Internship

Report
2013
TNB Liberty Power Plant

Mehran University of Engineering & Technology

Jamshoro
Naresh Kumar
(10IN06)
Industrial Engineering & Management Department
7/28/2013
 [TNB LIBERTY POWER PLANT] Internship Report

Foreword

This is the report of that all teachings, experiences & knowledge gained by me at
TNB Liberty Power Plant Mirpur Mathelo during my period of internship .i.e.
15/07/2013 to 28/07/2013.

I am much relieved to TNB Liberty Power Plant Mirpur Mathelo, along with it
would like pay thanks to all staff for being good to deal with & have wonderful
time there. Had come know about new stuff to learn and executed certain
dedication towards enhancement of practical knowledge of theoretical aspects at
academics period in university.

I am much delighted to be intern at TNB Liberty Power Plant Mirpur Mathelo; this
is one of leading organization known at international level. I would like to thank
each & every individual from TNB Liberty Power Plant Mirpur Mathelo, Who
assists me in every possible means. I was provided transport facility, academic,
practical knowledge and much more to have one-hand knowledge about practical
life.

Naresh Kumar (10IN06)

Industrial Engineering & Management Department
Mehran University of Engineering & Technology Jamshoro.

Thanks
 [TNB LIBERTY POWER PLANT] Internship Report

CONTENT

S/No# Topic
01 Introduction to TNB

02 TNB Liberty Power Plant Mirpur Mathelo

03 Departments at TNB Liberty Power Limited

04 HSE Department

05 Mechanical Department

06 BOP & Facility Department

07 Chemical Department

08 EIC & IT Department

09 Production/Operation Department

10 Control & Administration

11 Recommendations
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INTRODUCTION TO TNB

TNB stands for Tenaga Nasional Berhad, TenagaNasionalBerhad (TNB) is the

largest electricity utility in Malaysia and a leading utility company in Asia. TNB has
been keeping the Lights On in Malaysia ever since it was set up as the Central
Electricity Board in 1949, powering national development via the provision of
reliable and efficient electricity.

TNB’s o e usi esses a e i the ge e atio , t a s issio a d dist i utio of

electricity. Other than its core business, TNB has diversified into the manufacture
of transformers, high voltage switchgears and cables; the provision of
professional consultancy services; and architectural, civil, electrical engineering
works and services, repair and maintenance. The Company also engages in
research and development, property development and management services.
Tapping into opportunities available overseas, TNB is making inroads into
emerging markets, focusing on the Asia-Pacific, Middle East and North Africa
regions.

In 2005, the Company embarked on a 20-Year Strategic Plan with the ultimate
objective of transforming into a world-class player by the year 2025. To support
this vision, TNB invests significantly in the continuous professional development
of its employees through structured programmes. There is also renewed
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emphasis on sustainability, both of the organisation and of the Malaysian

environment. The Strategic Plan entails greater focus on green initiatives such as
the development of renewable sources of fuel, and more effective demand side
a age e t ia e e g effi ie , thus o ple e ti g the Go e e t’s
carbon reduction agenda.

As a leading Government-linked company, TNB also places strong emphasis on its

social responsibilities. Through its foundation Yayasan Tenaga Nasional (YTN),
established in 1993, the Company runs numerous CSR programs that benefit the
underprivileged. Among its many successful social outreach programs are those
that education via scholarships and better health for all.

TNB is also diversifying its service at world level, TNB posses a Liberty Power
generation plant in Pakistan and also in others countries of the world.
TNB is expanding their service and developing at very versatile level.
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TNB LIBERTY POWER PLANT MIRPUR MATHELO

TNB Liberty Power Plant Mirpur Mathelo is a Malaysian organization and this is
the first sub branch of Tenaga Nasional berhad across Malaysia, this work under
independent Power Producer (IPP). TNB Liberty Power Plant Mirpur Mathelo is
Combined Cycle Power generation Plant, This organization is situated at very
appropriate position in District Ghotki of Sindh. TNB Liberty Power is designed to
produce 235 MW of electricity, It is been working since 2011. The installation
work of this plant was done by Italian Company ANSALDO Energia. After
completion TNB started providing service to local electric Supplying Company i.e.
WAPDA since 2011.

