Internship Report

Muhammad Anas Razi

Air University

University ID BEEP-200311

Internship Duration: 6 weeks

Internship Location: Guddu Power Plant Unit 747MW, Guddu, Kashmore

Internship Role: Trainee Electrical Engineer

Checked by:
Instructor:

Training Center:

HR Department:
 Abstract

This report summarizes my six-week internship at Guddu Power Plant, focusing on its 747
MW Combined Cycle Power Plant. The internship aimed to provide practical experience in
the operation and management of a combined cycle system, encompassing both gas and
steam turbines. Key activities included participating in routine maintenance, performance
monitoring, and understanding the heat recovery process used to enhance plant efficiency.

The experience allowed me to apply academic concepts to real-world scenarios, gain

insights into the operational practices of a large-scale power plant, and develop essential
professional skills such as teamwork and problem-solving. This internship significantly
contributed to my understanding of the power generation industry and has informed my
career aspirations within the energy sector.
 Acknowledge

I would like to express my sincere gratitude to Mr. Bashir Magsi for his invaluable guidance
and support throughout my internship at Guddu Power Plant. His expertise and mentorship
were instrumental in helping me understand the intricacies of the combined cycle power
generation process and in enhancing my practical skills.

I also extend my thanks to Forman Mola Bux for his assistance and insights during my time
at the plant. His support and willingness to share knowledge greatly contributed to my
overall learning experience.

I am grateful to both for their encouragement and for making this internship a highly
educational and enriching experience.
 Table of Content

1. Internship Objective
2. Introduction
3. Weekly learning Experience
a. Week 1 Overview of CCPP
b. Week 2 Gas Turbine
c. Week 3 Maintenance of Gas Turbine
d. Week 4 Steam Turbine
e. Week 5 Electrical and Control System
f. Week 6 Review and Applications
4. Key Learning
5. Challenges and solutions
6. Conclusion
 Internship Objective

The primary objective of this internship at Guddu Power Plant was to gain practical
experience and deepen understanding of the operations and management of a Combined
Cycle Power Plant. Through hands-on involvement in the 747 MW unit, the aim was to:

1. Enhance Technical Skills.

2. Apply Theoretical Knowledge.

3. Understand Operational Practices..

4. Develop Professional Skills..

5. Explore Career Opportunities

 Introduction

The Guddu Power Plant Unit 747MW is a significant power generation facility located in
Sindh, Guddu, on the bank of the Indus River. This combined cycle power plant consists of
two gas turbines, each generating 243MW, and one steam turbine producing 261MW,
contributing to a total capacity of 747MW.

The plant plays a crucial role in meeting the region’s energy demands by efficiently
converting natural gas into electricity.The combined cycle process involves the use of gas
turbines to generate electricity, with the excess heat being utilized to produce steam that
drives the steam turbine, thus maximizing energy output and efficiency.
 Daily Learning Experience

Week 1: Introduction to the Combined Cycle Power Plant

A Combined Cycle Power Plant (CCPP) is an advanced and efficient type of power
generation facility that utilizes both gas and steam turbines to generate electricity. Here’s a
detail:

Overview

A Combined Cycle Power Plant combines two thermodynamic cycles to achieve higher
efficiency and reduced emissions compared to traditional power plants. This process
involves using the waste heat from a gas turbine to produce steam, which then drives a
steam turbine to generate additional electricity.

Advantages

• High Efficiency:

CCPPs can achieve efficiencies of 50% to 60%, significantly higher than traditional
power plants, due to the utilization of waste heat for additional power generation.

• Lower Emissions:

The higher efficiency leads to lower greenhouse gas emissions per unit of electricity
generated.

• Operational Flexibility:
 CCPPs can quickly adjust output to meet fluctuating power demands, making them
suitable for integrating with renewable energy sources.

Applications

Combined Cycle Power Plants are commonly used in various applications, including:

• Base Load Power Generation: They provide a stable and efficient source of
electricity for continuous operation.

• Peak Shaving: They can be used to meet peak electricity demands, often in
combination with renewable energy sources.

Challenges

• Initial Cost: The capital cost of constructing a CCPP is higher than that of
simple cycle power plants due to the complexity and additional components like the
HRSG and steam turbine.

• Maintenance: The combined systems require careful maintenance to ensure

efficient operation and longevity.

