SUMMER INTERNSHIP REPORT

TWO WEEKS INTERNSHIP

AT
UKAI THERMAL POWER STATION (UTPS)
(A Unit of G.S.E.C.L, Ukai)

L.D. College of Engineering,

Ahmedabad

BACHELOR OF ENGINEERING IN ELECTRICAL ENGINEERING (Semester – VII)

SUBMITTED BY:

Name Enrollment No.

1.Mali Dasharathkumar B 200280109065
2.Patel Harshil D 200280109131
3.Patel Abhay M 200280109059
4.Patel Tejas D 200280109058
5.Patel Jenish M
200280109131
 ACKNOWLEDGEMENT

I would like to thank the entire Ukai Thermal Power Station. Who has provided
me the sessional internship. I am thankful to Chief Engineer sir of UTPS. Under
the guidance of Engineers of UTPS I learned many things in practical which I
learned in classroom.

I am also thankful to workers of their respective department, who were always

ready to clarify my doubts and helped me to increase my knowledge in my core
field.

I wish to express my deep gratitude to all the concerned persons, whose

enthusiasing support and co-ordination have given me the success to complete
my training in the organization.

I hope that my report will reflect my technical knowledge and

innovativeness, which I gained at Ukai Thermal Power Station, Ukai.
 DECLARATION

This report is based on the summer internship I have undergone in the premises
of Ukai Thermal Power Station (UTPS)- A unit of Gujarat State Electric
Company Limited (GSECL), Ukai from 27 July 2023 to 10 August. I obtained
the knowledge of Boilers and Electric auxiliaries related to Boilers, Turbines
and Generators, and Switchyard through the selfless efforts of the Employee
arranged to me by the company administration. The experience of the training
was good and I learned lots of things. I was successfully able to complete the
training.
 PREFACE

Industrial Training is meant to expose the students of engineering of the actual

Industrial Processes about which they have mean studying in detail from their
semesters. They have spent the last two years in gaining theoretical knowledge of
various manufacturing and assembly processes.

The two-week training has exposed us to the actual application of the various
studied. The training period has been very interesting wherein we got to know
how the final product comes to the market. Each product undergoes a number of
qualities control test to bring in uniformity and quality.

Each field requires skilfully handling and training at given at each step which will
help us in the long run.
 INDEX

1. Introduction
I. GSECL
II. Necessity of Power Plant
III. Ukai Thermal Power Plant IV.
Summary of Internship

2. Boiler
I. Introduction of Boiler
II. Procedure in Boiler
III. Condenser

3. Turbine and Generator

4. Super-heater, Economizer and Air preheater
5. Electrostatic precipitator
6. Ash Handling Plant
7. Switch yard
8. Conclusion
 1. Introduction
Electricity generation is the process of generating Electric Power from source of
energy. In thermal power plant prime mover is steam driven. In thermal power
plant prime mover is steam driven. Water is heated, turns into the steam and
spins a steam turbine which drives a process condenser and recycled to where
it is heated where it was heated. Generally various types of fuels are used to heat
water and turns into steam to run turbine. Some power plant uses coal, some
uses oil and some uses nuclear energy to burn boiler. Some prefer to use the
term energy centre because such facilities convert forms of heat energy into
electrical energy. Certain thermal power plants also are designed to produce
heat energy for industrial purposes of district heating, or desalination of water,
in addition to generating electrical power. Globally, fossil fueled thermal power
plants produce a large part of manmade CO 2 emissions to the atmosphere, and
efforts to reduce these are varied and widespread. Almost all coal, nuclear,
geothermal, solar thermal electric, and waste incineration plants, as well as
many natural gas power plants are thermal. Natural gas is frequently combusted
in gas turbines as well as boilers. The waste heat from a gas turbine can be used
to raise steam, in a combined cycle plant that improves overall efficiency. Power
plants burning coal, fuel oil, or natural gas are often called fossil-fuel power
plants. Some biomass-fueled thermal power plants have appeared also. Non-
nuclear thermal power plants, particularly fossil- fueled plants, which do not use
co-generation are sometimes referred to as conventional power plants.

I. GSECL
 Gujarat State Electricity Corporation Limited (GSECL) was incorporated in
August 1993 and is registered under the Companies Act, 1956 with the
objectives to initiate a process of restructuring of Power Sector and to
mobilize resources from the market for adding to the generating capacity
of the State and improving the quality and cost of existing generation.

GSECL has initiated its activities in the field of Generation of Power.