The Plant is occupied with two turbines 1st Gas Turbine and 2nd Steam Turbine.
Configuration of plant is 1x1x1, combined power plant; it consist of G.T x Boiler x
S.T, This CCP system accomplish it task/production while following these
parameters. The main source of this plant is Gas while alternative also there
Diesel. TNB Liberty Power Plant is providing electricity within 132 Kilo Volt
capacity.
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TNB Liberty Power Plant has made GSA agreement with OGDCL Qadirpur, which is
23Km approximately away from Plant. And PPA is done with local Electric
Supplying organization i.e. WAPDA. The Distribution lines are given to vicinity
a ea’s feede
1. Ghotki
2. Mirpur Mathelo
3. Daharki
4. Guddu Left

The Plant is equipped with all that facilities to achieve respective goal and total
number of employees is 100. The residential facility is also available for the
permanent staff only. The transport facility is available for vicinity areas.

 Plant Layout:

While installing or establishing any organization Plant Layout is one the basic and
major aspect to enroll in. In Plant Layout is set of complete analysis, research of
area, geographical condition and examined to coincide the conditions type and
need of concern organization.

This CCP is situated at a very magnificent location; District Ghotki Sindh is one of
the significant sites for industrial investors. Being occupied with natural resource
of gas and petroleum and located at iddle of the ou t ’s main highway and
railways too.

This CCP is situated at between the two major fertilizer industries i.e. Engro and
FFC, The next major aspect is that two main Gas Supplying companies are near to
this; from one of them this CCP had made agreement to receive/take gas for its
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production purpose i.e. OGDCL Qadirpur and Mari Petroleum Limited. The water
canal is beside to this CCP plant, which is source for water for plant usage.

 Plant Specification:
 TNB Liberty Power Plant is Combined Cycle Power Generation/production
plant.
 Production Capacity is 235MW.
 Optimized & Safe waste to atmosphere.
 Dual Fuel mechanism i.e. Gas and Diesel Oil.
 Siemens Gas Turbine of Capacity of 160MW.
 Dual Pressure Boiler (HRSG) utilized for steam generation (525°C to 125°C).
 ABB Steam Turbine of Capacity of 80MW.
 5S and SEMS are followed for Safety.
 Automation System.
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DEPARTMENTS AT TNB LIBERTY POWER LIMITED

TNB LPL is focused to accomplish its objective via various departments within.
The departments of TNB LPL are combined contacted and are determined to
provide own sort of service for production. Following given are several
departments,

 HSE
 Mechanical
 BOP & Facility
 Chemical
 EIC & IT
 Production/Operation
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HSE DEPARTMENT
HSE stands for H+6ealth Safety Environment. Commonly this department
exists in all organization of production type. Safety is one of most prior and
first aspect to be governed while work/operating/operations in
organization. Health Safety Environment is clearing itself from its name as
tasks to be taken for procurement of Health and safe environment. HSE is
determined to prevent hazards from plant to environment and minimize
injuries for employees.
The individuals involved in this department are focused to maintain safety
at Plant and allot PTW (Permit to Work).
TNB LPL has Occupational Safety & Health Policy given below
i. Ensure that safety & Health matters are integrated into all our
operations & maintenance activities.
ii. Ensure that all operations and maintenance activities are undertaken
according to safe work procedures.
iii. Ensure that safety & health will e given high priority in all service and
procurement producers.
iv. Ensure that safety & Health inspection, monitoring and auditing will
be carried out regularly at our plant.
v. Provide training and information to all employees and contractors in
the exposure of particular hazards at work place.
vi. Promote Safety & health awareness among the employees and
public.

TNB LPL is highly determined on implementation of these points within

organization. All the tasks are given to be coinciding the HSE parameters.
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The Objective of safety is zero injury and efficient working of plant.

