internship report on shops and base maintenance.

1. HAMDARD UNIVERSITY, MADINAT-AL-HIKMAH,
HAKIM MUHAMMAD SAID ROAD,
KARACHI – 74600, PAKISTAN
P: (92-21) 36440035-40
SUMMER INTERNSHIP REPORT
SUBMITTED BY
MUSTAFA FURQAN
MUHAMMAD OSAMA
M. GHULAM MUSTAFA

2. ABSTRACT
The report credentials work done during the summer internship at Pakistan International Airline
Corporation (PIAC), Karachi. The report will give overview of corporation then our task completed
during the period of internship with our experiences.

3. ACKNOWLEDGMENT
I would like to express deepest appreciation to all those who provided me the opportunity to
internship at PIA. Firstly the HR department specially Sir Shahid Mahfooz who give us the
platform and learning environment.
I also acknowledge the Engineering staff and senior technicians those who give helped me to
improve the skills, knowledge, capabilities and competencies. Also treat us in very good way and
give answer of every question. In last I thank you to all give comments and advices.

4. Table of Contents
ABSTRACT .....................................................................................................................................................1
ACKNOWLEDGMENT....................................................................................................................................2
INTRODUCTION ............................................................................................................................................4
PAKISTAN INTERNATIONAL AIRLINE (PIA)...................................................................................................4
Mission statement of PIA.........................................................................................................................4
VISION OF PIA...........................................................................................................................................4
SLOGAN.....................................................................................................................................................4
HISTORY....................................................................................................................................................5
PIA FLEET IN PAST.....................................................................................................................................5
PIA FLEET IN PRESENT ..............................................................................................................................6
PW-127 ENGINE OVERHAUL SHOP: .............................................................................................................6
G-90 OVERHAUL SHOP:................................................................................................................................7
LANDING GEAR OVERHUAL SHOP: ..............................................................................................................8
PLATING SHOP........................................................................................................................................11
AUXILARY POWER UNIT (APU)...................................................................................................................11
WHEEL BAY SHOP.......................................................................................................................................12
BASE MAINTENANCE..................................................................................................................................12
ENGINE....................................................................................................................................................13
SENSORS .................................................................................................................................................13
2) STATIC PORT.......................................................................................................................................13
3) PITOT TUBE.........................................................................................................................................13
4) TAT Probe ...........................................................................................................................................13
5) ATC Sensor..........................................................................................................................................14
AIR FRAME..............................................................................................................................................14

5. INTRODUCTION
The following report describe the activities carried out in 2-weeks internship at Pakistan
International Airline (PIA) Engineering and maintenance. The following document contain the
information about organization along with its history and the experience at Shops and Base
Maintenance throughout the period from 5th-20th August, 2019.
PAKISTAN INTERNATIONAL AIRLINE (PIA)
Pakistan International Airlines (PIA) is one of the best airlines of the world and is the strong pillar
of Pakistan’s economy. It has its head office in Karachi. It is one of the largest airlines’ of Asia
operating scheduled services to 24 Domestic destinations and 39 International destinations in 25
countries across Asia. Its main bases are Karachi, Lahore, and Islamabad/Rawalpindi. Its
secondary base includes Peshawar, Faisalabad, Quetta, Sialkot and Multan from which it connect
the metropolitan cities with the main bases, the Middle East and the Far East. The airline is owned
by the government of Pakistan (87%) and other shareholders (13%).
Mission statement of PIA
“As a symbol of national pride, Pakistan international must strive to be an airline of choice
operating profitably on modern commercial concepts, capable of competing with the best in its
entire international and domestic markets and consistently exceeding customer expectations. It
should be a choice employer deploying modern technology in all spheres of its activities.”
VISION OF PIA
"To be a world class airline exceeding customer expectations through dedicated employees
committed to excellence"
SLOGAN
“Great people to fly with”