Overall, Combined Cycle Power Plants represent a significant advancement in power

generation technology, offering a balance of high efficiency and lower emissions.
Week 2: Gas Turbine Operations
Gas Turbines and Their Operation in a Combined Cycle Plant

1. Overview of Gas Turbines

Gas turbines are a type of internal combustion engine commonly used for power generation.
They operate on the Brayton cycle, also known as the gas turbine cycle. The key
components of a gas turbine include the compressor, combustion chamber, and turbine:

• Compressor: Compresses incoming air to a high pressure, increasing its

temperature and density.

• Combustion Chamber: Burns fuel (usually natural gas) in the compressed

air, raising the temperature and creating high-pressure gas.

• Turbine: The high-pressure, high-temperature gas flows through the

turbine, causing it to spin and generate mechanical energy, which is then converted
into electrical energy by a generator.

2. Brayton Cycle (Gas Turbine Cycle)

Gas turbine operates on brayton cycle. The Brayton cycle consists of the following
processes:
 1. Adiabatic Compression: Air is compressed in the compressor, increasing
its pressure and temperature.

2. Isobaric Heat Addition: Fuel is burned in the combustion chamber, adding

heat to the compressed air at constant pressure.

3. Adiabatic Expansion: The high-pressure, high-temperature air expands

through the turbine, doing work by spinning the turbine blades.

4. Isobaric Heat Rejection: The exhaust air is expelled from the turbine,
releasing heat at constant pressure.

The efficiency of a gas turbine is influenced by factors such as the compression ratio, the
temperature of the combustion process, and the efficiency of the turbine itself.
3. Combined Cycle Operation

In a combined cycle power plant like Guddu, gas turbines are used in conjunction with
steam turbines to improve overall efficiency. The process involves:

• Power Generation with Gas Turbines:

The gas turbines generate electricity by converting the energy from high-pressure,
high-temperature gases into mechanical and electrical energy.

• Heat Recovery:

The exhaust gases from the gas turbines, which are still hot, are directed to a heat
recovery steam generator (HRSG). The HRSG captures the waste heat from the gas
turbine exhaust to produce steam.

• Power Generation with Steam Turbines:

The steam generated by the HRSG is then used to drive a steam turbine, which
produces additional electricity.

By utilizing the waste heat from the gas turbines, the combined cycle process significantly
improves the overall thermal efficiency of the power plant, typically achieving efficiencies of
50-60% compared to the 30-40% efficiency of a simple gas turbine cycle.

4. Benefits of Gas Turbines in Combined Cycle Plants

• Higher Efficiency: Combined cycle plants achieve greater efficiency by

using waste heat to generate additional power.

• Reduced Fuel Consumption: Enhanced efficiency leads to lower fuel

consumption for the same amount of electricity generated.

• Lower Emissions: Improved efficiency often results in reduced emissions

per unit of electricity produced.

Overall, gas turbines are a crucial component of combined cycle power plants, providing a
flexible and efficient method of generating electricity.
Week 3: Gas Turbine Maintenance
Maintaining of gas turbines is crucial for ensuring their reliable operation, optimizing
performance, and extending their operational life. Proper maintenance helps prevent
unexpected failures, reduce downtime, and manage operational costs. The maintenance of
gas turbines involves a combination of routine inspections, preventive measures, and
corrective actions.

1. Types of Maintenance

• Routine Maintenance:

Includes regular checks and minor adjustments that ensure the turbine operates
smoothly. This may involve checking oil levels, monitoring vibrations, and
inspecting system parameters.

• Preventive Maintenance:

Scheduled maintenance tasks designed to prevent potential issues before they

occur. This often includes tasks such as cleaning, replacing filters, and checking
alignment.

• Corrective Maintenance:

Addressing issues that arise unexpectedly. This may involve repairs or replacement
of components that have failed or are showing signs of wear.

2. Maintenance Procedures

• Inspection and Monitoring:

Regular visual inspections and diagnostic monitoring help detect early signs of
wear, corrosion, or other issues. Key areas include the compressor blades,
combustion chamber, and turbine blades.

• Cleaning:

Components such as compressors and turbines need to be cleaned to remove

deposits, soot, or dirt that could affect performance. Cleaning schedules depend on
the operating environment and turbine type.

• Lubrication:

Regular lubrication of moving parts is essential to reduce friction and wear. The
lubrication system should be checked frequently to ensure proper function and to
avoid contamination.

• Replacement of Parts:
 Components such as filters, seals, and bearings may need periodic replacement.
High-wear parts like turbine blades and nozzles often require inspection and
replacement based on usage and condition.

• Performance Testing:

Periodic performance testing is conducted to verify that the turbine is operating

within its design specifications. This includes checking efficiency, output, and
operational parameters.