This department posse over all control on plant at safety concern, which includes
Fire fighting, first aid, doctor, ambulance etc. certain instruction/tools are given
for work place, we called it PPE (Personal Protective Equipments) in technical
term. The o o PPE’s are given below,

 Safety Helmet
 Safety Shoes
 Safety Goggles
 Ear Plugs
 Safety Apron
 Gas Filters
 Fit Dress

Although safety is main responsible for occupational safety by reducing hazards in

the work place and enforcing mandatory job standards and to improve health
program for worker.TNB LPL is following certain well known techniques for HSE
and are given below
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 SEMS
SEMS stands for safety Excellence Management System. This is one of the
famous method for Safety, This generally cover few points;
a. Premises and Housekeeping
b. Mechanical, Electrical and Personal Housekeeping
c. Fire Protection and safe Guarding
d. Accident reporting and investigation
e. OSH Organization
 5S
5S is Japanese technique; it is set of those aspects that had been made for
restoring the normal condition after nuclear attack on Japan. Although 5S
proven to be efficient and had met the demand.
Ge e all 5“ te h i ue o sists of fi e poi ts sta ti g ith “ , a d those
are given as;
1. Sort (Separating the Things)
2. Set in Order (Arrangement)
3. Shine (Cleaning & Procurement Maintain)
4. Standard (Labeling)
5. Sustain (Maintaining 4S)
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MECHANICAL DEPARTMENT
Mechanical department at TNB LPL has significant services, although all
departments have their own intentions. Mechanical department provide various
service to production plant. And these services are circulating on regular bases
and have very vital role in closing and initiations time.
While plant in operation session, all mechanical tasks are deal by this department
like maintenance, compressors, heavy Tool/Equipments, Motors, shafts etc.
The Mechanical work is generally spread in all plant, indeed whole plant is
occupied with machinery.
Mechanical Department majorly focuses on Maintenance, stationary, motors,
heat exchangers, compressors and pumps. Mechanical department has two
workshops i.e. Maintenance Workshop and Equipments Workshop. Staff is also
there to encounter problem.
Following few parameters are given, which are given governance of Mechanical
Department.

 Maintenance:
Maintenance is set of tasks which are employed to make any machine in its
working condition or tends to. Maintenance is a vital tool for machinery to
work under required circumstance. At this CCP maintenance is categories in
two types.
1. Preventive Maintenance
2. Corrective Maintenance
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 Preventive Maintenance
The maintenance activities which are taken to prevent the problems or other
words it can be regulated as maintenance done to prevent/avoid breakdown of
machines. It can be on day bases/ weekly bases depend upon the average
breakdown period of machine. Although every machine comes with pamphlet, in
which maintenance period is given. Mostly the estimations are done for this sort
of maintenance.

Generally preventive maintenance is done on plan or on inspection like hearing

any extra sound, Oil change, Temperature, pressure etc. Preventive Maintenance
is vital tool to avoid the problem regularly and taking efficient action would never
alter any fault in process.

 Corrective Maintenance

The maintenance activities which are taken when the problem has occurred
already and time to resolve it, those resolving actions would cover Corrective
Maintenance. When any machine get fault in it or breakdown has machine off,
the specific maintenance efforts are taken at that time, those efforts are called
Corrective Maintenance.

In Corrective Maintenance we just need to be making out solution for breakdown

or exact fault.

 Sheet Work:
Sheet Work is one important and basic task of mechanical department, all the
design of every machine is prescribed in sheets, onwards its mechanical
i di idual’s dut to fo a hi e e ha is a o di g to sheet.

At TNB LPL all sheet work were made to be done br ANSALDO Engergia
company, Further all the sheet is available for guiding and mitigating any sort
of trouble. There are three types of engineering drawing.
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 Orthographic
Orthographic is that type of design in which we deal with lines,
shapes (2D) and machines design by combining various shapes
together.
 Isometric
Isometric sheet work is that work in which we are concern to
solid design with 30° titled with reference to plan. This
methodology is used for finding the three dimensions (3D).

 P & ID
P & ID stands for Piping & Instruments Design; the plant has
major scope of this type of design. This design combines both
orthographic and isometric and form the complete mechanism
of main process at sheet. At TNB LPL all the sheet work is in P
& ID form.

 Equipments:
Equipments are the tools and stuff that supports the operation process being
in progress. All equipments have their own significance in the processes; all
equipments jointly accomplish the total work. There are two types of
Equipments used in TNB LPL, given below.

