Pakistan International

Airlines

Internship Report

Submitted to:
Mr. Shahid Mehfoz

Submitted by:
The final year students from the Mechanical Engineering Department of

“Quaid-e-Awam University of Engineering, Science & Technology”

Aerospace Group Members:

 Atif Munir 15ME64
 Hamza Sultan 15ME32
 Mehtab Akber 15ME77
 Quaid-e-Awam University of Engineering,
Science & Technology, Nawabshah

Abstract

Within our educational program at the Quaid-e-Awam University of

Engineering, Science and Technology Nawabshah, we got the
opportunity to complete an internship at Pakistan International Airlines
(PIA) and gather beside practical experience in the area of Aerospace.
During the period, we had gained an insight into the processes of engine
overhaul and maintenance, jet engine inspection & testing etc. We got
the chance to closely observe the different airplanes in the maintenance
line including ATR 42 & 72, Airbus 310 & 320 and Boeing 777 which
helped us to learn the engineering behind these aircraft. Beside this, we
were able to learn the basic theoretical concepts and principles of
aviation and flight that enabled us to analyze and understand the field of
aerospace.
 Acknowledgments

We would like to whole-heartedly thank the engineering staff at the PIA

for not only accommodating us in their hectic office but also providing
an enriching experience to us in their busy schedule. Also, we would like
to thank the HR Manager and complete staff of PIA Training Center for
providing us with this wonderful opportunity to experience the
corporate as well as technical culture characteristic of aviation
maintenance all around the world. The work culture in PIA really
motivates. Everybody is such a friendly and cheerful companion here
that works stress never comes in the way.

We would like to especially thank Mr. Shahid Mehfoz for providing us a

chance to get this great experience.

Students of QUEST
Table of Contents
1. INTRODUCTION ............................................................................................................... 5
2. POWER PLANT & ENGINE OVERHAULING DIVISION ...................................................... 6
3. LANDING GEARS SECTION ........................................................................................................ 6
4. ENGINE TEST BENCH SECTION ................................................................................................ 7
5. MACHINE SHOP............................................................................................................................. 8
6. ELECTROPLATING SHOP............................................................................................................. 8
7. COMPONENT OVERHAUL SHOP ............................................................................................. 8
8. PROPELLER SHOP.......................................................................................................................... 9
9. BASE MAINTENANCE (WIDE-BODY)...................................................................................... 9
10. NON-DESTRUCTIVE TESTING LAB ........................................................................................ 10
11. CONCLUSION ............................................................................................................................... 10
 1. INTRODUCTION:
Pakistan International Airlines was born on January 10, 1955, as the National Flag
Carrier, and incorporated in the SECP on December 4, 2015, winning many global
accolades since its inception. PIA's vision is to be a world-class profitable airline
meeting customer expectations through excellent services, on-time performance,
innovative products and absolute safety. PIA's fleet of modern aircraft are spacious,
comfortable, and designed to get you to your destination safely. PIA operates a
range of advanced aircraft, ranging from the world's preferred Boeing 777 airplane
to the super-quiet Airbus A-320. PIA flies across the globe to 27 destinations in 19
countries across Asia, Europe and North America, and services to 25 domestic
destinations. PIA is driven by the highest standards of quality, safety, and
convenience with travelers at the center of all their growth and improvement
decisions. PIA believes in building strong relationships with customers, partners,
employees, and the communities in which it operates. PIA practices active
corporate citizenship through social services, support for non-profit organizations,
medical services for employees, the promotion of sports, and educational
initiatives. PIA is much more than a national airline, it is a national institution. In
continuation of its unwavering commitment to Pakistan's development, the PIA
Sports Division was set up in 1958. PIA's contribution to the advancement of
Pakistani sports remains unparalleled – no other organization in the country has
consistently invested in the promotion and development of sports.
 2. POWER PLANT & ENGINE OVERHAULING DIVISION:
PIA's power plant division offers comprehensive repair, overhaul modification,
testing and calibration services for a range of aircraft engines. In this engineering
area, we got training under 3 sections.
i. CFM
ii. ATR
iii. APU
This section offers repair/test and engine run facilities for a variety of GE, Pratt &
Whitney CFM Engines.
 We were able to learn the following things:
 The construction and working principles of the jet engine.
 The Brayton Cycle (Constant pressure open cycle).
 The mechanisms and assembly involved in the jet engine.
 Observed ATR 42 & 72, which are maximum efficient at low altitude.
 ATR consists of two modelers, AGB & Turbomachinery.
 Differences between ATR and other engines.
 Purpose of APU & its installation position.

