FFBL

POWER
COMPANY
LTD

INTERNSHIP REPORT

Comprehensive Internship Report of

Coal Based Power Plant FPCL

Prepared by,
Muhammad Dawood Bilal
Intern, Instrumentation Department

Supervisor,
Sir Farhan Aslam
REFERENCE INDEX:
1.--------------------------------------------------------------------------Introduction 04

- Overview of FFBL Power Company Ltd

- Description of Plant Capacity and Components

2.---------------------------------------------FFBL POWER COMPANY LTD CASH 05

- Introduction to CASH

- Coal Delivery and Handling

- Sorbent Handling and Transfer

3.-----------------------------------------------Combustion Reaction and Steam 11

- Fuel Combustion in the Furnace

- Heat Transfer to Water Tubes

4.-----------------------------------------------Steam Turbine Power Generation 13

- Overview of Power Generation

- Back Pressure Turbine

- STG Unit Control Panels (UCP)

5.---------------------------------------------------BOP and Cooling Towers Area 15

- Introduction

- Cooling Towers

- Water Treatment Process

- Balance of Plant Area

- Instrument Air Compressors in the BOP Area

- Instrument Air Compressor CIK-1011-B Job Activity

6.---------------------------------------------------------------------------------------- Flue Gases and

Ash Handling---------------------------------------------------------------------------------------- 22

- Introduction

- Coal Combustion and Air Supply

- Flue Gas Treatment

- Bottom Ash Handling

7.--------------------------------------Distributed Control System (DCS) FPCL 24

- Overview

- System Components and Connections

8.---------------------------------------------------------------SIEMENS PLC S7-400 26

- Introduction

- Redundancy of System

- Precise Control and Monitoring

G. Process Variables--------------------------------------------------------------------------------28

- Pressure

- Temperature

- Flow

- Level

10.-------------------------------------------STG-01 Rotor Replacement Activity 31

- Reason for Replacement

- Activity Details

- Installation of new Rotor

11.--------------------------------------------------------------Conclusion to Report 35
 Introduction
The FFBL Power Company Ltd FPCL is a coal-based power plant with a capacity of
118 MW. The Plant has 2 250 Metric Tons CFB (Coal Fluidized Bed) Boilers and 3
Condensation STG’s that generate power at both 50hz and 60hz frequencies. 2 STG’s
generate power of 24MW at 60hz frequency whereas 1 STG generates power of
60MW at 50HZ frequency. The Back Pressure Turbine also generates 10MW of power,
but its main purpose is to reduce pressure to certain requirements, from FFBL Plant.
This plant uses both local and imported coal, alongside an integrated Distributed
Control System (DCS) and PLC System that maintains seamless operations and
monitoring.
During my internship in the Instrumentation Department at FPCL, I gained hands on
experience in various aspects of plant operations, particularly in the Coal Ash
Sorbent Handling Area and how the CFB Boiler works in making steam. This report
documents my learning journey, detailing the
processes and instrumentation involved in coal handling, combustion, steam
generation, and power production. It also highlights the importance of precise
instrumentation in maintaining the plant's efficiency and safety

Furthermore, The Generator Rotor replacement activity was one of the important
parts of my internship as I gained experience and came to know about generator’s
Rotor, saw how the Electrical and Instrumentation team performed tasks that were
required before and after startup of generator.
FFBL POWER COMPANY LTD CASH
Introduction to CASH:
This introduction outlines the key stages involved in the management of coal, ash,
and sorbents, highlighting the mechanisms in place to maintain operational efficiency
and environmental
compliance.

Efficient handling of coal, ash, and sorbents is vital for the operations at FFBL Power
Company Ltd. This system involves a series of processes, from the delivery and
weighing of coal to its transfer, crushing, and storage, ensuring a steady and reliable
fuel supply for power generation. Additionally, effective handling of ash and the use of
sorbents contribute to minimizing the environmental impact of the power plant.