3. Major Maintenance Activities

• Overhaul:

A comprehensive process involving disassembly, inspection, repair, and reassembly

of the gas turbine. Overhauls are typically done at scheduled intervals or after a
significant number of operating hours.

• Hot Section Inspection:

The inspection of the high-temperature areas of the turbine, such as the combustion
chamber and turbine blades, to assess and repair damage caused by high
temperatures.

• Major Component Replacement:

Replacement of major components such as the turbine blades, nozzles, and

combustors. This is usually done during major overhauls or when significant wear is
detected.

6. Challenges and Best Practices

• Wear and Tear: Managing the natural wear and tear of components
through timely maintenance and part replacements.

• Technological Advances: Adapting to new technologies and maintenance

practices that can improve efficiency and reduce costs.

• Training: Ensuring that maintenance personnel are properly trained and

skilled in handling turbine maintenance tasks.

Effective gas turbine maintenance is a combination of scheduled tasks, real-time

monitoring, and corrective actions that together ensure the turbine operates efficiently and
reliably throughout its service life.
Week 4: Steam Turbine Operations

1. Overview

The Guddu Power Plant includes a steam turbine with a capacity of 261 MW. This turbine is
part of the combined cycle system and plays a crucial role in generating additional
electricity by utilizing the waste heat from the gas turbines. The steam turbine operates in
conjunction with two boilers and contributes to the overall efficiency and capacity of the
plant.

2. Boilers

The plant features two boilers designed to produce steam by using the waste heat from the
gas turbines. These boilers are integral to the combined cycle process:

• Heat Recovery Steam Generators (HRSGs):

The boilers at Guddu Power Plant are likely Heat Recovery Steam Generators.
HRSGs capture and convert the exhaust heat from the gas turbines into high-
pressure steam.

• Function:

The HRSGs operate by transferring heat from the gas turbine exhaust to water or a
thermal fluid, producing steam at high pressure. This steam is then directed to the
steam turbine to generate additional power.

• Efficiency:
 By using the waste heat from the gas turbines, the HRSGs enhance the overall
efficiency of the plant, allowing it to generate more electricity with the same amount
of fuel compared to a simple cycle power plant.

3. Steam Turbine Operation

• Design and Capacity:

The steam turbine at Guddu Power Plant has a capacity of 261 MW. It is designed to
convert the thermal energy from the high-pressure steam into mechanical energy,
which is then used to drive a generator and produce electricity.

• Operation:

The steam turbine operates in a closed-loop cycle where steam generated in the
HRSGs is fed into the turbine. As the steam passes through the turbine blades, it
expands and cools, causing the turbine to spin and generate power.
 • Components:

Key components of the steam turbine include the high-pressure (HP) turbine,
intermediate-pressure (IP) turbine, and low-pressure (LP) turbine stages. Each
stage is designed to handle different pressure levels of steam, optimizing the
efficiency of energy conversion.

• Efficiency:

The efficiency of the steam turbine is influenced by factors such as steam

temperature, pressure, and the quality of the steam. High-efficiency turbines are
designed to operate effectively across a range of conditions, ensuring optimal
performance.

4. Maintenance and Performance

• Maintenance:

Regular maintenance of the steam turbine involves inspection of blades, seals, and
other critical components. Maintenance activities include cleaning, lubrication, and
replacement of worn parts to ensure reliable operation and prevent failures.

• Performance Monitoring:

The performance of the steam turbine is monitored continuously to ensure it

operates within design parameters. Performance metrics include power output,
steam flow, and efficiency.

• Challenges:

Common challenges include managing wear and tear on turbine blades, addressing
steam leaks, and maintaining optimal alignment and balance. Regular inspections
and preventive maintenance are essential to address these issues.

5. Contribution to Plant Efficiency

• Combined Cycle Benefits:

The steam turbine significantly enhances the overall efficiency of the Guddu Power
Plant. By utilizing waste heat from the gas turbines, the plant can achieve higher
overall thermal efficiency compared to a simple cycle plant.

• Power Generation:

The steam turbine’s 261 MW capacity adds substantial electrical output,

contributing to the plant’s total generation capacity and supporting grid stability.
Overall, the steam turbine at Guddu Power Plant, along with the associated boilers, is a key
component in maximizing the efficiency and output of the combined cycle system, playing a
vital role in meeting the plant’s power generation goals.
Week 5: Electrical Systems and Controls

1. Electrical System Overview

The electrical system at Guddu Power Plant is designed to handle the generation,
distribution, and management of electrical power generated by both the gas and steam
turbines. It ensures that the electricity produced is efficiently transferred to the grid while
maintaining operational stability and safety.