 Static Equipments:

Those e uip e ts hi h do ’t ha ge thei positio ith espe t to gi e a is

while functioning. Generally usage of static equipments fixed and had a very
important focus because it is very difficult to change again and again, in case of
any fault in equipments. List of common static equipments are given below.

 Piping
 Valves
 Stack
 Boiler
 Vessel
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 Steel Structure
 Tanks
 Electric lights

 Dynamic Equipments:

Those equipments which change it position with respect to axis or surroundings,

those equipments which can rotate or move. Although Dynamic Equipments are
easy to change in compare with static equipments. Commonly used dynamic
equipments are as under,

 Motors
 Turbines
 Engine
 Compressor
 Fans
 Pumps
 Condenser

 Workshops:
Mechanical Departments has two workshops for respective activities, workshop
contains machine like Lathe, Drilling, CNC, Grinding, Cutting and all other
machines required for overcome any mechanical problem.

 Compressors:
Compressor is the machine which intake atmospheric air and compresses it via
pressure mechanism. The pressure is transmitted to air due to low volume and
incremental kinetic energy.

TNB LPL needs compressed air for combustion at Gas Turbine to run it.
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BOP & FACILTY DEPARTMENT

BOP stand for Balance of Plant, BOP & Facility department encounters all those
efforts for plant to balance it or keeping in working order and Facility indicates
providing facilities to support plant means all that extra stuff or indirect things
which are like to be supporting for plant process and employee as well.

The tasks of this department are to maintain and equipped all those materials,
which are needed to support the production. BOP & Facility department is
focused to provide its services to Plant area and also at demotic utilities to.

The balancing of plant includes Civil, Mechanical, Power, Light, Communication,

Air condition and residence areas.

 BOP:
Balance of plant include all that stuff that are needed to maintain the
process in working conditions, like providing cool water to plant for process
purpose, Fire Fighting system, Personal Protective Equipments (PPE) and
safety in coordination with HSE Department. Given below little description
about actions taken in account of BOP.
 Fire Fighting System
Fire Fighting System is spread in all plant area, In case of
any fire, the fire alarm would be raised and effective would
be executed as per plan. There are three methods to deal
with fire emergency,
1. Water Showering (Open Area)
2. Carbon Dioxide (Electric Area)
3. Water With Foam (Diesel/Fuel)
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The automatic system is adopted for fire response, When

ever fire alarm rises, the area is need to be emptied and
after few second response get start according to area type.
Fire Fighting System include
i. Fire Hydrant System (Indoor/Outdoor)
ii. Deluge Valve
iii. CO2 Cylinder Protection System
iv. Fixed Foam Stations
v. Portable Foam Trolley
vi. Fire Extinguishers (CO2 & Dry Powder)
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Fire Hydrant System Control Valve

Fire Fighting System is totally inspected by panel spread in various area i.e. Gas
Turbine Hall, Gas Turbine Control Room, Steam Turbine Hall, Steam Turbine
Switch Gear Room, Ware House, 132 KV Substations and master Fire Fighting
Control Panel is in Central Control Room.

 Facility:
Facility of this department include that service with is supportive to
operations, Like providing equipments of welding for welding purpose,
facilitating employee to work concern to their need for working at plant.

BOP & Facility Department is also dealing with civil work, if any sort of
construction breakdown occur then it is also managed under this Department. As
like the same facility of transport and vehicle utilized for plant purpose are also
covered under this. Overall this department has a vital implication at TNB LPL.
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CHEMICAL DEPARTMENT
Chemical Department at TNB LPL serves like utility/inventory for
production. Chemical Department is located near and middle of plant with
the name of Water Treatment Plant (WTP). Many chemical functions are
performed here for water treatment, making natural water feasible for
Plant processes. Majorly function is making water suitable for steam
turbine and also making pure drinking water.
Chemical Department deal with water only at Plant, the Source of water
intake is Canal Water and ground water. Plant is Equipped with a clarifier
and chemical treatment with water to make it able for plant process and
utilization.