Energy has been universally recognized as one of the most important

inputs for economic growth and human development. It has been
recognized as one of the key drivers for rapid growth and poverty
alleviation. The Installed power generation capacity of the State has
increased from 315 MW in 1960-61 to 28277 MW in 2019-2020 (as on
31.03.20). The install capacity of GSECL is 7038.57 MW (as on 30.06.22).
The per capita energy consumption of power in the State of Gujarat in
2021-22 was at 2283.19 units.

II. Necessity of Power Plant

 Energy provides the powers to progress. The natural resources of a
country may be turned into wealth if they are developed, used and
exchanged for other goods this cannot be achieved without energy.
Availability of sufficient energy and its proper use in any country can result
in this people using from substantial level to the highest standard of living.
It has been found that countries whose national output is mainly
agricultural and whose population lives mostly in rural communities enjoy
low per capita growth of energy consumption is dependent is the extent
to which industrial activity forms a part of its energy usage a distinct
change. Once energy is made suitable in excess of domestic needs it has
been round that it is not used solely as a consumer good but becomes
factor of production. A growing proportion of energy is being met all over
the world the electricity. This trend will further be stimulated because of
increasing availability of clean electricity. This applies especially to
developing countries because their industrial progress will be based on
modern technologies, which generally use electricity intensively.

III. Ukai Thermal Power Plant

 Ukai Thermal Power Station of the Gujarat State Electricity Corporation
Limited, India(GSECL), is a power station with an installed capacity of
1,110 MW. It is one of Gujarat's major coal-fired power plants, located on
the bank of the Tapi river because of water resources, along with
hydroelectric power plant with the same name. It is coal based thermal
power plant so water is essential thing for power generation. There are
multiple plants with multiple capacity of generation.

Stage Number of unit Installed Status

capacity(MW)

Stage I 1 120 Retired from service

Stage II 2 120 Retired from service

Stage III 3 200 Running

Stage IV 4 200 Running

Stage V 5 210 Running

Stage VI 6 500 Running

Ukai TPS unit-6 was first unit in GSECL having a capacity more than 500
MW.

IV. Summary of Internship

Internship is process to learn and watch things practically which I l learned

in classroom and from the books. It is the initial stage of professional life.
 Basically it was two weeks summer industrial internship in duration of 24
July, 2023 to 5 August 2023 at Ukai thermal power plant which is located
at Ukai near the riverbank of Tapi river. It works under GSECL. In 1 st week
I was in Electrical Maintenance Department of Unit 3,4 and 5. In 2nd week
I was in Switchyard of this units. I also visited control unit of this sections.
I also learned about how thermal power plant works. I visited the coal
handling plant of Ukai thermal power plant. There are many workers and
engineers with knowledge of their knowledge of respective field. This is
the basic summery of the summer internship.

2. Boiler

I. Introduction of Boiler

As the name indicates boiler is use to boil water and turns into steam. There
are various types of boilers based on fuel used in boiler. There is coal fire
boiler, oil fire boiler, gas fire boiler etc.

Here, boiler used is of water tube type. It is coal fire boiler. In the boiler,
heat energy transfer takes place through tube walls and drum. The gases
lose their heat to water in the boiler or superheated. The escape heat is
used to heat the water through economizer. ID and FD fans are used to
produce artificial draught. The fuel oil is used to ignite the boiler and
pulverized coal is lifted from the coal mills by PA fans.
 Generally, ID fans, FD fans and PA fans are use the High tensile motor. It
operates at the 6.6kv. For the lubrication of this motor LOP (Loop Oil Pump)
pumps are used. This pumps operates on 415v. It is Low tensile motor.

II. Procedure in Boiler

Initially there is not flame in boiler. To produce fire in boiler oil is taken in
use. Generally, there are two types of oil used in boiler, FO and DLO. FO
stands for fuel oil and DLO stands for diesel light oil. Density of FO is more
than DLO. So initially DLO is used to spread in boiler. At that time PA fan is
not operating. So there is no coal in boiler. Sparker is used to produce initial
spark. It operates at 11kv, so step up transformer is placed before the
striker.

In starting fuel oil is spread out by the FO gun. It is in form of sufficient drop
to burn the oil. Then the sparker turns on for 8-10 second. For this period
FO will start burning in boiler and fire produces in boiler. When the fire is
sufficient to burn high density DLO oil then the DLO gun is use to spread the
oil in boiler and then FO gun will be getting off automatically by the control
loop. Here temperature of DLO is increased to reduce the thickness of oil.

When sufficient fire is produced in boiler to rotate turbine at desired speed,

the DLO gun turns off. This is the initialization of producing fire in boiler.
 Water pipes are placed in boiler, which carries the water which is use to
convert in steam.