Coal Delivery and Handling:

o Coal arrives at the power plant via trucks from different areas,
primarily from Thar but sometimes imported coal is also used from
places like Afghanistan etc.

o The coal is first dropped onto an underground conveyor; to reduce dust

the water is sprayed on the coal using Water Fog Pumps (S7) when
being dropped onto the conveyor belt.

o There are level transmitters LT’s that measure the amount of Coal
being dropped onto the conveyor belt.
Weighing and Transfer:
o The coal is first transferred to TT-1 (Transfer Tower).

o There are four belt weighers that measure the amount of coal being
transferred to TT-1 through conveyor belt.

Conveyors and Bypass:

o From TT-1, there are two
different conveyors.

o One conveyor is a bypass

conveyor that bypasses the
stack (where coal is not
stacked) and transfers coal
directly to TT-3.

o The second Conveyor

transfers coal to Coal Shed
through Stacker.
TT-2 and Dumper:
o At TT-2, the coal drops into a dumper.

o TT-2 also connects to two conveyors: the bypass conveyor and the
stack conveyor, hence the coal gets stacked through the stacker and
if needed then bypassed through the bypass conveyor.

Stacking and Coal Shed:

o The stack conveyor transfers coal to the stacker in the Coal Shed,
where the coal is stored.

o Coal shed stores coal and there are SOV’s (Solenoid Operating
Valves) that spray water at coal, so dust remains minimized.

Reclaiming and Transfer Towers:

o The coal in the Coal Shed is claimed by a reclaimer.

o The reclaimer transfers coal to TT-4.

Crushing and Grinding:
o From TT-5, the coal moves to the crusher house, by passing
through the Metal Detectors. These Metal Detectors work on the
principle of EMF. When Electric Charge is supplied to the metal,
Electric charges appear and create Electro
Magnetic Field (EMF). In this way once a metal piece passes through
the Magnetic Field it gets detected hence the Conveyor Belt gets
tripped.

o The crusher house grinds the coal to the required size 1mm since some
coal may be in large pieces, so the heavy particles get dropped into
Grinder and small particles which do not need grinding drop to
conveyor from where they move to TT-6.

TT-06 to TT-07 and Tripper Car:

o The grinded coal is transferred from TT-6 to TT-7.

Finally, from TT-7 to Tripper Car the coal reaches the coal bins, the Coal
gets dropped into the Coal bins from Tripper Car.
 Sorbent Handling and Transfer:
Lime Delivery and Storage:
o Lime arrives at the power plant via trucks and is dropped into the limestone yard.

Transfer to Sorbent Crusher Area:

o Conveyors transport the lime from the yard to the sorbent crusher area.

o In the sorbent crusher area, the lime is stacked in bins.

Grinding Process:
o Lime often comes in a rock-like shape, which is not suitable for direct use.

o To make it more effective, lime is ground into smaller particles using column mills.

Limestone Conveyor Compressors:

o The ground lime is then transferred through limestone conveyor compressors.

o These compressors create pressurized air at 7 bars.

Sorbent Flow and Boiler Bins:

o The pressurized air helps the
sorbent (lime) flow through
pipes.

o Eventually, it drops into the

sorbent bins located at the boiler.

o Each boiler has its own dedicated

bin for storing both coal and
sorbent.
Combustion Reaction and Steam:
Fuel Combustion in the Furnace:
o The coal stored in the Coal Bins enters the furnace.

o Here, the three essential components for combustion come together:

 Fuel (Coal): The primary source of energy.

 Flame: Ignition occurs, creating intense heat.

 Oxygen (Air): Required for the chemical reaction.

Heat Transfer to Water Tubes:

o There are water tubes surrounding the furnace.

o Cold water cannot be directly used due to thermal shock, so we

follow a specific path:

 Superheaters: The water passes through superheaters,

where it absorbs heat and becomes warm.