 Clarifier:
The Clarifier is mechanism where canal water is treated with FeCl3 to
separate the MUD and dust particle from water. This Overall process is
called Pre-Filtration. From this pre-filtered water is sent to WTP (Water
Treatment Plant) for further cleaning. Although Ground water is also
alternative, this is cleaner than canal water, but the canal water posses
more quantity of mineral in it compare to ground water. Fecl3 is treated
with canal water in clarifier tank, The Fe react with non-metal mineral
presents in water, while the Cl react with metal present in water. Chlorine
generally takes mud particles with it become thick and stay in bottom of
the tank. Upper water is mud free and move to WTP for further
purification.
After reaching at WTP, there is very little amount of mud particles present
is water. Onwards treatments are done depending upon sort of output
needed.

 Reverse Osmosis:

Reverse Osmosis is generally called as RO, this is filtration process through

which water get even more clean and become Mineral Water. Reverse
osmosis (RO) is a water purification technology that uses a Semi-Permeable
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membrane. This membrane-technology is not properly a filtration method.

RO can remove many types of molecules and ions from solutions and is
used in both industrial processes and in producing potable water.

At TNB LPL RO plant is providing mineral water to general drinking and

domestic purpose.

 Demineralization:
The process of extracting all minerals from water and getting only water
with no any mineral in it, the water which we get is called Demin Water.
Demin Water is very essential for Turbine and plant processes because
water is utilized for condensation and steam generation, Indeed all parts of
machinery are made up of iron and steel, which get rust while interacting
with mineral existing in water. Then it is efficient to use Demin water for
Steam Generation, Condensation, Cooling tower and other machinery use.

Overall the Chemical Department is clarifying waste water and making it cable
to use again, although zero hazard waste is objective of every
industry/organization, and it is reason of glade that TNB LPL is following the
Environment Protection Rule set by the government of Pakistan.
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EIC & IT DEPARTMENT

EIC & IT stands for Electrical, Instrumentation Control and Information
Technology, EIC & IT department deal with electric appliances, Instruments; their
control and information, communication of interdepartmental and overall contact
with satellite.

TNB LPL being a power generation plant has an imperative service of this
department and there are continuous services via this department. This
Department covers the whole electric generation mechanism to distribution line
to feeders and also deals with mechanism to generate power efficiently.

 Electrical:
Electrical Departments deal the product of this plant i.e.
Electricity/Current/Power. This section covers all those equipments and
machines that are utilized to transfer power generated from Generators to
Switchyard of Plant. Electrical Departments also concern with WAPDA in
account of total number of units output to WAPDA.

 Switchyard
Switchyard is the power distribution area of plant, where generated
power from turbines comes with 13`2 Kilo volts from transformer.
This area contains circuit breakers, switch and isolated stuff and
grounding wires. All equipments are indicated by color coding
according to their use/sort. There are three colors Red indicates the
main dangerous power line, Yellow line indicates grounding line and
blue line is indicated for communication and extracting data from the
system of the system.

TNB LPL is diversifying their production into six different lines. Every
line is contact with isolated circuit breaker in case of repairmen not
to disturb other line.
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 Generators
Generator is device which produces electrical Energy by mean of
mechanical Energy. It consists of Stator and windings in it. When
stator is revolved by any external rotatory force, then windings start
producing potential difference and hence charges are produce. There
are three stuff needed for electricity production

1. Motion
2. Conductor
3. Magnet

TNB LPL Having two generators of 160 MW and 80 MW production

capacities.

 Transformer
Transformer is device which varies the potential difference by
mechanism of different number of windings. Transformer is utilized
for step upping and Step Downing. At TNB LPL there are two Major
transformers 1. Unit transformer which produce 11.5 Kv Power which
Supply to Bus Bar and second transformer, 2. Main Transformer, this
transformer step up the power from 11.5Kv to 132Kv.
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 Instrumentation Control:
Instrument Control is an art of measuring process. The phenomenon
utilized for calculating different variables/parameters of process and in case
of any fault also for correction purpose. Instruments utilized for control
mechanism can be undertaken this phenomenon. The control of every
process is done by certain instruments/equipments and to manipulating
that how instruments are make to follow the set standards. Instruments

 Control Process
are utilized for monitor, control and meet the quality of output.

Those process which are executed only for controlling Purpose.

Control processes are complete strategy to follow, there are various
techniques depending upon the nature of process. There are three
Types of Control Process,
1. Primary Element
2. Secondary Element
3. Final Controlling Element

This is figure given indicating that little devices can be source to control
different processes.