2. Power Generation and Distribution

• Generation Units:

The plant’s electrical system encompasses the power generation units, which
include gas turbines and the steam turbine. Each unit is connected to a generator
that converts mechanical energy into electrical power.

• Voltage Regulation:

The electrical system manages different voltage levels generated by the turbines.
Voltage regulation equipment, such as transformers and switchgear, ensures that
the generated voltage is adjusted to suitable levels for distribution.

• Switchgear and Circuit Breakers:

Switchgear and circuit breakers protect electrical circuits from faults and overloads.
They allow for the safe switching and isolation of electrical components during
maintenance or emergencies.

3. Control Systems

• Control Room:

The control room is the central hub for monitoring and managing plant
operations. Operators use advanced control systems to oversee real-time
data, manage turbine performance, and ensure overall plant efficiency.

• Supervisory Control and Data Acquisition (SCADA):

 SCADA systems provide remote monitoring and control capabilities. They collect
data from field devices and sensors, enabling operators to manage plant operations
from a centralized location.

4. Electrical Protection and Safety

• Protective Relays:

Protective relays detect abnormal conditions such as short circuits or overloading

and initiate corrective actions, such as disconnecting affected circuits to prevent
damage.

• Safety Interlocks:

Safety interlocks are systems designed to prevent hazardous conditions by ensuring

that certain operational sequences are followed. They protect both equipment and
personnel by enforcing safety protocols.

• Emergency Shutdown Systems:

In the event of a critical failure or hazardous condition, emergency shutdown

systems automatically shut down the plant to prevent damage and ensure safety.

5. Instrumentation and Monitoring

• Sensors and Transmitters:

Various sensors and transmitters are used to monitor parameters such as

temperature, pressure, flow, and voltage. These instruments provide real-time data
to the control systems.

• Data Logging:

Data logging systems record operational data and performance metrics, which are
used for analysis, troubleshooting, and historical reference.

The electrical system and control mechanisms at Guddu Power Plant are critical for efficient
and safe operation. They ensure that power generation is optimized, electrical distribution
is managed effectively, and all systems operate within specified parameters.
Week 6: Review and Application

I recently completed an internship at Guddu Power Plant, specifically in the 747 MW unit,
and it has been an incredibly enriching experience.

Learning Experience:

During my time at the power plant, I gained hands-on experience in several critical
areas of power generation. The opportunity to work directly with the 747 MW unit
allowed me to understand the complexities of large-scale power production and the
operational intricacies involved. I was involved in routine maintenance tasks,
performance monitoring, and troubleshooting, which provided me with a deep
insight into the technical and operational aspects of power generation.

Mentorship and Training:

The team at Guddu Power Plant was exceptionally supportive. My mentors were
knowledgeable and always willing to share their expertise. They guided me through
various processes and provided valuable feedback, which greatly enhanced my
learning experience.

Challenges:

One of the key challenges I faced was adapting to the high-pressure environment of
a power plant. The need for precision and the importance of safety protocols were
emphasized throughout my internship. Navigating these aspects taught me a lot
about the importance of diligence and attention to detail in such a critical industry.

Overall, my time at Guddu Power Plant was invaluable. I am grateful for the opportunity and
the experience has significantly contributed to my growth as an aspiring professional in the
energy sector.
Key Learnings

• Technical Skills: Acquired in-depth knowledge of gas and steam turbine operations,
including start-up, shut-down, and maintenance procedures.

• Practical Experience: Gained hands-on experience in routine inspections, predictive

maintenance, and troubleshooting of turbines.

• System Integration: Understood the critical role of electrical systems and controls in
ensuring the efficient and safe operation of the combined cycle power plant.

• Teamwork and Communication: Developed strong teamwork and communication

skills by collaborating with experienced engineers and participating in group
discussions and problem-solving sessions.

Challenges and Solutions

• Challenge 1: Initial difficulty in understanding the complex interactions between the

gas and steam turbines.
Solution: Regular discussions with mentors and reviewing technical manuals
helped clarify these interactions.

• Challenge 2: Adapting to the rigorous safety standards and protocols required in a

high-risk environment.
Solution: Attending safety briefings and adhering strictly to guidelines ensured
compliance and safety during all activities.

Conclusion
My internship at the Guddu Power Plant Unit 747MW has been a great experience. It
provided me with a solid foundation in the operation and maintenance of combined cycle
power plants, particularly in the areas of gas and steam turbines. The practical exposure,
coupled with the theoretical knowledge gained, has significantly contributed to my
development as an electrical engineer. I am confident that the skills and insights I have
acquired will be invaluable as I continue my career in the power generation industry.