INTRODUCTION

Nishat Mills Limited is the flagship company

of Nishat Group. It was established in 1951.
It is one of the most modern, largest
vertically integrated textile companies in
Pakistan. Nishat Mills Limited has 238,032
spindles, 794 Toyota air jet looms. The
Company also has the most modern textile
dyeing and processing units, two stitching
units for home textile, two stitching units
for garments and Power Generation
facilities with a capacity of 130 MW. The
Company’s total export for the year 2018
was Rs. 38.862 billion (US$ 353.03 million).
Due to the application of prudent
management policies, consolidation of
operations, a strong balance sheet and an
effective marketing strategy, the growth
trend is expected to continue in the years

INTERSHIP REPORT to come. The Company’s production

facilities comprise of spinning, weaving,
processing, stitching and power
Nishat Mills (Power Plant) generation.

Muhammad Saqib Irshad

BE- Mechanical, NUST
[email protected]
0301-4421466
Table of Contents
Power Plant of Nishat Mills:....................................................................................................... 2
Working Principle of Four Stroke Diesel Engine: ....................................................................... 3
1. Intake stroke ...................................................................................................................... 4
2. Compression stroke ........................................................................................................... 4
3. Power stroke ...................................................................................................................... 4
4. Exhaust stroke .................................................................................................................... 4
Common Components of Internal Combustion Engines ........................................................... 5
Cylinder: ................................................................................................................................. 5
Combustion portion: .......................................................................................................... 6
Expansion portion: ............................................................................................................. 6
Head: ...................................................................................................................................... 7
Piston: .................................................................................................................................... 7
Fuel Injection pump: .............................................................................................................. 8
Fuel Injector: .......................................................................................................................... 9
Flywheel and damper: ......................................................................................................... 10
Camshaft and Rocker Arm: .................................................................................................. 10
Turbocharger: ...................................................................................................................... 11
Charged Air Cooler: .............................................................................................................. 11
Purifier: ................................................................................................................................ 12
Alternator:............................................................................................................................ 13
Plate Heat Exchangers: ........................................................................................................ 13
Cooling Tower: ..................................................................................................................... 13
Candle Filter: ........................................................................................................................ 15
Gas Admission Valves: ......................................................................................................... 15
Engines at Nishat Mills Power Plant ........................................................................................ 16
Daihatsu Engines: ................................................................................................................. 16
Engine CC: ............................................................................................................................ 17
Indicated Horsepower: ........................................................................................................ 17
Wartsila 20V34DF Engine: ................................................................................................... 18
CAT GAS (3516C) Engine ...................................................................................................... 20
Working Circuits ....................................................................................................................... 22
 Fuel Circuit ........................................................................................................................... 22
Lube Oil Circuit ..................................................................................................................... 22
Air Circuit ............................................................................................................................. 23
Cooling Water Circuit ........................................................................................................... 23
Jacket Water Circuit ............................................................................................................. 24
Analysis of Work Environment ................................................................................................ 24
Conclusion ................................................................................................................................ 24