 PLC
PCL stands for Program Logic Control; PLC is a system which works
under given instructions. PLC can be a simple circuit, which is already
programmed. PLC is programmed for certain set standards givens.
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 Numatic Control
Numatic Control is mechanism in which control of variable process is
done by mean of Aerodynamics. Pressurized air is taken for
execution of various control mechanisms, like valves are control by
Numatics. There are also numatic machines which are operated on
pressurized air.

 Information Technology:
Information is the data of anything, and it is transformed by mean of
technology, this all system is covered in Information Technology. Getting data
sending has become part of life even in personal life also in organization
sector. TNB LPL is connected with Malaysia, NPCC and RPCC. Data is
continuous under focus and can be operated via information technology. This
Information technology has made this world as Global World.
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PRODUCTION/OPERATION DEPARTMENT
Production/Operation Department is the main objective accomplishing
department. Operation defines the mechanism that how all resources are
directed to result output/production. This CCP Plant is determined to complete
production under two main aspects

1. Utilities
2. CCP Operations

These two aspects are the main mechanism of the plant to generate power, these
includes variety of processes and machinery.

This is overview of plant, the CCP is held in Shaded areas and all non-shaded areas
are utilities of the plant, which employee service/task for proper happening of
CCP Operations.
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 Utilities
Utilities of plant include all those parameters and process which
support the CCP Operations. As service is always needed for every
task to execute. Utilities at TNB LPL is being discuss below to show
their dedications towards main production.
 Cooling Tower
Cooling Tower is a cycle of cooling system for the plant. Water is utilize
for the transformation of heat, Water gains heat from machinery and
bring at cooling tower section, where hot water is thrown from nozzles
and heat is extracted by means of big fan. And water become cool and
again departure to machinery section to suck heat.

This all system keeps on moving and whole cooling mechanism is done
by Cooling Towers. At TNB LPL cooling tower are used for condensation
process of steam Turbine.

 Gas Reduction Station

Gag Reduction Station is that place where high pressure is reduce up to
the utilization pressure. The gas comes with a high pressure and it would
be dangerous for machinery to utilize directly hence pressure is reduce
and also moisture are removed present in Gas. The valve and tube are
insulated with Aluminum Cladding Sheet and color coding is also given,
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orange Color indicates line of Gas while red indicates line of water as fire
responsive actions.

 Unloading Bay
Unloading Bay is a place, where goods are unloaded for utilization
purpose and it is located beside Fuel Tank, mostly Fuel are is unloaded
and by the using of tubes, fuel is sucked and driven to Fuel Tanks.

 Demin Water
As we have already elaborated in Chemical Section, Demin Water is
called for its Demineralization. Demin Water is best for machinery
pu pose e ause it do ’t alte a usti g i the a hi e pa ts a d held
to raise the machinery life.

 BSDG
BSDG stands for Black Start Diesel Generator, These are generators
situated beside of the maintenance workshop. Black Start Diesel
Ge e ato s a e the alte ati e solutio of Po e , he the e ould ’t
be any other source of power. At TNB LPL there are two BSDGs are
present of Capacity 2.5 MW/each.

These generators are reason of initiation of plant after every shutdown,

initially turbines are forced to move on the power of these generators
and also supply power to utilities purpose. These are directly connected
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with Fuel tank for intake of Fuel. These generators have very striking
implications for the plant.

 Fuel Tank
The Fuel Tank is a container filled up of Fuel Oil i.e. Diesel. Fuel Tank is
considered as utility because at initiation after every shutdown Diesel is
used at Gas Turbine to start initial RMPs and also used for other
machinery as well, like BSDG, vehicles etc.

At TNB LPL Fuel Tank is of much high capacity and connected directly
with its utilization places. The Fire System is also there to response any
unwanted happenings, The tank is equipped with two main motors, one
for filling and other for supplying to respective directions.

 Condenser
Condenser is mechanism of steam Cooling, It is mostly located beside of
every steam Turbine and gains steam with high temperature and make it
in the water form.