6. HISTORY
Pakistan International Airlines (PIA) began when Pakistan was not an independent state. In 1946
Muhammad Ali Jinnah realized the need for an airline network and called upon the help of an
industrialist Mirza Ahmed Ispahani to develop a flag carrier for the nation. Meanwhile an airline
called “Orient Airways” registered in Calcutta was formed on 23 October 1946. In February 1947,
the airline brought three DC-3 airplanes from a company in Texas, and in May of that year the
airline was granted a license to fly. Services were started in June from Kolkata to Sittwe and
Yangon. This was the first post-war airline flight by a South Asian registered airline company. Two
months after this, Pakistan was formed. Orient Airways began relief flights to the new nation and
soon after, it moved its operations to Karachi and began flights to Dhaka on 7 June 1954. In
addition, the first two domestic routes in Pakistan were established from Karachi to Lahore,
Peshawar, and Karachi to Quetta to Lahore. On 11 March 1955, Orient Airways merged with the
government’s proposed airlines, becoming ‘Pakistan International Airlines Corporation’. During
the same year the airline opened its first international service from Karachi to London. In March
1960, PIA became the first Asian airline to use Jet aircraft when Boeing 707 services were
introduced.
PIA FLEET IN PAST
1) AIRBUS A300
2) AIRBUS A310
3) AIRBUS A321
4) AIRBUS 330
5) BOEING 720
6) BOEING 737
7) BOEING 747
8) DOUGLAS DC-8
9) DOUGLAS DC-3
10) FOKKER F27

7. PIA FLEET IN PRESENT
1) BOIENG 777
i) 777-200LR
ii) 777-200ER
iii) 777-300ER
2) AIRBUS A320
3) ATR
i) ATR42
ii) ATR72
In this internship report I explain my experience through shop by shop.
PW-127 ENGINE OVERHAUL SHOP:
In this shop our instructor is SIR YASIR (AIRCRAFT ENGINEER). In this particular engine overhaul
shop we see the PW-127 turbo probe engine which is used for the ATR aircrafts i.e. ATR-42 and
ATR-72. The following ATR-42 and ATR-72 shows the number of passenger can be sited in
airplane. Pw-127 is the double spool , two stages centrifugal compressor engine which produce
about 2619 eshp (1953KW) and 2400 rpm which is to be decreases to 1200rpm. With the engine
following component is attached i.e. EEC (Electronic Engine Control) which control the fuel--, fuel
filter, oil filter, air heater near the lower side of propeller because when aircraft flying at the low
pressure created on propeller which produces the ice, fuel heater to make fuel in liquid phase.

8. In this shop we meet with inspection team who check the engine with the BSI equipment which
is used to see the interior condition of the engine and other pasts of airplane.
G-90 OVERHAUL SHOP:
In this section our instructor is “SIR SHAHID” (senior technical engineer). Sir firstly make the
concept about that how an airplane is flying? , and fuselage. In aircraft there is two types of
controls.
i) Primary control surfaces
ii) Secondary control surfaces
Primary control surfaces:
There is following there control without these aircraft is not to be able to fly.
a) Aileron
b) Rudder
c) Elevator
Secondary controls control:
a) Flaps
b) Slat
c) Spoiler

9. GE90-94B is dual rotor, axial flow, and high bypass turbofan engine. There is two types of turbo
machine is used in PIA i.e. GE90-94B and GE-115B which is install in Boeing 777. GE-94B produce
about 94,000 pound force and there are 2D blades and GE90-115B produce about 110,000-
115,000 pound force and there are curved blades which is to called 3D blades. During certification
testing in 2002, the GE90-115B engine set a world-record 127,900 lbs. of thrust. Sir take all
internees to shows the Boeing 777 illustrate more.
LANDING GEAR OVERHUAL SHOP:
The instructor “Sir Itisham” (Senior Technician) briefly explain about the shop overhaul
capability that it equip to overhaul of two aircraft landing gear which is ATR-42/ATR-72 and A320.
There are two landing gears used in aircrafts;
1. Nose Landing Gear.
2. Main Landing Gear.
Barrel (casing/clothing).
NOSE LANDING GEAR Shock absorber.
Rotating Tube.

10. Main Landing Gear Barrel
Shock absorber
➢ Shock absorber used in landing gear for gaining less reaction of the action, when the
aircraft strikes the ground. It basically absorb the large amount of energy.
➢ Shock absorber contains cylinder which is charged by nitrogen gas (that is light weight,
compressible) and Red oil and skydrol is used for housing and the orifice plate is used to
separate the nitrogen gas and oil.
➢ Nose landing is used for turning or change the direction of aircraft max 90 deg to the right
and 90 deg to the left. And the changing of direction of nose landing gear by the cockpit
through electronic signal.
➢ In Main landing gear the axle are fixed but in nose landing gear it is not fixed.

11. ➢ Main landing gear having side stud (connected with actuator and hold maximum load of
landing gear).
REPAIR AND MOD SHOP:
In this our teacher is “Sir Badar-u-din” (Office Engineer). This shop further divided into three sub
shop which is
i) Plasma Shop
ii) Welding Shop
iii) Plating Shop
Firstly sir badar explain about the tag i.e. yellow tag shows repair component, red tag shows scab
component, blue tag means serviceable component, etc. then we tought about CMM
(Component maintenance manual) which shows the dimensions, tolerance and other
specifications. Sir shows a Brake assembly part with yellow tag and worksheet which shows that
repair component and worksheet show about the issue then repair shop engineer check CMM
and send to respective repair area.

