Supervised Industrial Training

ELECTRICAL MAINTENANCE & TROUBLE

SHOOTING

From 20-Febuary-2023 to 29-September-2023

Student Name Muhammad Kamran

Registration Number (1104E-S20-022)

BSc Electrical Engineering Technology Department of

Electrical Engineering Faculty of Engineering Practices

& Sciences Nazeer Hussain University

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 Preface

This industrial training report represent the engineering expertise I acquired during my training
at the Electrical Department in KS&EW. The primary objective of this training was to get
technical proficiency in the field of Electrical Technology, after the completion of 3 years of
academic studies as a student of Bachelor of Science in Electrical Engineering Technology at
Nazeer Hussain University, Karachi. This report has been prepared as a part of completion of the
industrial training according to the regulation of National Technologists Council (NTC) and the
Higher Education Commission (HEC) of Pakistan.

Throughout a duration of 32 weeks, from February 20, 2023, to September 29, 2023, this training
experience provided me an opportunity to expand my skill set and apply theoretical knowledge
in practical work

The document mainly consists of three chapters, the introduction about the training
establishment, my overall training experience and the conclusion on the training.

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 Acknowledgment

First of all the whole praise to ALMIGHTY ALLAH, the creator of the universe and anything in
this universe. He made us super creature, blessed us to accomplish this work. We are very
thankful to Allah Almighty, Who has provided us such an opportunity to gain knowledge in
KS&EW Limited. It was a great experience to do training over here. We learnt many things
practically which we have learnt theoretically earlier. We also pay our gratitude to the Almighty
for enabling us to complete this training Report within due course of time

I would like to thank Engr. Muhammad Irfan Shaikh (Assistant Professor Electrical Engineering
Department) for meticulously planning academic curriculum in such a way that students are not
only academically sound but also industry ready by including such industrial training patterns.

I would also like to thanks Engg. Liaqat Ali (Director B,S Engg.) for the positive attitude he
showed for my work, always allowing me to question him and giving prompt replies for my
uncertainties in all the fields including educational, social and managerial work.

I would also like to acknowledge and my heartfelt gratitude to Engr. Syed Saad Ali
(coordinator) who continuously supported me ini every possible way, from initial advice to
encouragement till this date.

Finally, I would also like to thanks Mr Adnan Jabbar (Site In charge), Mr. Tanveer Ahmed (AM)
for giving me this opportunity and guiding me during the course of the training

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Profile of the Organization
Karachi Shipyard is the oldest Heavy Engineering Works of Pakistan which is catering
for its Ship Building, Ship Repairing, Submarine/Warship Construction and
Heavy/General Engineering requirements. KSEW was established in early 1950's as a
project of PIDC. It was incorporated as a public limited company in 1957. The
shipyard spread over an area of 29 hectares (71 acres). KSEW has a large Ship
Building Hall, three Ship Building Berths, two Dry Docks, three Foundries (Iron, Steel
& Non-Ferrous), Fabrication Shops, one machine shop and other supporting facilities
like Carpentry, Pipe Fitting and Light

Karachi Shipyard is strategically located on the cross roads of South Asia and Gulf
region. It is designed to carryout Shipbuilding and Ship repair business for the local
and foreign customers. The major local customers - PN, PNSC, MSA, KPT, PQA, GPA
in the public sector and vide range of customers in the private sector have been well
served over the last forty seven years. Facilitates installed, are suited to build and
repair medium size ships up to 18,000 TDW and multipurpose cargo vessels up to
26,000TDW.

Today, KS&EW enjoys a unique status of a public limited company with its entire
shares owned by the Government of Pakistan under the administrative control of
Ministry of Defense (as an autonomous body). While, still remaining in public sector, it
maintains, corporate sector outlook and work methodology. It is the first state owned
organization to have acquired ISO 9001 : 2000 certification. Till to date, it has built 434
ships, repaired 5000 vessels and built over 2000 heavy engineering units suiting the
requirements of local and foreign clients.

Karachi Shipyard is the only shipbuilding company in Pakistan. It has built numerous
cargo ships, tugboats and support vessels, naval vessels and submarines.