 Economizer: Further along, the economizer preheats the water.

 The preheated water then flows into the tubes surrounding the furnace.

Steam Generation:
o As the tubes absorb heat from the furnace, the water inside them
reaches the required temperature.

o At this point, water undergoes a phase change, becoming steam.

o The steam travels back through the superheaters for additional heating.
Steam Drum:
o Finally, the heated steam is transferred to the steam drum.

o The steam drum acts as a reservoir, storing the high-pressure steam.

o From here, steam is ready to generate electricity.

 Steam Turbine Power Generation:
The Steam from boiler travels through main pipes from where it is distributed to each
turbine and is used to generate power. Further we have:

o FPCL’s coal-fired power plant has a total capacity of 118 MW.

o It consists of three condensation steam turbines (STGs) and one back
pressure steam turbine (BPSTG).
o The three condensation STGs include two 24 MW turbines that generate power
at 60 Hz and one 60 MW turbine that generates power at 50 Hz.
o The 60 MW turbine’s power is sold to K-Electric as part of a business model.

Back Pressure Turbine:

o The back pressure turbine serves a dual purpose:
o It takes steam from the system and reduces its temperature and pressure
to meet the requirements for FFBL’s operations.
o The remaining steam, which would otherwise go to waste, is used to generate
an additional 10 MW of power through a connected generator.

STG Unit Control Panels (UCP):

Each steam turbine generator (STG) has its own dedicated
Unit Control Panel (UCP) to monitor and control its
operations. These UCPs play a crucial role in ensuring
efficient performance and safety.

Overview
This report details the Unit Control Panel (UCP) setup for the
Steam Turbine Generator (STG) at FFBL Power Company Ltd.
The system integrates various components to ensure
efficient control and monitoring of turbine operations. The
STG setup is also redundant to ensure continuous operation
even if one component fails the other system is ready to
take over the primary one.

System Components and Connections

1.Power Supply:
- The system is initially connected to a 24V Power Supply Unit (PSU).

- From the PSU, it connects to a Terminal Block (TB) Header.

- Redundant power supplies ensure continuous operation.

2.TB Headers
- Each system has 4 TB headers:
Analog Input (AI), Analog Output (AO), Digital
Input (DI), and Digital Output (DO).

- These TB headers serve as the initial

connection points for the system.

3.I/O Cards
- From the TB headers, the connections go to I/O cards.

- These I/O cards manage the analog and

digital inputs and outputs of the system.

4.Fuses and Junction Box

- The connections then lead to the Junction
Box (JB), which acts as an isolation point
between the internal system and the field
instruments.

5.Instruments:
- One key instrument is the Temperature Transmitter (TT).

- When the TT receives a signal, it sends it back through the JB to the AI card.

Bentley Nevada 3500:

The Bentley Nevada 3500 system is an essential component of the STG unit,
providing advanced vibration monitoring and protection. It is connected to critical
points in the STG to ensure early detection of any mechanical issues. The Bentley
Nevada 3500 system is used to monitor the STG's mechanical condition, ensuring the
equipment operates safely and efficiently.
Hence the Unit Control Panel plays a vital role in monitoring the operations of Steam
Turbine Generators (STG).

BOP and Cooling Towers Area:

Introduction:
At FFBL Power Company Ltd, the Balance of Plant (BOP) and Cooling Towers area are
essential for efficient plant operations. Cooling towers manage excess heat through
fan units to optimize
cooling. The BOP area includes Boiler Feed Water (BFW) Pumps, Instrument Air
Compressors, and Deaerators, all critical for maintaining water quality and system
functionality. Proper water treatment, oxygen removal, and the use of moisture-free
air ensure the longevity and efficiency of plant equipment. Together, these systems
support seamless power generation and operational reliability.