3. LANDING GEARS SECTION:

Overhaul/repair of landing gears of Airbus and Boeing aircraft. Landing gear is the
undercarriage of an aircraft or spacecraft and is used in both takeoff and landing.
We familiarized with the different components, terminologies, and principle of the
landing gear.
Landing gear works on the principle of the shock absorber and is made up of robust
material. Basically, it consists of an Oleo (inside the barrel) that creates damping
effects due to oil and air.
Following are some allied components of landing gears:
 Drag Strut
 Torsion Links
 Barrel
 Brake Assembly
 Bogie Beam
 Shock Strut/ Absorber
FUNCTION OF A LANDING GEAR:
 Support the static load of an aircraft on ground or water.
 Provide a means of ground maneuver/taxiing.
 Absorb the landing shocks.
 Dampen the vibration.
 Facilitate aircraft for takeoff and landing.
 Providing the aircraft with the braking and steering functions.

4. ENGINE TEST BENCH SECTION:

There were two test benches where we visited, one for engines of Aircraft like
Airbus and other for ATR engines. This is the only Engine Test Cell in Asia. After
completion of the overhauling of these engines, they are tested in Engine Test
Cell. This test is called an off-wing test. The engine is tested and compared with
standard engines provided by the manufacturer. The engine is kept in a closed
room where it is tested and run from the control room. This test shows all the
parameters involved in the engine. This is the complete simulation of the engine
performed at the test cell.
5. MACHINE SHOP:
In this shop, a part/ tool of the required dimension is obtained by different
machining processes. The machine shop is divided into two sections.
i. Light Machinery Area
ii. Heavy Machinery Area
Following are the machines that are available at the machine shop and we found
them functional.
a) Horizontal Lathe Machine
b) Vertical Lathe Machine
c) CNC Machine
d) Milling Machine
e) Boring Machine
f) Surface Grinding
g) Radial Drill Press
h) Cylindrical Grinding
6. ELECTROPLATING SHOP:
Electroplating is the process of plating one metal onto another by hydrolysis, most
commonly for decorative purposes or to prevent corrosion of a metal.

7. COMPONENT OVERHAUL SHOP:

Repair/ overhaul of the fuel system and miscellaneous systems (mechanical)
components ranging from the check valve to sophisticated equipment.
The aircraft fuel system consists of 3 portions.
 Main engine fuel system component.
 APU component.
 Airframe component.
 8. PROPELLER SHOP:
The propellers are installed in Turboprop Engine aircraft like ATR aircraft to
generate thrust. The propeller is of the airfoil shape. The propeller blades are
mounted on the hub along the shaft which is powered by the turbine at the back.
Understood the basic assembly of the propellers that includes a spinner, blades,
pitch change assembly, barrel, and oil transfer tube. Also, the concept of deicing
and heating element at the blade.
9. BASE MAINTENANCE (WIDE-BODY):
Base maintenance is a heavy maintenance which requires the aircraft to be taken
out of traffic for carrying out modifications on it. It is mainly planned maintenance,
primarily C- and D-checks, but also includes repairs, modifications, and upgrades.
Base maintenance department offers cost-effective and high-quality maintenance,
repair and overhaul services for its airline fleet. The highly qualified engineering
personnel offer comprehensive engineering services, backed up by excellent
equipment and systems. In this section we visited the following sections:
 Structural Repair Service:
The base maintenance team is backed up by the state of the art structure
repair shop which can perform repairs on individual structural components
of aircraft and also has the capability to develop repair schemes.
The structure of an airplane is made up of a material having a high strength to
weight ratio. Most made up of aluminum alloys having strength as good as steel.
The material is basically a composite material. There are 3 types of composite
materials in aviation they are:
 AFRP: Aramid Fiber Reinforced Polymer
 GFRP: Glass Fiber Reinforced Polymer
 CFRP: Carbon Fiber Reinforced Polymer
There are generally two types of ceramics structures they are:
 Laminate Structure
 Sandwich Structure
 10. NON-DESTRUCTIVE TESTING LAB:
NDT is a wide group of analysis techniques used in science and industry to
evaluate the properties of a material, component or system without causing
damage. Following are the NDT methods learned:
i. Eddy Current
ii. Ultrasonic
iii. Liquid Penetrate
iv. X-Ray
v. Magnetic-Particle

Understood the purpose the NDT and its applications. Also, visually observed
Eddy Current and Ultrasonic Test at some specimens.
CONCLUSION:
The complete experience was very fine at PIA. We had been given more time to
professional development and increase our creative and analytical approach in the
field of aviation. PIA helped us to link between our theoretical knowledge to the
practical real-life work. Throughout our internship days, our performance was very
fine according to the staff and supervisors. We will really love to get appoint for the
job in the future at PIA or any other aviation industry.