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5
Management Profile

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Table of content.
TITLE AND NATURE OF TRAINING 1

PREFACE 2

ACKNOWLEDGEMENT 3

BACKGROUND & PROFILE OF ORGANIZATION 4

SCHEDULE OF TRAINING 9

SUMMARY 10

SKILLS AND EXPERIENCE 11

PROJECTS CARRIED OUT. 13

HANDS-ON SKILLS ACQUIRED. 14

PROBLEM AND CHALLENGES ENCOUNTERED. 16

PROBLEM SOLVING PROCESS/APPROACH. 17

SUPERVISORY TASKS. 18

SUGGESTIONS FOR ENHANCING PRODUCTIVITY. 20

QUALITY MANAGEMENT SYSTEM IN PLACE. 21

SAFETY FEATURES AT WORKPLACE. 22

CONCLUSION 23

REFERENCES AND APPENDIXES 25

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 Training Title
Electrical Maintenance & Trouble
Shooting of Cranes and Welding machines

Schedule of Training

From
20-Febuary-2023
to
28-September-2023

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 Summary
 Supervisor Conducted Fire Fighting Training at Workplace.

Class A: solid materials such as wood or paper, fabric, and some

plastics
Class B: liquids or gas such as alcohol, ether, gasoline, or grease
Class C: electrical failure from appliances, electronic equipment, and
wiring
Class D: metallic substances such as sodium, titanium, zirconium, or
magnesium
Class K: grease or oil fires specifically from cooking

 Supervisor lecture conducted about the PPE’s

o (Safety shoes, Safety googles, Safety helmet, Electrical gloves,

Insulted tools, Ear protection plugs, coverall)

 The training focused on developing our ability to diagnose and rectify

electrical faults efficiently.

 I received thorough instruction on safety protocols and best practices when

dealing with electrical equipment to prevent accidents and ensure a secure
working environment.

 The training also encompassed learning how to carry out

 Repairs and replacements of faulty components

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 Skills & Experienced

Safety Protocols: I was trained to follow strict safety protocols while working on
electrical systems to prevent accidents and ensure the well- being of the crew and the
machines.

Strong Electrical Fundamentals: A solid understanding of electrical

principles, circuits, and components is key for effective troubleshooting.

Electrical Safety: Understood and followed proper safety procedures when

working with electricity is paramount. This includes knowledge of electrical hazards,
proper grounding techniques, and the use of personal protective equipment (PPE).

Multi-meter Usage: Learnt to use a multi-meter to measure voltage, current, and

resistance. It's an essential tool for electrical troubleshooting.

Electrical Circuit Tracing: learnt the skill of tracing electrical circuits to locate
faults, identify connections, and understand the flow of electricity through a system.

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Wiring and Connection Inspection: Learnt to inspect and identify issues with
wiring, connections, and disconnections. This includes checking for loose
connections, damaged insulation, and overheating.

Use of Electrical Tools and Equipments: This helped me to proper use of

electrician's tools and the standard types of meters used for measuring current,
voltage, and resistance.

Electrical Maintenance Practices: I was exposed to best practices for Electrical

maintenance. I learned to make and implement preventive maintenance schedule

Adapting to Challenging Environments: I learned to adapt and implement

suitable solutions to address these challenges effectively.

Problem-Solving Skills: I encountered various technical challenges that

demanded innovative problem-solving skills. I learned to think critically and develop
effective solutions to complex electrical issues.

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 Projects carried out

 Started by conducting a thorough assessment of the Machines. This includes

reviewing the system documentation, schematics, and previous maintenance records.
Inspected the physical condition of the system, including wiring, connections, and
control components.

 Developed and implemented a preventive maintenance plan to ensure the long-term

reliability of the machine. This involves tasks such as cleaning, lubricating, and
inspecting components, tightening connections, and verifying proper alignment of
motor-driven equipment.

 Performed functional testing of the motor control system to ensure all control inputs
and outputs are functioning as intended. This includes testing push buttons, switches,
relays, contactors, and other control devices.

 In case of any issues or malfunctions, conduct troubleshooting to identify the root

cause. This may involve using diagnostic tools such as multimeters, clamp meters to
measure electrical parameters and identify abnormalities. Followed a systematic
approach to isolate the faulty components or circuits.

 When faulty components are identified, replaced them with new ones that meet the
system specifications. This include relays, contactors, motor starters, or control
boards. Ensured proper installation and followed manufacturer guidelines.

 Maintained detailed documentation of all maintenance activities, troubleshooting

steps, component replacements, and software updates performed. This documentation
serves as a reference for future maintenance, helps track the history of the system, and
assists in analyzing recurring issues.