1.Cooling Towers:
o Cooling towers play a crucial role in heat exchange. They help cool down the
excess heat generated by various equipment and processes.
o There are two main types of cooling towers:
  Natural Draft Cooling Towers:
These towers rely on the natural flow of air. They have a tall stack that allows
hot air to rise and escape, creating a pressure difference that draws in fresh air
from the surroundings. No fans are required for air circulation in natural draft
cooling towers.

 Forced Draft Cooling Towers:

In forced draft cooling towers, fans are placed horizontally. These fans actively
circulate air to enhance the cooling process. Water is cooled through
evaporation as it encounters the air. The cooling towers are strategically
designed to optimize airflow and cooling efficiency.

2.Cooling Tower Components:

o Hot Water Inlet: Hot water enters the cooling tower from the top.
o Drift Eliminators: These prevent water droplets from escaping with the air.
o Water Distribution Nozzles: These nozzles spray the hot water over the cooling fill.
o Cooling Fill: It increases the surface area for heat exchange, allowing the
water to cool down as it trickles through.
o Fan Unit: Located at the top, the fan forces air upwards through the tower,
enhancing the cooling process.
o Cold Water Basin: The cooled water collects at the bottom and is then
recirculated back into the system.
3.Water Treatment Process:
o Raw water is not directly used; instead, it undergoes purification.
o Water purifying agents, including alum, are used to remove unwanted particles.
o Alum acts as a flocculant, combining smaller particles into larger ones for easier removal.
o Further water treatment involves adding phosphate, polymers, and sulfuric
acid (H₂SO₄) to ensure water quality.
o This treatment minimizes corrosion and damage to pipes caused by impurities.
 Balance of Plant Area:
 The BOP area is known as Balance of plant, it consists of several components
like the BFW Boiler Feed Water Pumps, IAPA Instrument Air and Plant Air and
Deaerator. The BOP ensures that all supporting systems function correctly, as
any failure can impact the entire plant’s operation.

Condensed Water to Deaerator:

o The condensed water from steam
turbines is directed to deaerator,
which is a crucial
component in the water treatment process.

Oxygen Removal:
o The deaerator removes oxygen from
the water to prevent rusting and
corrosion in the system, ensuring the
longevity of the equipment.

Storage Tank:
o The water is then stored in a storage
tank, ready for further use in the
system.

Boiler Feed Water

(BFW) Pumps:
o Finally, the deaerator water is pumped
towards the boiler using Boiler Feed
Water (BFW) pumps, ensuring a
continuous supply of treated water for
the boiler.
o The BFW Pumps are also based on redundancy where 1 or 2 are working at
a time and the third one is on standby.
Crucial Role:
o Boiler Feed Water (BFW) Pumps are essential in steam generating power
plants, often referred to as the backbone of steam generation.
o They ensure a continuous supply of water to the boiler, which is
critical for steam production.

Impact of Maintenance or Failure:

o If any BFW pump undergoes maintenance or fails, the entire steam generation
process can be halted.
o Without steam, no power can be generated, leading to significant operational
disruptions and potential financial losses for the plant.
 Instrument Air Compressors in the
BOP Area:
The Instrument Air Compressors are used for several plant operations, where there is
need of Moisture and oil Free air. CIK-1011 Model Instrument Air compressors are
used, further we have:

Redundancy and Operation:

o The plant utilizes three instrument air compressors, labeled A, B, and S.
o These compressors operate on a redundancy basis, meaning one or two are
active at any given time while the third remains on standby.
o This setup ensures continuous operation and reliability, minimizing downtime.

Usage of Instrument Air:

o Instrument air is essential for various parts of the plant, including Solenoid
Operated Valves (SOVs).
o It is also used for operating different instruments like grinders and screwdrivers.
o The air is specifically treated to be moisture-free, which is crucial for
preventing rust and corrosion in sensitive instruments.
Moisture Free Air:
The moisture free nature of the instrument air is vital for maintaining the integrity and
longevity of the instruments. Moisture can cause rust and other forms of corrosion,
leading to potential failures and maintenance issues.