III. Condenser

In condenser, the water passes through various tunes and steam passes
through a chamber containing a large number of water tubes (about
20000).

The steam gets converted into water droplets, when steam comes in
contact with water tubes. The condensate is used again in boiler as it is
dematerialized water and 5-6 heats the water, which was in tubes, during
the process of condensation. This water is sent to cooling tower.
3. Turbines and generator

Turbine is form of heat engine in which available heat energy in the form
of steam is converted into kinetic energy to rotate the turbine by steam
expansion in suitable shaped nozzles in Thermal Power Station there are
reaction turbines.
 The turbine consists of three stages: high pressure, intermediate
pressure and low pressure. Steam enters the turbine at 350oC with
maximum allowable temperature of 545oC. Cold reheat steam goes
to boiler, reheated at 540oC, then fed to medium pressure parts of the
turbine. Then, after cooling it goes to hot well.
The pressure of high pressure turbine is around 130 kg/cm^2, in
intermediate pressure turbine it will reduce up to 50 kg/cm^2.

The shaft is coupled with generator. The generator converts the

kinetic energy of the rotating shaft to electric energy. Field windings

are excited by D.C. power using exciter. Shaft of generator rotates at

3000 rpm speed. The capacity of generator is 200MW for unit 3,4.
 Hydrogen gas is one of the best cooling media chosen for turbo-

Alternator Cooling.

4. Super-heater, Economizer and Air preheater

I. Super-heater
The function of a superheater in a boiler is to increase the
temperature of the steam above its saturation temperature.
This is done in order to improve the efficiency of the steam
turbine and to prevent the formation of steam pockets in the
turbine.
 II. Economizer
Economizers are heat exchangers that transfer the heat in the flue
gas to another medium‚ generally the boiler feed-water‚ although
other streams are sometimes used such as make-up water. There
are 2 types of economizers: non-condensing and condensing.

III. Air preheater

The purpose of the air preheater is to recover the heat from
the boiler flue gas which increases the thermal efficiency of the
boiler by reducing the useful heat lost in the flue gas.

5. Electrostatic precipitator

It is an electronic device, which removes the ash particles from the

smoke through furnace of boiler. It helps in prevention of air
pollution. It works on the principle that a charged particle is attracted
towards opposite charge. When the fly ash comes between the
opposites charged plated it gets charged and is attracted towards the
plates and then collected from the plates. Here rapping motor is use
to clean the collecting plates. Hammers are connected with the shaft
of rapping motor and it continuously use to hit on the collecting plates
for the selected time period. There are 72 ESPs in 6th unit of Ukai
thermal power plant. There are 8 rows of the ESPs and each row
contains 9 Esp. Each ESP contains two hopper. The field for first 3 ESP
is more than other 6 ESPs. So when fuel gasses flows from the ESPs
by the ID fan then big particles of Ash will attract with first 3 ESPs and
other small particles attract with other ESP’s collecting plat. The field
 of ESP is decreasing from 1 to 9. Generally, applied DC voltage of ESP
is more than 10kv. It is also depends on the generating capacity of
plant.

The fly ash is stored in hopper from the ESP.

6. Ash Handling Plant

Ash from the hopper is collected at the sylone. From the sylone ash
forwarded to other companies for making block. Bottom ash was
converted in slurry by adding 75% water in Bottom ash. Then slurry is
dumped in the ash pond. Ash is not discharged as such to pollute the
land, air and water, but slurry of ash is made in ash handling plant and
this slurry is dumped in the wasteland, kept for the purpose.
7. Switch yard

Switchyard is the area, which feed the grid supply to the station
transformer and fees The grid by the power generator by the unit. The
power supply control is administrated Here and the units consumed
and supplies are recorded in the control room. The Connections of
220KV BUS to the station transformer is done by using the isolated
And gas filled circuit breakers.
Here there are two switchyards. One is for 220KV and another is for
440KV. Both are connected with the ICT (Inter Connected
Transformer). At the ukai thermal power station 220KV switchyard is
connected with hydro electric line.
8. Conclusion
This training focussed upon increasing our knowledge and interest in
toward the Production of Electricity using Coal as a primary
source/fuel. Because Electricity is most efficient and necessary needs
to peoples in these days so its production at most efficient method with
minimum cost and in proper sequence with less wastage. I learnt how
to produce it by turbine, generators, cooling towers, water and
maintain it. It was a great experience. It increase my practical skills
that’s the main thing which I learnt in the training session. Thus, I
believe that my training session will be beneficial for various purposes
& hence our efforts Will be fruitful.