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 Hand on Skills Acquired

 Developed a strong understanding of electrical systems, including the basics of

circuits, wiring, and components. This knowledge helped me to diagnose and
troubleshoot problems effectively.
This knowledge encompasses both AC and DC systems, and I gained insight into the
various components and their functionalities.

 Electrical Troubleshooting of Welding machine: Started by checking the

power supply to the welding machine. Ensured that the input voltage meets the
machine's requirements and that the power connections are secure. Used a
multimeter to measure voltage at different points in the electrical circuit, from the
power input to the control circuits. Looked for any voltage drops, open circuits, or
short circuits.

 Component Inspection and Replacement: Inspected the various components

of the welding machine, such as the transformer, rectifier, capacitors, relays, and
control circuits. Looked for signs of damage, overheating, or burnt components.
Replaced faulty components which were identified, with new ones that meet the
manufacturer's specifications.

 Welding Circuit Troubleshooting: Focused on the welding circuit, including

the electrode holder, cables, and welding gun. Checked for loose connections,
damaged cables, or worn-out electrodes. Tested the welding circuit to ensure proper
current flow, and measure voltage and resistance during welding operations. Found
issues with arc stability, uneven welding, or improper current output, investigated
potential causes and addressed them accordingly.

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 Maintenance: Performed routine maintenance tasks on the welding machine and
cranes, such as cleaning dust and debris, lubricating moving parts, and checking for
proper cooling and ventilation. Followed the manufacturer's recommended
maintenance schedule and guidelines.

 Documentation: Maintained detailed records of all repair and troubleshooting

activities, including the steps taken, components replaced, and test results obtained.
This documentation will be useful for future reference, tracking recurring issues, and
analyzing the performance of the welding machine.

 Expert Assistance: when the troubleshooting and repair tasks were beyond my
expertise, i got assistance from a senior

 Installation and Wiring: This hands-on experience allowed me to develop skills

in equipment installation, connecting electrical circuits, and ensuring secure and
reliable connections.

 Repair Electronic PCBs: PCB repairing work allowed me to learn new skills in
electronic field, use of multi meter to test electronic components and learnt to read
component values.

 Safety Practices: I learned and implemented safety practices specific to multiple

working environment. These skills contributed to maintaining a safe working
environment for me and others.

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 Problems & Challenges

As a trainee, I faced several challenges while tracing faults in machines and changing old
fuse system to a new distribution panel. The task was made even more challenging due to
various factors, including the complexity of the old electrical wiring, equipment, and panels,
as well as the limited workspace and the strict adherence to safety regulations that were
necessary.

In certain instances, the faulty components were located in hard-to-reach areas, such as
confined spaces or underground. This made a significant barrier as gaining access to these
areas required the removal of obstacles and the disassembly of equipment, often requiring
me to work in uncomfortable positions.

Another difficulty I faced was the need to wear appropriate personal protective equipment
(PPE) in warm weather and areas. The combination of the warm environment and the
requirement of wearing PPE added an extra layer of discomfort and made the task more
physically demanding.

Additionally, repairing faults within limited timeframes proved to be quite challenging. This
was particularly true when troubleshooting complex issues and conducting complex repairs.
The pressure to complete the repairs within the allotted timeframe while ensuring
thoroughness and accuracy added to the overall difficulty of the task.

Although these challenges, I approached each situation with determination and a

commitment to learning. During this time, I developed valuable skills and techniques that
helped me overcome these obstacles and become more proficient in fault tracing and
electrical repairs.

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 Problem solving process/approach.

Collected information from the machine operator or review any error or burn symptoms
observed. This information helped in understanding the nature of the problem and narrowing
down potential causes.

Identified thorough visual inspection of the machine to any visible signs of damage or loose
connections. Checked for frayed cables, loose or disconnected wires, burnt components, or
any other visible abnormalities.

Verified that the machine is receiving a stable and appropriate power supply. Ensured that
the power source is delivering the correct voltage.

Once the problem had been identified and the necessary repairs made, thorough testing of the
machine was conducted to verify that the issues had been successfully resolved. This
involved test operations and closely monitoring the machine's performance. Special attention
was given to ensuring that the machine was producing the desired working quality and
operating correctly.

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 Supervisory tasks

Supervising and coordinating the work of electrical maintenance technicians, assigning tasks,
and ensuring that work is completed efficiently and effectively.

