An Industrial Internship Report
submitted by
Sujan Saravanan S
21BEC0183
in partial fulfillment for the award of the degree of
B.TECH
in
ELECTRONICS AND COMMUNICATIONS ENGINEERING
Acknowledgement
CERTIFICATE:
Sno title Page no
1 Introduction/Background Objective (Pages 1-4)
of the Internship
Organizational Structure
Various Domains of the Company
Assigned Domain/Department
2 Recent Work Methodology and 5-6
Challenges in the Industry
3 Persons Interacted with, Machinery 7-9
Observed, and Learnings
4 Detailed Description of Internship 10-11
Work (Digital Diary)
5 Software and Hardware Utilized 12
6 Summary 13-15
Experience Enhancement
Comments for Improvement
7 Appendix 16
Introduction:
Mettur Thermal Power Station-1 (MTPS-I) stands as a cornerstone of power generation in the
region, comprising four 210 MW coal-fired units that collectively supply a significant portion of
the area's electricity needs. Nestled amidst the industrial landscape, MTPS-I plays a vital role in
ensuring reliable and sustainable power supply to support economic growth and community
development.
Importance of Thermal Power Generation
Thermal power stations like MTPS-I are critical infrastructures that convert thermal energy from
burning coal into electrical power. This process involves a series of intricate steps, from coal
procurement and handling to steam generation, turbine operation, and electricity generation. The
station's ability to efficiently convert coal into electricity underscores its importance in meeting
energy demands.
Coal Procurement and Handling
MTPS-I utilizes both Indian and imported coal sourced from mines across Odisha, Telangana,
Indonesia, and China. The journey of coal begins with maritime transport, where ships laden
with coal dock at designated ports. From there, rail networks play a crucial role in transporting
coal to the power station, where it undergoes crushing, pulverization, and ultimately combustion
in the boilers to produce steam.
Operational Scale and Impact
Operating at a massive scale, MTPS-I exemplifies the complexity of thermal power generation.
Each step in the process, from coal handling to electricity transmission, involves intricate
machinery and systems meticulously managed by skilled personnel. The impact of MTPS-I
extends beyond power generation, contributing to employment, industrial growth, and
infrastructure development in the region.
Internship Objectives and Placement
The primary objective of my internship at MTPS-I was to gain practical insights into the
operation and maintenance of thermal power plants. Specific goals included understanding coal
handling processes, boiler operations, and turbine systems. The internship provided an
opportunity to explore the organizational structure of MTPS-I and gain exposure to various
domains in which the company operates.
Organizational Structure and Domains of Operation
MTPS-I operates under a hierarchical organizational structure encompassing departments
responsible for power generation, maintenance, logistics, safety, and administration. The station's
operations span multiple domains, including coal procurement, energy production,
environmental compliance, and community engagement.
During the internship, I was assigned to the Operations and Maintenance department, focusing
on coal handling, boiler operations, and turbine systems. This placement facilitated hands-on
experience and in-depth learning under the guidance of experienced professionals.
In the following sections, I delve deeper into the specifics of my internship experience,
highlighting key learnings, challenges encountered, and the impact of this immersive learning
opportunity on my personal and professional growth.
Recent Ongoing Work Methodology in the Industry and Challenges
The thermal power generation industry is continually evolving, adopting new methodologies and
technologies to improve efficiency, reliability, and environmental sustainability. Understanding
the recent trends and challenges in this dynamic field is crucial for professionals and
organizations striving to excel in power generation.
Trends and Innovations
1. Digital Transformation: One of the prominent trends in the thermal power industry is the
adoption of digital technologies for enhanced monitoring, control, and predictive maintenance.
Integrated SCADA (Supervisory Control and Data Acquisition) systems allow real-time
visualization of plant operations, enabling operators to optimize performance and detect
anomalies swiftly.
2. Automation and AI: Automation plays a pivotal role in streamlining operations and reducing
human intervention in routine tasks. Artificial Intelligence (AI) algorithms are employed for
predictive analytics, optimizing combustion processes, and improving equipment reliability.
3. Renewable Energy Integration: With increasing focus on sustainability, many thermal power
plants are integrating renewable energy sources such as solar and wind to reduce carbon footprint
and meet regulatory requirements.