TABLE OF FIGURES
Figure 1: PV Diagram of Diesel Cycle ...................................................................................................... 5
Figure 2: 2D view of piston motion and clearance volume of liner ........................................................ 6
Figure 3: Cylinder Head ........................................................................................................................... 7
Figure 4: Piston ....................................................................................................................................... 7
Figure 5: Fuel Injection Pump ................................................................................................................. 8
Figure 6: Fuel Injector Crankshaft: .......................................................................................................... 9
Figure 7: CrankShaft ................................................................................................................................ 9
Figure 8: Vibration Damper................................................................................................................... 10
Figure 9: Camshaft and roller guide ...................................................................................................... 10
Figure 10: Turbo Charger ...................................................................................................................... 11
Figure 11: Charged Air Cooler ............................................................................................................... 11
Figure 12: Alfa Level Purifiers ............................................................................................................... 12
Figure 13: Heat Plate Exchanger ........................................................................................................... 13
Figure 14: Cooling Tower of capacity 150 meter cube per hour .......................................................... 14
Figure 15: Candle Filter ......................................................................................................................... 15
Figure 16: Gas Admission Valve ............................................................................................................ 15
Figure 17: 8DL-32 Daihatsu turbo charged diesel engine ..................................................................... 16
Figure 18: Wartsila 20V34DF Engine..................................................................................................... 19
Figure 19: CAT GAS (3516C) Engine ...................................................................................................... 20
Figure 20: General Fuel Circuit.............................................................................................................. 22
Figure 21: General Lube Oil Circuit ....................................................................................................... 22
Figure 22: Air Circuit ............................................................................................................................. 23
Figure 23: Cooling Water Circuit ........................................................................................................... 23
Figure 24: Jacket water General circuit ................................................................................................ 24
Power Plant of Nishat Mills:
Nishat Mills Limited Bhikki has established modern, highly reliable and extremely efficient
captive co-generation power plants to cater in house energy demands. It is responsibility of
power plant unit to provide energy to other units of the mill. These facilities are using single
Wartsila, 3 Gas Caterpillar and 3 Daihatsu for power generation with total generation capacity
of 19.2 Mega Watt. Gas, Furnace Oil, Diesel is being used as fuel for power generation in
power plant.
Daihatsu engines were bought and put in work at plant in 1994 and since then these engines
have performed well to cater energy requirements of the Mill. Moreover, Wartsila
commissioned in 2014 is one of the most modern and reliable engines, available in the
market. Likewise, Gas Powered Caterpillar Gas Engines with 1.5 MW generation capacity each
are easy to operate and produces energy at low cost.

Working Principle of Four Stroke Diesel Engine:

In the Power Plant, the Daihatsu and Wartsila are both 4 stroke diesel engines working on the
heavy fuel oil. The working mechanism of an ordinary 4 stroke engine is based on conversion
of chemical energy of the fuel into mechanical energy of the crankshaft and further
conversion of this mechanical energy into electrical energy using an alternator. Such a
combustion engine utilizes four distinct piston strokes (intake, compression, power, and
exhaust) to complete one operating cycle. The piston makes two complete passes in the
cylinder to complete one operating cycle.

The 4-stroke internal combustion Diesel Engine is named after its working principle in which
the piston does four strokes to complete a combustion cycle. Each stroke is the complete
movement of the piston from one extremity to the other.

The four-stroke engine has a camshaft gearing that is 1:2 that of the crankshaft. A full turn of
the crankshaft is then equal to the piston moving up and down once, it takes another turn of
the crankshaft or 720° to complete a full four-stroke cycle. Each of the strokes has a specific
purpose to go through the combustion cycle:
➢ Intake
➢ Compression
➢ Power
➢ Exhaust
1. Intake stroke
Just before the piston reaches the top dead centre (TDC) of crankshaft rotation, the exhaust
valve remains open and the flow of the exhaust gases escaping causes a low pressure to occur
in the cylinder. With the intake valve opening, the low pressure helps to pull in fresh air into
the cylinder and this suction is aided by the piston moving down to complete the intake
stroke.

2. Compression stroke
The compression starts at the bottom dead centre (BDC) after the intake suction completes.
As the piston travels up towards TDC again the air inside the cylinder is compressed, causing
it to increase in pressure and temperature. At the end of the compression stroke, the fuel is
injected into the cylinder. The intake and exhaust valves remain closed.

3. Power stroke
Both valves remain closed as the piston passes TDC on the second revolution of the
crankshaft. The air-diesel mixture gets ignited causing pressure and temperature to rise. This
forces the piston downward, exerting mechanical work to turn the crankshaft and generate
power. A typical 4-stroke diesel engine has an efficiency of just over 40%, the remaining work
is converted into heat losses that escape with cooling and exhaust gases.