Developing maintenance schedules, prioritizing tasks, and allocating resources to ensure that
maintenance activities are carried out according to established timelines and production
requirements.

Overseeing the inspection and testing of electrical systems and equipment to identify
potential issues, troubleshoot problems, and ensure compliance with safety standards and
regulations.

Collaborating with other departments to develop preventive maintenance programs, to

minimize downtime, optimize equipment performance, and extend the lifespan of electrical
assets.

Ensuring that all electrical maintenance activities are conducted in accordance with safety
procedures and regulations, and promoting a culture of safety among team members.

Providing guidance, training, and mentorship to electrical maintenance technicians,

identifying skill gaps, and implementing training programs to enhance the knowledge and
capabilities of the team.

Maintaining accurate records of maintenance activities, including work orders, equipment

history, inspection reports, and maintenance logs. Generating reports on maintenance
performance, equipment reliability, and resource utilization.

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Collaborating with engineer for equipment upgrades, modifications, or replacements to
improve reliability, efficiency, and performance.

supervising and coordinating a team of technicians or electricians involved in

troubleshooting electrical machines, assigning tasks, and ensuring effective communication
and collaboration among team members.

Providing technical guidance and expertise to the troubleshooting team, assisting with
complex troubleshooting scenarios, and ensuring that the team is equipped with the
necessary knowledge and skills to effectively diagnose and resolve electrical machine
problems.

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 Suggestions for enhancing productivity.

Implement Preventive Maintenance Plans: Suggest daily scheduled inspections,

testing, and maintenance can help identify potential issues before they become critical,
reducing downtime and increasing overall productivity.

Continuous Training and Skill Development: Encourage and facilitate ongoing

training programs for technicians. Stay updated with the latest advancements in electrical
systems and provides opportunities for skill development. Well-trained technicians can work
more efficiently and effectively, leading to increased Productivity.

Install Voltage and Current Controlling Devices to ensure that electrical machines are
operated within the specified voltage and current limits. Overvoltage or under-voltage
conditions can cause overheating, insulation breakdown, and other issues that can lead to
untimely failure.

Timely changing faulty components is crucial in maintaining the optimal functioning of

electrical systems and equipment. When a component is identified as faulty through
maintenance activities or troubleshooting, it is important to replace it promptly to prevent
further issues and potential damage.

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 Quality management system in place

Quality Policy and Objectives:

Develop a quality policy that reflects the commitment of KSEW's management to quality
and customer satisfaction. Define quality objectives aligned with the shipyard's overall goals,
and ensure that they are communicated and understood by all employees.

Documentation and Document Control:

Establish a comprehensive system for managing documents and records related to quality
management. This includes procedures, work instructions, quality manuals, specifications,
drawings, and other relevant documents. Implement document control measures to ensure the
accuracy, revision control, and availability of documents.

Training and Competence:

Establish a training program to enhance the skills and competence of shipyard personnel.
Identify training needs, provide necessary training sessions, and maintain records of training
activities.

Inspection and Testing:

Develop procedures for conducting inspections and tests at various stages of shipyard
operations. This includes incoming material inspections, in-process inspections, and final
inspections. Ensure that personnel involved in inspection and testing are qualified and have
access to appropriate tools and equipment.

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 Safety features at workplace.

Safety Training and Education:

Conduct regular safety training programs to educate employees about safe work practices,
hazard identification, emergency procedures, and the proper use of personal protective
equipment (PPE).

Personal Protective Equipment (PPE):

Provide appropriate PPE, such as helmets, safety glasses, hearing protection, gloves, and
safety shoes, to employees working in hazardous areas or performing tasks that require
protection.

Fire Safety:
Install extinguishers, fire hydrants systems, throughout the shipyard. Develop and practice
emergency response plans for fire incidents.

Machinery and Equipment Safety:

Implement safety measures for machinery and equipment, including machine guarding,
lockout/tagout procedures, and regular inspections and maintenance.

Fall Protection:
Install fall protection systems, such as guardrails, safety nets, and personal fall arrest
systems, in areas where there is a risk of falls from heights. Ensure that employees working
at heights are trained in fall protection techniques.

Safety Inspections and Audits:

Conduct regular safety inspections and audits to identify potential safety hazards and non-
compliance with safety regulations. Address any identified issues promptly and track
corrective actions.

