Power plants are industrial facilities that generate electricity from primary energy sources, such as coal, natural gas, nuclear, solar, or wind energy. Most power plants use one or more generators that convert mechanical energy into electrical energy. What is the most common type of power plant? A steam turbine power generating plant is the most common type of power plant today. This type of plant converts heat into electricity usually using a boiler, and a turbine to drive an electric generator

1. CPGCL GENCO-II, THERMAL
POWER STATION, GUDDU
DECEMBER-2018 Internship Report

2. 1
Internship Report On:
CENTRAL POWER GENERATION COMPANY LIMITED, GENCO-II,
THERMAL POWER STATION, GUDDU
Submitted By : Arham Khan (D-17-CH-35)
Younas (D-17-CH-25)
Ahmed Ali (D-17-CH-75)
Area Assigned : Chemical Plant 747 MW CCPP
Submitted To : Khalid Ayaz Soomro
(Training Department TPS Guddu)
Internship Duration : 15 Days ( 17-12-2018 to 31-12-2018)
University : Dawood University of Engineering and
Technology, Karachi
Department : Chemical Engineering
Submission Date : 31-12-2018

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Table of Contents
Title
1. Acknowledgement
2. About
3. Steam Water Cycle
4. Condenser
5. Boiler
6. Turbine
7. Generator
8. Combined Cycle Power Plant (CCPP)
9. Clarification
10. De-Mineralization
11. Cooling Tower
12. Corrosion
13. Hydrogen Gas Generation
14. Occupational Health & Safety
15. Fire Safety & Fire Extinguishers
16. Recommendations
17. Conclusion

4. 3
ACKNOWLEDGEMENT
At the very beginning, We would like to express our deepest gratitude to Almighty
ALLAH for giving us the strength and the composure to complete our internship
and prepare this report within the scheduled time.
We would like to place on record our deep sense of gratitude to Chief Executive
Officer, GENCO-II, TPS, Guddu for his allowance of internship to us.
We would also like to thank, to all the staff and officers of TPS Guddu for their
kind direction and proper guidance, to us in every phase of this internship.
In the last we want to express our deep gratitude to our parents, group members
and all well-wishers, whose enormous helps assist us to complete this report.

5. 4
ABOUT
The Guddu Thermal Power Plant is a thermal power station located in Guddu,
Sindh, Pakistan. Built in 1980s, the power plant was built with joint technical
cooperation and financial assistance from the union of Soviet Socialist Republics
(USSR).
In April 2014, the then-Prime Minister Nawaz Sharif inaugurated commissioning
of two gas turbines of 243 MW each.
As of 2017, the station had 17 installed power units and its contribution to the
national grid stood between 1400 MW to 1750 MW.

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STEAM THERMAL POWER PLANT EQUIPMENT
(Steam Water Cycle)
The circulation of water from condenser to boiler is called water cycle and from
boiler to turbine and then again in condenser is called steam cycle. Collectively it
is called steam water cycle. All the equipments of this system are explained
below.
CONDENSER
It is a large hollow box, Rows of small tubes are installed in it. Cold water passes
through these tubes. Steam condense outside these tubes and collected in “hot
well” which is at the bottom of condenser. While converting steam into water a
vacuum is also created in the condenser which make the turbine operation more
efficient because pressure of exhaust steam is reduced by condensation than the
inlet pressure of turbine.
OPEN CYCLE SYSTEM is the process in which the raw water after used for cooling
is wasted back into the canal.

7. 6
CLOSED CYCLE SYSTEM is a process in which the raw water which becomes hot
itself after cooling process in condenser is collected back into the cooling towers
and after the cooling, water is used for similar process.
BOILER
Boilers are built in variety of sizes, shapes and forms to fulfil conditions of
different kinds of plants. Generally boilers are classified into two groups.
(i) FIRE TUBE BOILERS
Boiler whose combustion products pass through the tubes. Heat is transferred to
water which surround the tubes.
(ii) WATER TUBE BOILERS
Boiler whose products of combustion pass through, around the tubes containing
water.
PARTS OF BOILER
BOILER AUXILLARIES
 Steam drum

8. 7
 Super heater
 Generation tubes (upriser)
 Downcomer
 Furnace
 Economizer
 Cyclone separator
 Burners
 Stack/Chimney
 Re-heaters
BOILER EX-AUXILLARIES
 Air pre-heater
 Induced draft fan
 Forced draft fan
 Recirculation fans
BOILER SAFETY EQUIPMENTS
 Interlock system
 Safety valves
TURBINE
A turbine is a rotary mechanical device that extracts energy from fluid flow and
converts it into useful work. The work produced by a turbine can be used for
generating electrical power when combined with a generator. A turbine is a
turbomachine with at least one moving part called a rotor assembly, which is
shaft or drum with plates attached. Moving fluid acts on the blades so that they
move and impart rotational energy to the rotor.
Gas, Steam and Water turbines have a casing around the blades that contains and
controls the working fluid.
TYPES OF TURBINE
(i) Impulse type turbine
(ii) Reaction type turbine
(iii) Velocity compound types turbine