4. Exhaust stroke
With the piston reaching BDC the second time, the exhaust valve opens to evacuate the hot
spent air from the cylinder into the exhaust manifold. As the piston loses speed nearing TDC
to complete its four-stroke cycle the exhaust gases escaping cause a pressure difference to
develop which creates a suction when the intake valve opens.
PV diagram of Diesel 4 stroke cycle is shown below:
0-1: Intake of fresh air into the cylinder, Isobaric process.
1-2: Adiabatic (ideally isentropic) compression of the air.
2-3: Reversible heating, Qin is the heat introduced by fuel combustion, Isobaric Process
for Diesel Engine and Isochoric for Gas Engine because in Gas Engine combustion
happens at once.
3-4: Adiabatic expansion (ideally isentropic) during the power stroke with work
being done by the piston
4-1: Isovolumetric reversible exhaust, Qout is the heat vented out
1-0: Isobaric release of air into the atmosphere
 Figure 1: PV Diagram of Diesel Cycle

Common Components of Internal Combustion

Engines
Cylinder:
The cylinder of the engine encloses the liner. The liner is the part of the engine where the
combustion takes place. The piston moves through the liner of the cylinder. Cylinder is usually
divided into two portions:
Combustion portion:
It is the portion where combustion happens during power stroke. Volume of combustion
portion is also called clearance volume. Clearance volume is equal to Vo shown in figure
below. During compression stroke, all gases are compressed at high pressure in clearance
volume.

Expansion portion:
The distance along which piston moves during each rotation is called Expansion portion.
Expansion portion is equal to the distance between top dead center and bottom dead center
which is equal to stroke length. It is called expansion portion because it is the volume in which
piston moves when gases expand during power stroke because of its high pressure and
temperature.

Figure 2: 2D view of piston motion and clearance volume of liner

Head:
Head is placed on the combustion side of the cylinder. Head provides housing to inlet valves,
outlet valves, starting air valves, fuel injector and safety valves. These valves are pushed down
by rocker arm to open them. However, starting air valves are operated by air coming from
distributor and safety valves opens towards outside on their own when pressure inside the
cylinder exceeds the limit either due to choking of exhaust valves or high fuel injection by fuel
injector due to any abnormality.

Figure 3: Cylinder Head

Piston:
The piston is a moving disk encased in a chamber which is made gas-tight by cylindrical rings
called the piston rings. Two piston rings are attached to the Piston namely:
➢ Scraping Ring
➢ Compression Ring
Scraping ring removes lubrication oil from
cylinder wall as piston moves downward so
that fuel oil do not burn during combustion.
While Compression ring do not allow air to
flow out of the cylinder due to gap between
piston and liner.
Piston moves inside the chamber as a fluid
inside the chamber grows or contracts. A
cylinder helps in the change of heat energy
into mechanical work. The connecting rod
connects the piston to the crankshaft
integrally converting linear motion of the
piston into rotation of the crank shaft.

Figure 4: Piston
Fuel Injection pump:
The fuel injector, as the name implies, pumps oil to high pressure and injects into fuel injector
which using this pressure, sprays oil finely in liner. Fuel injection pump are has plunger which
is moved up and down just before power stroke by roller guide for fuel injection. Control
sleeve controls how much fuel is to be injected in fuel injector and hence in liner. Control
sleeve is connected through rack to the governor. Governor controls the flow of oil in cylinder
by moving control sleeve though rack. For emergency shutdown, we can close move governor
manually too to avoid major disaster.

Figure 5: Fuel Injection Pump

Fuel Injector:
Fuel Injectors are responsible for injection of fuel in the form of very small droplets in
combustion cylinder at very precise time to run engine using minimum fuel. Fuel is injected
in the form of fine spray by injector at about 900 psi pressure so that combustion happen at
once. This creates high peak pressure and temperature and area enclosed by PV graph
increases.
As we know:
𝑊𝑜𝑟𝑘 𝑑𝑜𝑛𝑒 𝑝𝑒𝑟 𝑐𝑦𝑙𝑐𝑒 = 𝐴𝑟𝑒𝑎 𝑖𝑛𝑙𝑐𝑜𝑠𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑃𝑉 𝑔𝑟𝑎𝑝ℎ
Hence, work done by engine per cycle increases and hence efficiency of engine increases.