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Conclusion
I would like to express my sincere gratitude to all my relevant university teachers,
office managers, site engineers, site supervisors, and colleagues for their unwavering
support and guidance during challenging situations, which has greatly contributed to
my personal and professional growth. I am truly grateful for their presence and
encouragement, which has significantly improved my ability to learn and excel.

The industrial training program at KS&EW has been an invaluable opportunity for
me to gain practical experience and enhance my skills in the Maintenance department.
Throughout the training period, I have had the privilege of delving into various
aspects of the Shipyard, allowing me to develop a profound understanding of the
industry's operations, processes, and best practices. This exposure has not only
broadened my knowledge but has also honed my problem-solving abilities and critical
thinking skills.

Working within a disciplined and structured work environment has been instrumental
in shaping my technical expertise. Moreover, it has instilled in me a strong sense of
professionalism, meticulous attention to detail, and unwavering commitment to
adhering to safety protocols. These attributes will undoubtedly serve as a solid
foundation for my future endeavors as an electrical technician.

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I am immensely grateful to the Maintenance Department of KS&EW for providing
me with this exceptional learning experience. Their guidance, mentorship, and
willingness to share their expertise have been invaluable in shaping my understanding
of the industry. I am confident that the knowledge and skills I have acquired during
this training will serve as a solid stepping stone in my career, enabling me to make
meaningful contributions to the field of electrical maintenance.

Once again, I extend my heartfelt appreciation to everyone who has been a part of my
journey at KS&EW. Their support and belief in my abilities have been a constant
source of motivation, and I am truly grateful for the opportunity to have been a part of
such a remarkable learning environment.

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Appendix

List of Abbreviations

* KSEW: Karachi Shipyard and Engineering Works Ltd.

* MoDP: Ministry of Defense Production

* Pakistan Navy: Pakistan Navy

* MOD: Ministry of Defence

* CNC: Computer Numerical Control

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Glossary of Terms

* Shipbuilding: The process of designing, constructing, and launching ships.

* Ship repair: The process of maintaining and repairing ships to keep them
seaworthy and operational.

* Engineering: The discipline of designing, building, and maintaining structures,

machines, and systems.

* Manufacturing: The process of converting raw materials into finished products

through the use of machines, tools, and labor.

* CNC machining: A type of manufacturing process that uses computer-controlled

machines to remove material from a workpiece.

* Fabrication: The process of creating a structure or product by combining

individual parts or components.

* Welding: A process of joining two or more materials by applying heat, pressure, or

both.

* Piping: A system of pipes and fittings used to convey fluids, gases, or slurries.

* Electrical: A system of electrical components and wiring used to provide power

and control to a ship or other device.

* Electronics: A system of electronic components and circuits used to provide

control, monitoring, and communication functions.

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References

* Karachi Shipyard and Engineering Works Ltd. (2023). About Us. Retrieved
from https://www.ksew.com.pk/about-us/

* Karachi Shipyard and Engineering Works Ltd. (2023). Products and

Services. Retrieved from https://www.ksew.com.pk/products-and-services/

* Karachi Shipyard and Engineering Works Ltd. (2023). Shipbuilding.

Retrieved from https://www.ksew.com.pk/shipbuilding/

* Karachi Shipyard and Engineering Works Ltd. (2023). Ship Repair.

Retrieved from https://www.ksew.com.pk/ship-repair/

* Karachi Shipyard and Engineering Works Ltd. (2023). Engineering.

Retrieved from https://www.ksew.com.pk/engineering/

* Karachi Shipyard and Engineering Works Ltd. (2023). Careers. Retrieved

from https://www.ksew.com.pk/careers/

* Karachi Shipyard and Engineering Works Ltd. (2023). Contact Us. Retrieved
from https://www.ksew.com.pk/contact-us/

* Pakistan Navy. (2023). Karachi Shipyard and Engineering Works Ltd.

Retrieved from https://www.paknavy.gov.pk/karachi-shipyard-and-
engineering-works-ltd/

* Ministry of Defence Production. (2023). Karachi Shipyard and Engineering

Works Ltd. Retrieved from https://www.modp.gov.pk/karachi-shipyard-and-
engineering-works-ltd/

* Wikipedia. (2023). Karachi Shipyard and Engineering Works Ltd. Retrieved

from
https://en.wikipedia.org/wiki/Karachi_Shipyard_and_Engineering_Works_Ltd

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