9. 8
GENERATOR
It is final and main part of power house where electricity is produced. An
electrical generator is a device where mechanical energy convert into electrical
energy.
In generator a magnet moves with the movement of turbine shaft. Electric field is
produced in the winding of stator. The winding will heat up due to current
pressure which may resist in the flow of current so it is necessary to keep it cool.
Therefore demi-water and hydrogen gas are used for this purpose.
COMBINED CYCLE POWER PLANT
A combined cycle power plant uses both a Gas and a Steam turbine together to
produce up to 50% more electricity from the same fuel than a traditional simple
cycle plant. The waste heat from the gas turbine is routed to the nearby steam
turbine, which generates extra power.

10. 9
How a CCPP produces electricity
This is how a combined-cycle plant works to produce electricity and captures
waste heat from the gas turbine to increase efficiency and electrical output.
1. Gas turbine burns fuel.
 The gas turbine compresses air and mixes with it fuel that is heated to a
very high temperature. The hot air-fuel mixture moves through the gas
turbine blades, making them spin.
 The fast spinning turbine drives a generator that converts a portion of
the spinning energy into electricity.
2. Heat recovery system captures exhaust.
 A heat recovery steam generator (HRSG) captures exhaust heat from the
gas turbine that would otherwise escape through the exhaust stack.
 The HRSG creates steam from the gas turbine exhaust heat and delivers
it to the steam turbine.
3. Steam turbine delivers additional electricity.
 The steam turbine sends its energy to the generator drive shaft, where
it is converted into additional electricity.

11. 10
WATER CONDITIONING
CLARIFICATION
Clarification is the removal of suspended matter that has color and turbidity from
water by chemical means. Practically all surface water contains small amount of
mud, clay, salt, decayed, vegetation, micro organisms, sewage and industrial
wastes.
These insoluble must be removed to prevent fouling of feed water, pretreatment
equipment or to prevent deposits in the boiler water.
Process of Clarification
1. Coagulation
Coagulation is the process of change utilization of finely divided collided
impurities in water into masses that will settle rapidly and filtered out for this
purpose coagulants are used.
2. Flocculation
It is defined as the bridging to gather of coagulated particles. In short coagulation
involves neutralizing the negative charge and providing a nucleus for the
suspended particles to adhere, while flocculation is bridging together of
coagulated particles to form a bigger particle floc that can settle.

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3. Sedimentation
It is the process in which bigger coagulated particles(flocs) settle down to provide
a clear water free from suspended matter.
DE-MINERALIZATION
De-mineralization is a type of water purification. While it can refer to any
treatment process that removes minerals from water, the term de-mineralization
is typically reserved specifically for ion-exchange processes used for near total
removal of ion mineral contaminants. Often, the term de-mineralization and de-
ionization are used interchangeably.
De-mineralization utilizes both cation and anion exchange resins, sometimes even
in the same column or bed. Following de-mineralization, the treated water will be
of a high level of purity comparable to distilled water, but typically at a much
lower cost.
Purpose of De-Mineralization
 Removal of ionic substances
 Reduction of conductivity
 Control of pH

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Main Parts of De-Mineralization Plant
(i) Cation Exchangers
In cation exchanger the cation resins within a de-mineralization system will
exchange cations, or the contaminants having positive charge by releasing
hydrogen ion (H+
) to react with them. Common cationic contaminants include:
Calcium (Ca2+
), Iron (Fe3+
), Magnesium (Mg2+
), Manganese (Mn2+
), Potassium (K+
),
Sodium (Na+
)
(ii) De-Carbonizer
De-Carbonization is a equipment where dissolved gases such as CO2 and
Carbonates (CO3
-2
), Bicarbonates (HCO3
-
) are removed from water by vacuum
mechanism or by blowing air through showering de-ionized water.
(iii) Anion Exchangers
In anionic exchanger the anion resins within a demineralization system will
exchange anions, or contaminants having a negative charge by releasing
hydroxide ion (OH-
) to react with the acid formed in cation exchanger.

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(iv) Mixed Bed Ion Exchangers
Mixed bed ion exchanger has both cation and anion exchangers resins. Thus the
remaining cations and anions exchangers are removed in this filter. Chemical
reactions involved are similar to cation and anion ion exchangers.
(v) Regeneration
 Cation exchange resins are regenerated by treatment with hydrochloric or
sulfuric acid, then washing with water.
 Anion exchange resins are regenerated by treatment with hydroxide
(NaOH), then washing with water.
COOLING TOWER
Cooling tower is a special type of heat exchanger that allows water and air to
come in contact with each other to lower the temperature of the hot water.
The prime function of cooling tower is to cool the hot water through its structural
design and fans therein 75% hot water get cold by evaporation whereas 25% hot
water get cold through air.
All cooling towers operate on the principle of removing heat from water by
evaporation.
How a Cooling Tower Works
Warm water from industrial equipment, commercial AC system or any other heat
source enters the tower and spread evenly at the top. As the water flows down
the tower, the equipment fill spreads it over the large area to increase the water-
air contact, thus enhancing heat transfer via evaporation.
A large volume of air is constantly moving along the fill courtesy of large fans in
the tower. As evaporation takes place, the water losses heat. It eventually enters
the tower sump at the bottom. The cool water than goes back to cool the initial
heat source and the cycle repeats. For the sake of system dilution, of portion of
the system water goes to the drain through the bleed-off valve. The makeup line
feeds the cooling tower with fresh water for replenishment.