Figure 6: Fuel Injector

Crankshaft:
The crankshaft rotates due to the power strokes of individual cylinders. This rotates the fly
wheel and this motion in turns, used to produce changing magnetic flux in the alternator coils
and hence current is induced in them.

Figure 7: CrankShaft
Flywheel and damper:
During four strokes of the engine, only power stroke rotates the crankshaft. To keep engine
rotating and avoid vibrations in the engine due to hammering effect of power stroke, fly wheel
is connected at one end of the crankshaft while vibration damper is connected at another
end. Due to heavy mass of fly wheel, it has large angular inertia which makes it capable of
performing three strokes of engine (suction, compression, and exhaust) without using any
external source and make engine operating.

Figure 8: Vibration Damper

Camshaft and Rocker Arm:

The rocker arm and camshaft along with the push
pins are the part of a mechanism that is used to
open and close the inlet and exhaust valve of each
cylinder in synchronization with strokes taking
place. Since the timings of the inlet and exhaust
valve are very integral to the working of the engine,
and even the smallest of the variation can disrupt
engine functioning, the mechanism of rocker arm,
camshaft and pushpins are specially designed to
open engine valves in conjunction with the strokes
of the engine.
In four stroke camshaft is connected to crankshaft
with gear ratio of 1:2. So during every two
revolutions of crankshaft, camshaft completes its
rotation once only. Roller guides are attached on
camshaft in synchronized manner which in pushes
the push rods to move rocker arm and open inlet
and outlet valve of the cylinder during suction and
exhaust stroke respectively.
Figure 9: Camshaft and roller guide
Turbocharger:
Turbo charger is utilized to build the productivity of the machine with up to 40% increase in
the efficiency. It comprises of a blower and a turbine. Both are associated with one another
through a shaft. Fumes of heated exhaust gases enter from the engine at turbine side and
pushes it, so turbine turns and thus pivots the blower too. The blower is in air circuit, so it
pressurizes the air, subsequently builds the proficiency of engine by putting an intake of
compressed air to the engine, via the charge air cooler. The fumes of exhaust gas through the
turbine gas channel grows in the turbine blade as they strike it at a special angle spinning the
turbine rotor and then passes by means of the gas outlet and into pipe that carries it to the
boilers for further utilization of the gas's heat energy. The compressor side of the
turbocharger receives air from atmosphere and enters the compressor. After the
compression, intake air temperature rises above 100OC which is then cooled down in charged
air cooler and entered the engine liners.

Figure 10: Turbo Charger

Charged Air Cooler:

Charged Air Cooler is a heat exchanger used for the purpose of cooling the charged air to a
given temperature by mean of cooling water. It is of a construction in which the air flows
across the bundle of plate fin tubes while the cooling water flows through the tubes in
opposite direction. This cooling water in turn gets heated up. This heat of water can be used
to operate water absorption chillers, to pre heat boiler inlet water, control humidity level in
the air of a room etc.

Figure 11: Charged Air Cooler

Purifier:
Purifiers is one of the many major devices that helps in smooth functioning of an engine. The
purpose of a purifier is to clean furnace oil/lubrication oil. It separates the oil from other
contaminants by centrifugal force. A line heater (steam powered) in used to raise the
temperature of the oil to about 95o-98o C. There are two types of purifiers, one is used for
HFO and the other one is used for Lube oil.
Purifiers works by employing the centrifugal force by rotating bowl at high speed which
separates the light material (lube or HFO oil) collecting it at center and pushes heavy material
(sludge) along the wall. Bowl of the purifier has number of discs inside it. These discs move
oil with rotation of the bowl.

Figure 12: Alfa Level Purifiers

Purifier features three water valves, heated lubrication oil/Furnace oil inlet valve, lubrication
oil/Furnace oil outlet valve and displacement water drain valve. These three water valves
have different functions, one for injecting displacement water (SV10) and other two for
opening (SV15) and closing (SV16) of purifier bowl for removing collected sludge out after
regular intervals. For removing collected sludge, flow of oil is cut off, bowl is opened, and
displacement comes in which flushes the sludge with itself from the bottom.
Alternator:
To make the electrical energy, the alternator must be rotated. The alternator is ordinarily
associated with the Engine's crankshaft. As the motor turns the alternators rotor inside the
stator. Both the stator and rotor are produced using wound copper and electrical steel. The
rotor has an electrical ow moving through it which actuated an electrical field. This electrical
field makes a current in the alternator's stator. This is how electricity is generated. The Auto
Voltage Regulator maintains the voltage of the alternator to a desired value.