Instrument Air Compressor CIK-1011-B Job

Activity:
Overview:
During my internship, I had the opportunity to observe and participate in a job activity
involving the Instrument Air Compressor CIK-1011-B. The RTD (Resistance
Temperature Detector) of this compressor was malfunctioning, displaying
inconsistent temperature readings between the HMI
(Human-Machine Interface) and the control system.

The instrumentation team from the front end addressed this issue by removing the
faulty RTD, testing it, and replacing it with a new one. The instruments used for testing
were from Ametek.
This hands-on experience provided valuable insights to me, highlighting the
importance of accurate temperature monitoring for the efficient operation of plant
equipment.

Flue Gases and Ash Handling:

Introduction:
In Circulating Fluidized Bed (CFB) boilers, the efficient combustion of coal and the
handling of resulting byproducts are critical processes. This system ensures optimal
generation of power while minimizing environmental impacts. A key aspect of CFB
boiler operation involves the precise management of air supply for combustion, the
treatment of flue gases, and the handling of ash. The following sections delve into the
detailed mechanisms of coal combustion, air supply, flue gas treatment, and ash
handling within a CFB boiler.

Coal Combustion and Air Supply:

In a CFB boiler, coal fluidizes inside the furnace.

To maintain combustion, air is essential. There are two fans involved:

1. Primary Air (PA) Fan: Sucks in air from outside and preheats it using super
heaters before introducing it into the furnace from the bottom.
2. Secondary Air (SA) Fan: Also draws in air from outside, preheats it using
super heaters before introducing it into the furnace from the middle.

The preheating ensures that the air isn’t too cold for efficient combustion.
Flue Gas Treatment:
o After coal is burned, the resulting flue gases contain harmful components
like NOx and SOx.
o These gases are collected by an Induced Draft (ID) fan.
o The ID fan connects to a baghouse where fly ash is removed from the bottom hoppers.
o Finally, the cleaned gases are released through the stack.

Sorbent Addition:
o To reduce the harmful impact of NOx and SOx emissions, sorbents are mixed
with the flue gases in the furnace.
o This process makes the gases less reactive and environmentally friendly.

Bottom Ash Handling:

o After coal combustion, the resulting bottom ash settles at the bottom of the furnace.
o This ash is collected and then passes through a bottom ash cooler.
o The cooler helps reduce the temperature of the ash.
o Finally, the cooled bottom ash is collected for further processing.
Distributed Control System (DCS) FPCL:
Overview

This section details the Distributed Control System (DCS) setup for FFBL Power Company Ltd,
focusing on PCS-1 (Boiler 1). The system integrates various components to ensure
efficient control and monitoring of the boiler operations. The entire system,
including computers, power supplies, and other components, is redundant, meaning
there is always a backup available. If one system goes down, another one is
activated automatically. System Components and Connections

1.Power Supply
- The system is initially connected to a 24V Power Supply Unit (PSU).

- From the PSU, it connects to a Terminal Block (TB) Header.

- Redundant power supplies ensure continuous operation.

2.TB Headers
- Each system has 4 TB headers: Analog Input (AI), Analog Output (AO), Digital Input
(DI), and Digital Output (DO).

- There are 5 systems in total:

- PCS-1: Boiler 1

- PCS-2: Boiler 2

- PCS-3: Balance of Plant (BOP)

- PCS-4: Medium Voltage (MV) Relays

- PCS-6: FFBL

3.Fuses and Junction Box

- From the TB headers, the connection goes through a fuse.

- The fuse is black in color.

- The connection then leads to the Boiler 1 Junction Box (JB), which serves as an
isolation point between the internal system and the instruments, such as
Pressure Transmitters (PT).
4.Instruments:
- When a Pressure Transmitter receives a signal, it sends it back through the JB
to a non-fuse connection and then to an AI (Analog Input).

