, 600 rpm.

This is connected to the 1st Bar Rolling in Production Plant through

GEARS.
Gears are used to reduce the speed of motor to a required level. And
also the direction in which it drives the Bar Rolling is opposite to the
rotation of the motor.

- Separately Excited DC Motors:

Ratings: 500 KVW, 600 V, about 900 rpm.

We have 2 separately excited DC Motors that are connected with

their respective Bar Rollings.
For separate excitation a driver (control panel) is used.
As main supply is AC, an inverter is used to inverts the AC into DC.
DC motor starting torque (speed) is very high so its takes large
amount of current at start. So for this it is driven by a control panel
that controls the speed of the motor by varying the voltage level.
At start speed is reduced by reducing the voltage level and gradually
motors speeds up when voltage is increased.

AC  Inverter  DC  Driver  Motor  Rolling

(Control Panel)

Each motor is connected with separate driver (control panel).

- Besides these motors we have 2 other induction motor of small

power ratings in Q-Shop.
Cage Motor and Wound Motor
 6

a) Cage Motor:
20 KW, no slipping and fixed speed.
Is used to push the steel Bars into the Gas Furnace where steels
are heated to a Red Hot temperature.

b) Wound Motor:
22 KW and variable speed.
And is used to pull out the steel Bars from Gas Furnace for
reshaping

Production Section (Plant):

Also known as Bar Rolling Steel Production Plant where steels of

different shapes are produced.
In this plant we have Crains a Gas Furnace and no. of Bar Rollings.

Crains:
Are used to lift and carry large and heavy objects, such as steel Bars.
motors etc..
In production plant we have 4 Crains and each one is further consists of
Control Room, Control Panel, 2 Induction Motors, Junction Box,
Resistance Box, Windings and Limit etc..

Gas Furnace:
Steel Bars are heated at very temperature inside the furnace by
injecting very hot gases, so that they are easily reshaped when passes
through Bar Rollings.

Bar Rollings:
The steel Bars which just come out of the gas furnace are passed
through Bar Rollings about 6-7 times so that the required shape is obtained.
In production plant we have a no. of Bar Rollings. All these processes of
passing steel bars through Bar Rollings and cutting the extra size of steel
bars are controlled by a person inside the control room in the production
plant.
 7

Testing of Transformer:

A 3-Phase step up transformer is bought that is to be placed on the

Crain to drive the motor.

Ratings: prim. 400 V, sec. 500 V, 50 KVA.

We have to check weather this transformer could be operated at

desired load or not before installing it on the Crain.
Max. Load current of the motor that is driven by this trans. is about
30 A.

An inductive load (coil) that can bear a max. Current of about 50 A

is connected to H.V side of the Trans.
After connecting the L.V side of trans. With 400V AC supply the
whole system was kept in this position for 5-6 min. during this time each
phase and line voltages and currents were noted down with measuring
device. And the load current that was measured with the help of equation

P = √3 V I Cosα

Came out about 46A, which is greater than the required full load
current for driving the motor.

Hence this Trans. is now ready for use on the Crain to drive the
motor (500V).

Installation of Crain:
 8

In last two days of my internship at Q-Shop I observed the Crain

installation which was going on in P1 shop.

The Crain was manufactured in Germany. And maximum Load it

can bear is 3000 KG (3 ton).

The Crain was comprises of

Control room, control panel, resistance boxes, junction box, limit,

cables, Rolling, wound motors and two transformers of different ratings.

Control room:
The whole mechanism (movement) of Crain is controlled from
control room.

Control panel:
It is used to ON and OFF the motor, control the speed and the
voltage level of the motor and the values of resistance in the resistance box.

Resistance box:
It contains different values of resistors, and the speed of motor is
changed by selecting different resistance in resistance box through cables.

Junction box:
All the windings those are used on the Crain for connection were
terminated in the junction box.

Limit:
Limit is used to stop the load from lifting above a certain height
(level).

Cables:
 9

Cables of different thickness and color were used for connecting

different parts with control panel. Each wound motor was connected with
the control panel through 6 cables having different color and thickness. 3
cables of same thickness were connected with control panel through
transformer for supplying power to the motor and the other 3 cables of same
thickness (but different from the cables those were used for supplying
power) were connected with resistance box for changing the values of
resistance to control the speed(torque induced) of the motor.

Wound motors:
Were used to drive the Crain, the Rolling placed on the Crain and
are also used to lift the load. These motors are driven by transformers.

Transformers:
Two transformers of different ratings were used to drive the motor
those were placed on the Crain.

___________________________________