Plate Heat Exchangers:

Heat allows the transfer of heat from one type of liquid to another for useful purpose, without
any physical contact between them. In plate heat exchanger, two liquid flows in opposite
direction in alternative plates. To increase the rate of heat transfer between two liquids and
get minimum approach, these plates are made thin and curly to increase surface area of
contact of liquid with plate.

Figure 13: Heat Plate Exchanger

Cooling Tower:
Cooling Towers are used to cool down water temperature by showering water in open air.
This cooled raw water in turn used to cool down compressed gas in Charged air cooler,
maintain temperature of Lubrication Oil, Diesel Oil and Jacket Water. In cooling towers, to
increase the cooling rate of water and make the heat removal process from water fast, an
exhaust fan is attached at top of cooling tower which pump heat out in atmosphere. Approach
of cooling tower must be below 8OC and it is better to be below 5OC. Approach of cooling
tower is calculated as follows:
𝐴𝑝𝑝𝑟𝑎𝑜𝑐ℎ = 𝑂𝑢𝑡𝑙𝑒𝑡 𝑊𝑎𝑡𝑒𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 − 𝑊𝑒𝑡 𝑏𝑢𝑙𝑏 𝑡𝑒𝑚𝑒𝑟𝑎𝑡𝑢𝑟𝑒
 Figure 14: Cooling Tower of capacity 150 meter cube per hour

Water quality of cooling water also needs to be maintained to avoid scales in plate heat
exchanger and to save water storage tank from fungi and bacteria. Following chemicals are
injected in water using dozing pump for this purpose:
➢ Sulphuric acid (To control pH).
➢ Bio Guard (To save storage and cooling tower walls from fungus).
➢ Deposit Guard (To avoid deposition of minerals in heat exchanger. It controls the TDS
of water).
➢ Total Guard (It is used as an alternative to both Bio and Deposit Guard).
TDS of raw water needs to be maintained between 2500 ppm to 2300 ppm. To drain solid
particles and solidified minerals due to Deposit Guard, blow down is attached. A filter collet
all the solid particles and when minerals get accumulated, blow down valve opens nematically
and drain them out.
Candle Filter:
Candle filters are used to remove debris from oil. It is very common type of filter which is
usually used to filter oil. A candle filter contains multiple mesh candles in the same dimension,
which are placed on or screwed on, parallelly. It has number of small candles so larger surface
area of filter is constructed in low construction volume. It can filter oil at larger rate. The
candle insert distinguishes itself by a particularly high resistance to differential pressure. Due
to the use of stainless-steel wire mesh, the candle filters can be cleaned many times and
economically used over a longer period. Primarily at high temperatures and in operating
conditions in which plastics, fleece or paper are unsuitable, a candle element made from
stainless steel is first choice.

Figure 15: Candle Filter

Gas Admission Valves:

To electrically control gas injection in liner during suction stroke a device is used called Gas
Admission Valves. At Nishat Mills Power Plant, only Wartsila engine uses gas admission valves
to control flow of gas into each cylinder, maximizing the efficiency of Engine.

Figure 16: Gas Admission Valve

 Engines at Nishat Mills Power Plant
Daihatsu Engines:
8DL-32 Daihatsu turbo charged diesel engine are being used at the power plant for energy
generation. Each engine has power generation capacity of 2 Mega Watt. There are three
engines of this type with total generation capacity of 6MW. These engines have 8 cylinders
attached in I-configuration. Stroke length of the engine is 400 mm and Piston diameter is
320mm. Fuel injector starts injecting fuel in cylinder when piston is 19O from Top Dead Centre.
Engine rotates at constant rpm of 600 during energy generation. These engines are especially
famous because of their ramp up speed. These engines can ramp up energy generation from
0.5 MW to 1.5 MW in less than a 30 s.

