summer-internship-report-2015

SUMMER INTERNSHIP REPORT’15


NAME: MIRZA ASHIR BAIG

ID NO: 057

INTERNSHIP PERIOD: 11TH JUNE TO 10TH JULY (4 WEEKS)

UNIVERISTY: DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY

CONTACT NO: 0313-2579169

E-MAIL: [email protected]


Executive Summary

In this internship report I will describe my experiences during my internship period. The internship report contains an overview of the internship company and the activities, tasks and projects that I have worked on during my internship duration. I did my internship at the Lubricant Manufacturing Terminal Korangi and at the Lubrication department in PSO House. During the internship period, I learned the whole manufacturing process of the different lubricants that are manufactured at that plant. I was assigned some projects like the line tracing of the pipes and increasing the efficiency of the production line.


Introduction to the organization:

PSO is the market leader in Pakistan’s energy sector. The company has the largest network of retail outlets to serve the automotive sector and is the major fuel supplier to aviation, railways, power projects, armed forces and agriculture sector. PSO also provides Jet Fuel to Refueling Facilities at 9 airports in Pakistan and ship fuel at 3 ports. The company takes pride in continuing the tradition of excellence and is fully committed to meet the energy needs of today and rising challenges of tomorrow.

Pakistan State Oil, the largest oil marketing company in the country, is currently engaged in storage, distribution and marketing of various POL products. The company’s current market share of 82.3% in the black oil market and 59.4% share in the white oil market, alone speak volumes about its success.

According to the report of the financial year 2014, published in September 2014, Pakistan State Oil Company (PSO), showed 73 per cent growth in profit-after-tax (PAT) to Rs21.8 billion, translating into earning per share (eps) at Rs80.31 from PAT at Rs12.6bn or eps at Rs46.52 the previous year.


Mission Statement:

We are committed to leadership in energy market through competitive advantage in providing the highest quality petroleum products and services to our customers, based on:

Professionally trained, high quality, motivated workforce, working as a team in an environment, which recognizes and rewards performance, innovation and creativity, and provides for personal growth and development

Lowest cost operations and assured access to long-term and cost effective supply sources

Sustained growth in earnings in real terms Highly ethical, safe environment friendly and socially responsible business practices


Internship Activities:

Visit of Lubricant Manufacturing Terminal (LMT) at Korangi, in which a brief introduction about the whole process and working of the plant was given.

Spent two weeks at LMT, in which I visited all the departments of the plant. After spending two weeks at LMT, I was assigned in the lubricant department at PSO House. During the last week of my internship, I spent few days in the Quality Assurance department.


LUBRICANT MANUFACTURING TERMINAL (LMT)

Since the establishment of the Pakistan State Oil, it has been playing a leading role in the oil industry of our country. It supplies round the clock, 24/7, uninterrupted oil supplies, all the way from Karachi to Khyber, through an integrated network of oil terminals and storage depots has been PSO’s distinctive feature. Besides selling the Mogas, Furnace oil, Diesel, Kerosene, Jet fuels, etc, PSO is committed to serve the local need of the Petrochemicals, and is ranked as the most reliable, cost effective and high-quality chemical supplier.

To meet all kinds of lubricant customers, that includes the automotive, hi-street and industrial consumers, PSO has set up a state-of-the-art Lubricants Manufacturing Terminal (LMT) at Korangi Industrial Area in Karachi. All the products that are being manufactured at this terminal are of international standards.


Silent features of the LMT Plant:

Automatic Batch Blending System – Entailing a single shift production capacity of 50,000 MT per

annum, a highly sophisticated system comprising of Automatic Batch Blender for production in batches and Simultaneous Metering Blender for continuous & bulk blends imported from ABB Cellier (France).

Automatic Can & Cap Manufacturing Machines – Built on latest technology and imported from Techne (Italy) & Battenfeld (Austria) respectively.

Automatic Can Filling & Capping Machines – Built on latest technology and imported from Comaco (Italy).