- The non-fuse connection is represented by an orange color to differentiate between

fuse and non- fuse connections.

5.Control and Monitoring

- The computer detects the input signal and sends a command to the controller.

- The controller relays the information to the Human Machine Interface (HMI).

- Operators monitor the inputs via the HMI.

- If changes are needed, the operator inputs the new value into the HMI.

- The controller then sends the command to the AO (Analog Output).

 SIEMENS PLC S7-400:
Introduction
:
The Siemens S7-400 PLC system is a high-
performance controller designed for demanding
industrial applications. Known for its reliability
and scalability, the S7-400 can handle complex
automation tasks and is ideal for large-scale systems.

At FFBL Power Company Ltd, the Siemens S7-

400 PLC system plays a crucial role in
monitoring and
controlling specific plant operations, such as
ash and coal handling.
Redundancy of System:
The Siemens S7-400 PLC system is redundancy based, featuring both primary and
secondary PLCs. This ensures continuous operation and reliability, as the secondary
PLC can take over if the primary one fails. This redundancy is crucial for maintaining
uninterrupted plant operations.

Connection to I/O Cards

Each PLC is connected to Input/Output (I/O) cards, which serve as the interface
between the PLCs and the plant’s field devices. These I/O cards receive signals from
the relays and instruments,
process them, and send the necessary commands back to the PLCs. This connection
is vital for the accurate transmission of data and control signals.

Interface with Relays and Instruments

The I/O cards are linked to relays, which then connect to various instruments within the plant.
These relays act as switches that control the flow of electricity to the instruments,
ensuring they operate correctly. The instruments monitored and controlled by the
PLCs include those used in ash and coal handling processes.

Precise Control and Monitoring

This setup allows for precise control and monitoring of single areas within the plant.
By focusing on specific processes like ash and coal handling, the Siemens S7-400
PLC system enhances the
efficiency and safety of plant operations. The ability to monitor and control individual
areas ensures that potential issues can be quickly identified and addressed,
maintaining optimal performance.
 Process Variables:
Pressur
e:
The force exerted per unit area. In industrial processes, maintaining accurate pressure
is crucial for safety and efficiency. Pressure sensors and transmitters are used to
monitor and control pressure
levels.

Pressure has 2 main types, Absolute Pressure and Gauge Pressure.

 Absolute Pressure: Absolute

Pressure is the total pressure exerted
on a system, including Atmospheric
Pressure.
 Gauge Pressure: It is the difference
between Absolute Pressure and
Atmospheric Pressure.

Temperature:
The degree of heat present in a system. Temperature control
is vital for processes like combustion and chemical
reactions. Instruments like RTDs (Resistance Temperature
Detectors) and thermocouples are commonly used to
measure temperature of various instruments and plant
operations.

 RTDs (Resistance Temperature Detectors)

Working Principle: RTDs operate on the principle that the
electrical resistance of a metal changes with
temperature. The resistance of the RTD element
increases with temperature, and this change in
resistance is measured and converted into a
temperature reading.
  Thermocouples
Working Principle: Thermocouples work based on the Seebeck effect, which
states that a voltage (Seebeck voltage) is generated when there is a
temperature difference between two dissimilar metals joined at one end. This
voltage is proportional to the temperature
difference and can be measured to determine the temperature.

Its Range is around 1400-1500C, and its graph is not so linear, hence
Thermocouples are not so precise.

Seebeck Effect: When two different metals are joined at one end and exposed
to different temperatures at the junctions, a voltage is produced due to the
movement of electrons from the hot junction to the cold junction.

Comparison for Plant Operations

 Accuracy: RTDs are generally more accurate and stable over a wide range of
temperatures compared to thermocouples.

 Response Time: Thermocouples typically have a faster response time than

RTDs, making them suitable for applications where rapid temperature
changes occur.

 Durability: Thermocouples are more rugged and can withstand higher

temperatures and harsher environments than RTDs.