A Condenser is combined tubes vessel, which reduce temperature of

steam and convert the state. Cool water is passed from tubes and steam
is injected over these tubes and at interaction point heat is exchanged.
Condenser always connected to cooling tower and hot water is replaced
by cool water.
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 CCP Operations
Combined Cycle Power is the main process of this plant. Combined cycle power
plant as in name suggests, it combines existing gas and steam technologies into
one unit, yielding significant improvements in thermal efficiency over
conventional steam plant. However the heat recovered in this process is sufficient
to drive a steam turbine with of electrical output approximately 50 per cent of the
gas turbine generator.

The Combined Cycle Power Plant or combined cycle gas turbine, a gas turbine
generator generates electricity and waste heat is used to make steam to generate
additional electricity via a steam turbine. Combined Cycle Operations are those
processes which jointly make a system to consume the heat from one system for
other. Although this is an efficient method of power production, the heat from
o e s ste is ought u de use of othe ’s a d this becomes efficient, productive
and environmental friendly.

Combined Cycle Power Operation includes three processes at TNB LPL, Jointly
these three processes makes this organization as Combined Cycle Power Plant,
the processes are done at following three different elements of plants;

1. Gas Turbine
2. HRSG
3. Steam Turbine

Mutually these operations are called Combine Cycle Power.

Combine Cycle Power Generation Operations follows two cycles

a) Braytone Cycle:
It is process of Heat Engine under constant pressure. This cycle cover Gas
Turbine Mechanism.
b) Rankine Cycle:

The process of conversion of heat energy into Mechanical Energy, This

Cycle covers all processes of CCP after Gas Turbine, which includes HRSG
and Steam Turbine.
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Diagram presenting how CCP cycle Works

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 Gas Turbine
Gas turbine is a mechanical device that converts Heat Energy into
Mechanical Energy.

Turbine is mechanical mover that rotates and connected to any

Generator, Compressor, Motor, shaft etc

Gas Turbine at TNB LPL is of dual start mechanism i.e. Gas and Fuel. Gas
Turbine has following main components to produce power,

i. Axial Compressor
ii. Combustion Chamber
iii. Turbine
iv. Generator
v. Lubricating Oil
vi. Stack

These all components equally make this device as power generation

machine. These components have equally and continuously
implication is power production processes.
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 Functioning of Gas Turbine

Gas Turbine works on Braytone Cycle, which consist of four Stages;

1. Compression of Air
2. Combustion
3. Rotations
4. Exhaust

Gas Turbine has air compressor, which intake air and compress it at 16 Bar of
pressure also moisture are extracted and Compressed air is thrown with pressure
on compressor blades which provide initial trigger to turbine up to 400rmp after.
The second stage starts here gas turbine consist of two combustion chambers
and each chamber has eight burners. Gas coming from GRS injected in burners
and ignition is given to produce flames with intermixing of compressed air, the
temperature reaches at approximated 1000°C at chamber. The Third stage is
Rotation, in the second highly temperature flame with pressure are produced at
combustion chamber and in this stage these flames are thrown on Turbine Blade
with very high pressure. The Speed of Turbine reaches to 3000rmps and at the
rotation is transferred to Generator connected and power is produced. On the
other side the lubricated oil is continuously revolving beside the turbine,
generator and shaft as coolant system for these equipments. Final Stage is
Exhaust, in this stage burnt gas are exhausted after moving from blades. At this
stage the temperature of burnt gases is approximated 550°C. The temperature of
550°C is transformed to Stack generally in Open Cycle but this is combine Cycle
the temperature of 550°C is used to recover heat in HRSG.
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 HRSG
HRSG stands for Heat Recovery Steam Generator. HRSG is like vessel which
acts like a boiler/heat exchanger, this is used in combine Cycle power
generation organizations only. This mechanical element used to
recover/utilize heat to generate steam for some effective purpose.
HRSG is closed pressurized vessel, which use exhaust of high temperature
and recover it by exchanging this heat with water by converting it into high
pressure steam.
HRSGs consist of six major components:
1. LP Economizer
2. HP Economizer
3. LP Evaporator
4. HP Evaporator
5. LP Super Heater
6. HP Super Heater
The different components are put together to meet the operating
requirements of the unit.
 [TNB LIBERTY POWER PLANT] Internship Report

 Functioning of HRSG
The function of HRSG start after gas turbine exhaust hot gas, HRSG recover
that heat by generating steam. Six Major components mutually work in
closed HRSG vessel, and drums to store LP and HP water/steam in them. At
TNB LPL HRSG is in vertical shape, The heat is transmitted from bottom to
top and temperature varies from 550°C to 125°C while exchanging heat
with water resulting dry steam with dual pressure i.e. High & Low Pressure.
These processes are carried out by mean of feed pumps and HP & LP
Circulating pumps.