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You will not note these processes easily because their simultaneous occurrence
creates a continuous loop. The figure below shows the process in a typical cooling
tower.
CORROSION
Corrosion is the natural process, which converts a refined metal to a more
chemically stable form, such as its oxide, hydroxide, or sulfide. It is gradual
destruction of materials (usually metals) by chemical and/or electrochemical
reaction with their environment.

16. 15
The Corrosion Triangle
How Corrosion Takes Place
Corrosion is an electrochemical process and for its occurrence an electrochemical
shell is required which consists of an anode, cathode and an electrolyte must
exists. Metal ions dissolve into electrolyte (water) at anode. Electrically charged
particles (electrons) flow through the metals to other point (cathode), where
electron consuming reactions occurs. The result of this activity is the loss of metal
and often the formation of deposit.
Corrosion Prevention Methods
 Environmental modification
 Metal selection and surface conditions
 Galvanization
 Cathodic protection
 Inhibitors
 Coatings
 Plating

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HYDROGEN GAS GENERATION
Electrolysis is a promising option for hydrogen production from renewable
resources. Electrolysis is a process of using electricity to split water into hydrogen
and oxygen. This reaction takes place in a unit called an electrolyzer. Electrolyzers
can range in size from small, appliance-size equipment that is well-suited for
small-scale distributed hydrogen production to large scale, central production
facilities that could be tied directly to renewable or other non-greenhouse-gas-
emitting forms of electricity production.
How Does It Work?
Like fuel cells, electrolyzers consists of an anode and a cathode separated by an
electrolyte. Different electrolyzer function is slightly different ways, mainly due tto
different type of electrolyte material involved.

18. 17
Why Generator is Cooled by Hydrogen?
In generator mechanical energy is converted into electrical energy. During this
process heat is produced. Rotor is made up of iron and steel and windings are
made up of copper. As this temperature increases, insulation properties of
windings are effective. Therefore H2 gas is used to remove that excessive heat. H2
has a unique property of quick absorbing as hollow, demi water is sent through it
to take away heat. The control of H2 temperature 4 coolers are installed at the 4
corners of generator. The secondary water passes over the tubes.
OCCUPATIONAL HEALTH & SAFETY
Occupational safety and health (OSH) is a multidisciplinary field concerned with
the safety, health and welfare of people at work. These terms also referred to the
goals of this field, so their use in the sense of this article was originally an
abbreviation of occupational safety and health program/department etc.
The goal of occupational safety and health programs include to foster a safe and
healthy work environment. OSH may also protect co-workers, family members,
employers, customers and many other who might be affected by the workplace
environment.

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FIRE SAFETY AND FIRE EXTINGUISHERS
Industrial fire safety is the set of practices intended to reduce the destruction
caused by fire. Industrial fire safety measures include those that are intended to
prevent ignition of an uncontrolled fire, and those that are used to limit the
development and effects of fire after it starts.
Four E’s of Fire Safety
 Engineering:- Safety at the design, equipment installation stage.
 Education:- Education of employees in fire safety practices.
 Enlistment:- It concerns the attitude of the employees and management
towards the program and its purpose. This necessary arose the interest of
the employees in fire accident prevention and safety consciousness
 Encouragement:- To enforce adherence to fire safe rules and practices.
Fire Extinguishers (Types & Uses)

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RECOMMENDATIONS
 Facilitation, The management of TPS Guddu should enhance more facilities,
so as to enable smooth running of the company’s activities.
 Opportunities, More opportunities should be created for the students to
do internship in this company.
 Allowance, The company should give allowance to interns most specially
residential accommodation allowances in these remote areas.
 Supervision, The company should increase and ensure more supervision
over the interns in order for the better understanding of any process
carrying out there.
 Safety, The company should also increase the safety measures and should
teach the students/interns about safety rules and regulations, that how to
react and manage things in any emergency situation.
CONCLUSION
In conclusion we benefited a lot in the field attachment in a way that we
managed to apply our theoretical knowledge from the university into
practice through many activities/observation/experiments we was
instructed to do.
Finally, the internship was both fruitful and fun for us and we would
encourage the other students to apply here for the internship and to avail
the opportunity of doing internship in this company to clear their concepts
and knowledge related to their field by observing things practically, that
were taught to them theoretically in the university.