Figure 17: 8DL-32 Daihatsu turbo charged diesel engine

Some specifications of 8DL-32 Daihatsu Engine:

Specification Rating
Cylinder configuration I-type
No of cylinders 8
RPM 600
 Piston Diameter 320 mm
Stroke length 400 mm
Horsepower 2680 hp
Energy Generation Capacity 2000 KW
Turbo RMP 22000
Exhaust Gases Temperature 500 OC
Engine type 4 stroke
Mean Effective Pressure 17.49 kg/cm3
Fuel type HFO/ LFO

Engine CC:
Engine CC is also called total displacement of Engine per cycle. It can be calculated from
volume of cylinder as follows:
3.14 2
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑎 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 𝑖𝑛 𝐶𝑢𝑏𝑖𝑐 𝐶𝑒𝑛𝑡𝑖𝑚𝑒𝑡𝑒𝑟 = x (Bore (cm)) x Stroke Length (cm)
4
3.14
𝑉𝑜𝑙𝑢𝑚𝑒 𝑝𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 𝑋 322 𝑋 40
4
𝑉𝑜𝑙𝑢𝑚𝑒 𝑝𝑒𝑟 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 = 32153.6 𝑐𝑚3
𝐸𝑛𝑔𝑖𝑛𝑒 𝐶𝐶 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑠𝑖𝑛𝑔𝑙𝑒 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 (𝑐𝑚3 ) 𝑋 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
𝑬𝒏𝒈𝒊𝒏𝒆 𝑪𝑪 = 𝟐𝟓𝟕𝟐𝟐𝟖. 𝟖 𝑪𝑪
Hence, Daihatsu 8DL-32 is 257228.8 CC Engine.

Indicated Horsepower:
Horsepower is a unit of measure of power Engine. To calculate mechanical power of the
Engine, it is convention to use horsepower instead of kW.
Indicated Horsepower of Engine is power generated due to combustion which can be
calculated as follows. It does not include loses due to friction.
𝑃𝑂 𝑋 𝐿 𝑋 𝐴 𝑋 𝑅𝑃𝑀 𝑋 𝑁𝑜. 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 2 1
𝐼𝑛𝑑𝑖𝑐𝑎𝑡𝑒𝑑 𝐻𝑜𝑟𝑠𝑒 𝑃𝑜𝑤𝑒𝑟 = 𝑋 𝑋
60 < 2 𝑜𝑟 4 𝑠𝑡𝑟𝑜𝑘𝑒 𝑒𝑛𝑔𝑖𝑛𝑒 > 746

322
17.49 𝑋 0.4 𝑋 4 𝑋 3.14 𝑋 600 𝑋 8 2 1
𝐼𝑛𝑑𝑖𝑛𝑐𝑎𝑡𝑒𝑑 𝐻𝑜𝑟𝑠𝑒 𝑃𝑜𝑤𝑒𝑟 = 𝑋 𝑋
60 4 746
𝑰𝒏𝒅𝒊𝒄𝒂𝒕𝒆𝒅 𝑯𝒐𝒓𝒔𝒆 𝑷𝒐𝒘𝒆𝒓 = 𝟐𝟗𝟓𝟕. 𝟎𝟏 𝒉𝒑
Wartsila 20V34DF Engine:
Wartsila is a Finland Engine Manufacturing Company. Wartsila is considered a brand in the
world of four stroke engine. Wartsila has manufactured most efficient diesel engines. Wartsila
20V34DF is a very powerful turbo charged tri fuel engine which comprises of 20 cylinders
which have a bore size of 340mm and stroke length of 420mm.It is shaped into V-type. i.e. it
has 20 cylinders connected in V type arrangement. Its total capacity is 8.6 MW. There is one
Wartsila Engine in this power plant.
It runs on HFO (Heavy furnace oil), Diesel and Natural Gas. Wartsila 20V34DF Engine have 750
rpm. In Wartsila 20V34DF Engine, during suction stroke, Inlet valves opens and gas injection
from gas admission valves starts at top dead center (360O). Duration of Gas injection is 32 ms
while suction stroke completes in 40 ms. During rest of the 8 ms only air enters the liner while
gas admission is closed. During compression stroke, Pilot Fuel Injection starts when piston of
the cylinder is at 35o and pilot fuel is injected by fuel injectors for about 1.7 ms. Duration of
pilot fuel injection varies depending upon requirement and is continuously updated by PLC.
Following is some basic calculation of injection timing:

𝑹𝑷𝑴 𝒐𝒇 𝑬𝒏𝒈𝒊𝒏𝒆 = 𝟕𝟓𝟎

𝑹𝒐𝒕𝒂𝒕𝒊𝒐𝒏𝒔 𝒑𝒆𝒓 𝒔𝒆𝒄𝒐𝒏𝒅 = 𝟏𝟐. 𝟓
𝟏𝒔
𝑻𝒊𝒎𝒆 𝒕𝒂𝒌𝒆𝒏 𝒃𝒚 𝒐𝒏𝒆 𝒓𝒐𝒕𝒂𝒕𝒊𝒐𝒏 = = 𝟖𝟎 𝒎𝒔
𝟏𝟐. 𝟓
𝟖𝟎 𝒎𝒔
𝑻𝒊𝒎𝒆 𝒇𝒐𝒓 𝒉𝒂𝒍𝒇 𝒓𝒐𝒕𝒂𝒊𝒐𝒏 = = 𝟒𝟎 𝒎𝒔 (𝒔𝒖𝒄𝒕𝒊𝒐𝒏 𝒔𝒕𝒓𝒐𝒌𝒆 𝒕𝒊𝒎𝒆)
𝟐
But out of 40 ms, for only 32 ms, fuel injects. While during other 8 ms only air injects, and
inlet valves closes.
As we know, PFI starts at 35O and injection continuously injects for 1.7 ms hence,
𝑻𝒐𝒕𝒂𝒍 𝒏𝒐 𝒐𝒇 𝒄𝒚𝒍𝒊𝒏𝒅𝒆𝒓𝒔 𝒊𝒏 𝑬𝒏𝒈𝒊𝒏𝒆 = 𝟐𝟎
𝑨𝒔 𝑬𝒏𝒈𝒊𝒏𝒆 𝒊𝒔 𝑭𝒐𝒖𝒓 𝒔𝒕𝒓𝒐𝒌𝒆, 𝒑𝒐𝒘𝒆𝒓 𝒔𝒕𝒓𝒐𝒌𝒆 𝒊𝒏 𝒐𝒏𝒆 𝒓𝒐𝒕𝒂𝒕𝒊𝒐𝒏 = 𝟏𝟎
𝟑𝟔𝟎
𝑫𝒆𝒈𝒓𝒆𝒆𝒔 𝒇𝒐𝒓 𝒇𝒖𝒆𝒍 𝒊𝒏𝒋𝒆𝒄𝒕𝒊𝒐𝒏 𝒂𝒏𝒅 𝒄𝒐𝒎𝒃𝒖𝒔𝒕𝒊𝒐𝒏 𝒇𝒐𝒓 𝒆𝒂𝒄𝒉 𝒆𝒏𝒈𝒊𝒏𝒆 = = 𝟑𝟔O
𝟏𝟎

So, injection at 35O is reasonable. Moreover,

𝟖𝟎 𝒎𝒔
𝑻𝒊𝒎𝒆 𝒓𝒆𝒒𝒖𝒊𝒓𝒆𝒅 𝒇𝒐𝒓 𝒐𝒏𝒆 𝒅𝒆𝒈𝒓𝒆𝒆 𝒓𝒐𝒕𝒂𝒕𝒊𝒐𝒏 = = 𝟎. 𝟐𝟐𝟐𝟐 𝒎𝒔
𝟑𝟔𝟎
𝟏.𝟕
𝑨𝒏𝒈𝒍𝒆 𝒓𝒐𝒕𝒂𝒕𝒆𝒅 𝒅𝒖𝒓𝒊𝒏𝒈 𝟏. 𝟕 𝒎𝒔 = 𝟎.𝟐𝟐𝟐𝟐 = 𝟕. 𝟔𝟓O