Combusted gas with temperature of 550°C coming from Gas, This process
contains six components hence posse’s six stages. First of all water is fed
into LP Economizer from condenser for pre-heating, following the same
mechanism water is also feed into HP Economizer for pre-heating purpose
in second stage. Second Stage completes when pre-heat water is store in
respective drums from LP & HP Economizers. At third stage circulating
pumps start circulating Pre-Heated water from LP Drum to LP Evaporator
and Fourth stage exits is same manner but it take pre-heated water from
HP Drum and circulating is done in HP Evaporators. In these stages
evaporators convert pre-heated water into in wet steam and are stored in
respective drums. Fifth starts when wet steam is fed into LP Super Heater
via circulating pumps and at this stage wet steam become dry steam with
the pressure of 4.5 Bars and same mechanism for the HP respectively with
pressure of 70 Bars at the sixth stage. Both Steams are directed to steam
turbine to rotate it.

Hence After this steam is condensate and sent to Economizers and

mechanism keep going into sixth stages.
 [TNB LIBERTY POWER PLANT] Internship Report

 Steam Turbine
Steam turbine is a mechanical device which converts thermal Energy
into Mechanical Energy, while connected with any generator/motor.
Steam Turbine produces 50% of power compare to Gas Turbine.

 Functioning of Steam Turbine:

Steam Turbine works on following steps;

i. Steam Inlet
ii. Turbine Rotation
iii. Steam Outlet

First of all steams of two type HP and LP with various pressures of 70 &
4.5 Bars comes in steam Turbine from HRSG. At second steps steam with
high pressure strike with blades of turbines that result in turbine
rotation. After rotating turbine steam in extracted out in condenser for
condensation and from there it is sent to HRSG.

Hence this mechanism keeps on going and power production is continues.

 [TNB LIBERTY POWER PLANT] Internship Report

CONTROL AND ADMINISTRATION

Everything that has executed always needed certain boundaries to be in those
and achieve respective goals. Control & Management have bit same function
coincide this.

 Control

Control work at plant is done in CCR (Central Control Room). Control functions
include all that tasks which coordinate various processes encountered at plant
for power production. At TNBLPL CCR is separate section located between the
both Turbines where each single activity is focused in account of production.
Control Section has access on all production activities, there are many others
control panels in different departments but there is always main control panel
is located within CCR. CCR is equipped with channels and bars which
coordinate whole system.

 Administration
Administration is the main pilot of whole plant area, which includes extra
section other than production. Administration Building is situated at initial of
plant area after security room on road. Administration supervision deals with
all relationship of TNB LPL with its outsides and interdepartmental.
Administration is focused on determine their objective and takes concern
actions respectively.
 [TNB LIBERTY POWER PLANT] Internship Report

Recommendations
Indeed TNB LPL has impressed me a lot; it is such an organized organization, I like
few parameters very much like assigning daily work, efficient Switchyard Circuit
Breaker system, safety efforts, Automation System, Plant layout, CCP as
environment friendly and

Although TNB LPL is installed by one of international Italian EPC Contractors

ANSALDO Energia with focused objectives, it is not my level to drag out errors,
but would like to put few words as recommendations.

 TNB LPL should formulate separate R & D (Research and Development)

Department to work for more efficient production system and also
conducting workshops for employee to modify current working techniques.
 TNB LPL Should has efforts to expand their production, by adding extra
system of energy production. Current energy crisis has altered a great need
of much energy consumption.
 There should be addition of small alternative generators, because when
some time gas pressure reduces for specific time period, which alter
production. While at low pressure of gas turbine should be connected with
small generators, so that it can produce energy for its plant purpose.

Indeed it was great experience to be interne at TNB LPL.