Automatic Drum Filling Machine – By-weight filling machine imported from Velcon (USA).

Tank Farm – Having an oil storage capacity of around 6000 MT.

SUMMER INTERNSHIP REPORT’15 State-of-the-art Warehousing Setup – Employing drive-in & drive-through pallets racking system.

Highly Efficient Fire Fighting System – Employing the best combination of automation technology and manual controls.

Central Air-conditioning System – Over 300 Tons of central air-conditioning has been carried out for Can Manufacturing & Filling Sections. Chillers are highly energy efficient and can operate on Natural Gas, Diesel & different forms of Recovered Waste Heat.

Self Power Generation System – Two Natural Gas driven generators of capacity 1200 KVA & 900 KVA each and one stand-by Diesel driven generator of capacity 1200 KVA.

Automatic Batch Blending System, having capacity of 50,000 MT per annum.

DEPARTMENTS AT LMT

I. BLENDING:

The Automatic Batch Blending (ABB) system provides an efficient means of producing small volume blends. ABB incorporates a primary blend vessel or tank equipped with a dynamic mixer, and one or more dosing vessels mounted on load cells for measurement of liquid volume (or mass by ratio). Typically all base oils and bulk additives are connected to the roof of the mixing kettle by dedicated piping to avoid contamination and accommodate automatic operation with minimal labor. This process is adapted for complex production with large product slate, the ABB is a powerful blending tool providing high accuracy and versatility in process sequence.


II. Can manufacturing unit: The can manufacturing unit prepares the bottles of all the sizes for PSO’s various products. This is done by two heavy duty blow molding machines which are imported from Italy, manufactured by TECHNE. This machine ensure low maintenance, low consumption and high repeatability of the produced bottles keeping dimensional accuracy at its highest level compared to other machines. These are the blow molding machines having the following features of the manufactured cans:

o Reliableo Affordableo Durable

SUMMER INTERNSHIP REPORT’15 o Non-reactive with chemicalso Leak proofo Eco-friendlyo Recyclable

These cans are manufactured by special plastic granular material that is imported from Saudi Arabia.

SUMMER INTERNSHIP REPORT’15 III. Can filling unit (CFU):

The can filling unit had 2 filling lines, each having capacity of 10 bottles which can be filled at once. Cans of different capacity are filled in this unit like of 0.7, 1, 4, 10 liters respectively.

The can filling process starts with the labeling of the bottles. Then the labeled bottles go into the filling unit. The lubricant oil comes from the storage tanks that are situated outside the filling unit. After the filling process, the bottles are sealed in the capping machine. Then comes the induction sealer, which ensures that the each bottle is finely sealed. It ensures the quality assurance of the lubricant oil. Each bottle is labeled by a batch code in the end.

IV. Warehousing setup:

SUMMER INTERNSHIP REPORT’15 ‘A warehouse is a planned space for the storage and handling of goods and material.’ In general, warehouses are focal points for product and information flow between sources of supply and beneficiaries.

PSO lubricant manufacturing terminal has a state-of-art warehousing unit to meet the demands of the lubricant supply.


V. Heating Ventilating & Air-conditioning System (HVAC): HVAC system of the LMT plant is used for the air-conditioning of the can manufacturing and can filling units. These chillers are of Absorption type, which run on the flue gases that comes out from the generator. The chiller plant LMT has capacity of over 300 Tons for air-conditioning. Chillers are highly energy efficient and can operate on Natural Gas, Diesel & different forms of Recovered Waste Heat.

VI. Power house unit: The LMT plant makes its own electricity which provides uninterruptible power supply for the manufacturing process. Power needs of this plant are met by its three heavy duty generators. Two of its generators are of GE Jenbacher Company which run on the Natural Gas and the other one is the stand-by generator which run on the Diesel.Two Natural Gas driven generators are of capacity 1200 KVA & 900 KVA each and Diesel driven generator of capacity 1200 KVA.

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