Hence PFI usually stops at 27.35O

 Figure 18: Wartsila 20V34DF Engine

In this engine, we have to first compress natural gas to 4.5 bar pressure before supplying to
engine. If we ran it over heavy fuel oil, its viscosity needs to be maintained at 2cst which is
achieved by used steam powered line heater. Steam used for heating Heavy Fuel Oil is
obtained from the 4.5 Ton Fire Tube powered by exhaust gases (400 OC) of Wartsila Engine.
Excess is steam is used in steam absorption chillers and chemical treatment of Warp. To
Further optimize the engine, two types of jacket water are circulated in Engine, High
temperature and low temperature. Water in High temperature line has outlet temperature
of about 98OC which passing from heat recovery unit (Plate Heat Exchanger) heats up water
line to about 93OC. This water is used in water absorption chillers.

Specifications of Wartsila 20V34DF Engine are given below:

Specification Rating
Cylinder configuration V-type
No of cylinders 20
RPM 750
Piston Diameter 340 mm
Stroke length 400 mm
Horsepower 11,524 hp
Energy Generation Capacity 8600 KW
 Turbo RMP 23000
Exhaust Gases Temperature 510 OC
Engine type 4 stroke
Fuel type HFO/ LFO/Natural Gas
Ignition type Auto ignition by Pilot fuel
Main Fuel Injection Timing 360O (0O)
Main Fuel Injection Duration 32 ms
Pilot Fuel Injection Timing 35O
Pilot Fuel Injection Duration 1.7 ms

CAT GAS (3516C) Engine

CAT GAS Engine are designed and manufactured by Caterpillar. There are three engine of this
type each having generation capacity of 1.5 MW. This is 16-cylinder turbo charges four stroke
V type engine. These engine uses spark for combustion. Its flywheel rotates at 1500 RPM. It
is small size engine because there is no fuel injection pump, preheater, fuel injector as we see
in diesel engine.
CAT GAS Engines uses natural gas as fuel but there is no need to first compress it like Wartsila
20V34DF Engine. In this engine, gas is injected in air which after passing through turbo charger
forms homogeneous mixture and its pressure also increases. This compressed mixture of gas
after passing from regulation valve enters in manifold from where it enters cylinder. Like
Wartsila 20V34DF Engine, Cat GAS Engines do not have gas admission valve for each cylinder.

Figure 19: CAT GAS (3516C) Engine

 Specifications of CAT GAS (3516C) Engine:
Specification Rating
Cylinder configuration V-type
No of cylinders 16
RPM 1500
Piston Diameter 150 mm
Horsepower 2000 hp
Energy Generation Capacity 1500 KW
Turbo RMP 59500
Exhaust Gases Temperature 570 OC
Engine type 4 stroke
Fuel type Natural GAs
Ignition type Spart Ignition
Working Circuits
There are 5 circuits that control the fluid flow throughout the process. These are:
➢ Fuel Circuit
➢ Lube Oil Circuit
➢ Air Circuit
➢ Cooling Water Circuit
➢ Jacket Water Circuit

Fuel Circuit

Figure 20: General Fuel Circuit

Lube Oil Circuit

Figure 21: General Lube Oil Circuit

Air Circuit

Figure 22: Air Circuit

Cooling Water Circuit

Figure 23: Cooling Water Circuit

Jacket Water Circuit

Figure 24: Jacket water General circuit

Analysis of Work Environment

➢ Skilled workers.
➢ Supportive and friendly environment
➢ Professional environment
➢ No compromise on performance
➢ Availability of first aid
➢ Availability of a proper fire plan and emergency exits

Conclusion
This four-weeks internship has been the most productive and informative period of my
student life so far. Everyone is very supportive and friendly and teaches in interactive way. I
am very inspired by the professional workflow being carried out here. I am looking forward
to more opportunities to get the honour of working here again.