12. PLATING SHOP
The basic purpose this shop is
• Curing the material from corrosion.
• Resizing the material.
• And decorating the material (flash chrome).
Five types of plating can be done in PIA plating shop
1. Cadmium plating
2. Chromium plating
3. Copper plating
4. Silver plating
5. Nickel plating
Plating can be done by electrolytic process by providing DC current. After plating, we remove
hydrogen gas for curing the cracks on the part by placing the part in oven and bake at 190 deg.
Striping is the process that is non-electrolytic process by dipping the part in aluminum nitride in
which removing the cadmium that is deposited before on part and after removing it is again
plating by the whole electrolytic process.
Masking is the process in which the area which not required for plating can be covered by Wax
and special tape.
AUXILARY POWER UNIT (APU)
In this our instructor is “Sir Mubashir Ali Khan (senior crew chief)”. APU is main source of giving
electric power which is use to start the main engine of aircraft. APU is also gas turbine engine.
The main difference between the APU and main engine is APU doesn’t give the thrust. APU is
normally fit on the tail of aircraft which is use aircraft fuel. If aero plane face in flight shutdown
(means engine is not working) then APU is used for relighting. In this shop, sir also give knowledge

13. about FADEC (Full Authority Digital Engine Control) which control the engine according to the
captain instruction, aircraft use JET A1 fuel and ETOPS (Extended-range Twin-engine Operational
Performance Standards) which inform about what time of aircraft is flying at one engine.
WHEEL BAY SHOP
In wheel shop there have two conditions
1. Tire change
2. Tire overhaul
In worn out condition of tire can be transported to the respective company for retread tire means
put the layer of rubber from shoulder to shoulder for reuse. Heated shield and drag keys which
is used to secure the tire from heat because when the tire hits the ground and applying breaks
the high heat generated. If the temperature is more than 320°C the fuse plug which is inserted
in the hub can be pin out itself to decreases the pressure of tire. Tire contains 5% steel, 45% nylon
and 50% rubber. Nitrogen gas can be filled in tires. After 1500 landings the overhauling of tire
required in Boeing 777 aircrafts normally.
To check the hub is serviceable or not, Non Destructive Testing method is used. The following
NDT method is use in this shop.
1. Eddy current
2. X-ray
3. Ultrasound
4. Fluorescent penetrant inspection (FPI)
5. Magnetic particle Inspection (MPI)
BASE MAINTENANCE
HR Mr Shahid Mahfooz give a letter of two days in base maintenance of aircraft. Here meet
with Mr. Daniyal (junior Tech) give a lecture of aircraft frame, engine, sensors for measuring

14. actual location of aircraft and some other sensors. At base one (B1), A320 aircraft is in check C6
inspection, which means after 6 years the inspection is should be done.
ENGINE
We learn that the engine is making by CFM Company which is CFM-56-5B and use 2380 engine
oil for lubrication and we also use hot air (Bleed air) of compressor mix with cool air (Ram air)
and make a desire temperature to cool turbine case and also use hot air for operating air
conditioner, pressurizing and anti-icing.
SENSORS
1. RADAR (radio detection and ranging)
Two types of radar are used in aircraft.
(a) Primary radar: Transmitter and receiver both are at one side, both are on airplane.
(b) Secondary radar: Transmitter at one side and receiver are at the other, one at the
land and other at the airplane.
Radar system are used to find the location, altitude of aircraft and it’s also used to fine the cloud density
etc.
2) STATIC PORT
It’s used to find the static pressure of aircraft surface.
3) PITOT TUBE
It’s used to find the total pressure of air and here is a formula of find dynamic pressure and velocity of
aircraft.
4) TAT Probe
In aviation, stagnation temperature is known as total air temperature and is measured by a temperature
probe mounted on the surface of the aircraft.

15. 5) ATC Sensor
Air traffic control (ATC) is a service provided by ground-based air traffic controllers who direct aircraft on
the ground and through controlled airspace, and can provide advisory services to aircraft in non-
controlled airspace.
AIR FRAME
Front cockpit side part of aircraft is Nose, middle part is fuselage and tail side part is empennage.
Cockpit area is pilot and copilot area, fuselage area is passenger and luggage’s load caring area.