Flow:
Flow refers to the rate at which a fluid (liquid or
gas) moves through a system. Flow
Transmitters and sensors help in monitoring
and controlling the flow rate to ensure the
process operates within desired parameters.
There are also Flow Control Valve that control
the amount of Flow.

Flow Control Valves are used to control

the Flow.
Level:
This indicates the height of a fluid in a container or vessel.
Level sensors and transmitters are used to maintain the
correct fluid levels, preventing overflow or dry running of
equipment.

LEVEL CONTROL VALVE

LEVEL
TRANSMITTER
 STG-01 Steam Turbine Generator’s Rotor
Replacement Activity

Introduction:
The rotor replacement activity for the 24MW Condensation Steam Turbine STG-01 was
a significant task undertaken to address abnormal vibration issues observed in the
generator. The rotor's
vibration deviations indicated a need for replacement to ensure optimal
performance and reliability. This activity involved the coordinated efforts of
the Mechanical, Electrical, and Instrumentation teams.

Reason for Replacement:

The primary reason for replacing the rotor was abnormal vibration readings. The
vibrations were outside the normal operational range, which could potentially affect
the generator's efficiency and longevity. To resolve this issue, the faulty rotor had to
be replaced with a new one.
Activity Details:
1.Preparation and Disconnection:
- Instrumentation Team:
- Removal of Instruments: The instrumentation team began by removing
all relevant instruments from the generator. This included Resistance
Temperature Detectors (RTDs) and proximity sensors.

- Disconnection from Unit Control Panel (UCP): The connections from the
Unit Control Panel (UCP) were also disconnected. This involved removing the
Terminal Block (TB) headers and I/O cards to ensure that the instruments and I/O
modules were no longer connected.

2.Mechanical Team Operations:

- Generator Removal:
- The Mechanical team took charge of removing the generator from its
position. This was achieved by first detaching it from the coupling.

- Coupling Function: The coupling plays a crucial role in connecting the generator to the
turbine.
It reduces the turbine's RPM from 6776 RPM to 1800 RPM, which is necessary for
60Hz frequency generation.

- Rotor Removal: With the generator disconnected and moved, the faulty rotor was
removed from the generator's housing.
3.Installation of New Rotor:
- New Rotor Placement: The new rotor was then installed in place of the old one.

- Reconnection of Instruments: After the new rotor was positioned, the

instrumentation team reconnected all the previously removed RTDs and
proximity sensors.

- Reconnection to UCP: The disconnections made earlier from the UCP were
reversed, with the Terminal Block (TB) headers and I/O cards being reconnected.
Conclusion to Activity:
The rotor replacement activity was successfully completed with the collaborative
efforts of the Mechanical, Electrical, and Instrumentation teams. The new rotor was
installed, and all necessary connections were reestablished. This replacement was
crucial in addressing the vibration issues and ensuring the continued efficient
operation of the STG-01 generator. The coordinated approach and careful execution
of tasks ensured that the generator could resume normal operation with enhanced
reliability and performance.
 Conclusion to Internship:
My internship at FPCL has been an enriching experience, providing me with valuable
insights into the operations of a coal-based power plant. The knowledge and skills I
acquired in the Instrumentation Department, particularly in handling and
maintaining critical instruments and systems, have significantly enhanced my
understanding of power plant operations.

A notable highlight of my internship was the involvement in the rotor replacement

activity for the 24 MW Condensation Steam Turbine Generator (STG-01). This
activity required a collaborative effort from the Mechanical, Electrical, and
Instrumentation teams. The careful execution of tasks, including the removal and
replacement of the rotor, re-establishment of connections, and the reinstallation of
instrumentation, demonstrated the importance of teamwork and precision in
maintaining plant operations.

I am grateful for this opportunity at FPCL and am confident that the skills and
knowledge I have developed, particularly through hands-on experiences like rotor
replacement, will be valuable in my future career.