4. Advanced Materials and Efficiency Enhancements: Research and development efforts are
focused on developing advanced materials for turbines and boilers, enhancing energy conversion
efficiency and reducing emissions.
Challenges Faced by the Industry
Despite the progress and innovations, the thermal power industry confronts several challenges
that necessitate strategic planning and adaptation:
1. Environmental Regulations: Stringent environmental regulations impose limits on emissions
of pollutants such as sulfur dioxide (SO2), nitrogen oxides (NOx), and particulate matter.
Compliance requires investment in pollution control technologies and operational adjustments.
2. Aging Infrastructure: Many thermal power plants globally are operating beyond their intended
lifespan, leading to reliability issues, increased maintenance costs, and the need for
modernization.
3. Energy Transition and Policy Uncertainty: Shifting energy policies towards renewables and
uncertainties surrounding future regulations pose challenges for long-term investment planning
in thermal power generation.
4. Operational Efficiency and Cost Management: Maintaining operational efficiency while
managing costs is a perennial challenge. Fuel price fluctuations, labor costs, and maintenance
expenditures impact the overall economic viability of thermal power plants.
5. Grid Integration and Reliability: Integrating thermal power plants into modern smart grids
requires robust communication networks and advanced grid management systems to ensure
stability and reliability of electricity supply.
Adapting to Change and Future Outlook
In response to these challenges, the thermal power industry is embracing innovation and
adaptation. Strategies include:
Investing in clean coal technologies such as ultra-supercritical and advanced combustion
techniques.
Implementing carbon capture, utilization, and storage (CCUS) technologies to reduce greenhouse
gas emissions.
Enhancing workforce skills through training programs focused on digitalization and renewable
energy integration.
The future outlook for the thermal power industry is shaped by a commitment to sustainability,
technological advancements, and strategic collaborations between industry stakeholders,
policymakers, and research institutions.
During my internship at Mettur Thermal Power Station-1 (MTPS-I), I had the invaluable
opportunity to interact with a diverse range of professionals and gain hands-on experience with
various machinery and equipment critical to power generation. These interactions and
observations were instrumental in shaping my understanding of thermal power plant operations
and refining my technical skills.
Professionals Interacted With
I engaged with professionals across different departments within MTPS-I, including:
Operations Engineers: I shadowed operations engineers responsible for overseeing coal handling,
boiler operations, and turbine performance. Their expertise in plant operations and
troubleshooting was instrumental in my learning process.
Maintenance Technicians: I collaborated with maintenance technicians tasked with preventive
and corrective maintenance of equipment such as pumps, valves, and turbines. Learning from
their practical approach to equipment upkeep provided insights into reliability-centered
maintenance practices.
Safety Officers: Interactions with safety officers emphasized the importance of adherence to
safety protocols in a high-risk industrial setting. Understanding safety procedures and emergency
response protocols was crucial for ensuring a safe working environment.
Shift Supervisors: Working alongside shift supervisors provided exposure to real-time
operational challenges and decision-making processes during plant operations. Their guidance
enhanced my situational awareness and problem-solving skills.
Machinery and Equipment Observed
My internship at MTPS-I offered exposure to a wide array of machinery and equipment,
including:
Coal Handling Systems: I observed the entire coal handling process, from the unloading of coal
from rail wagons to its transportation to the crusher and subsequent pulverization before being
fed into the boilers. Witnessing the scale and efficiency of coal handling operations was
impressive.
Boiler and Turbine Systems: I closely observed the operation of boilers, including the
combustion process, steam generation, and superheating. Learning about turbine systems,
including high-pressure turbines (HPT), intermediate-pressure turbines (IPT), and low-pressure
turbines (LPT), provided insights into the conversion of thermal energy into mechanical and
electrical energy.
Control Room Operations: Spending time in the control room exposed me to the intricacies of
plant monitoring and control systems. I gained insights into the use of SCADA systems for real-
time data visualization and decision-making.
Safety Equipment: I familiarized myself with various safety equipment deployed throughout the
plant, including fire suppression systems, personal protective equipment (PPE), and emergency
shutdown mechanisms.
Key Learnings and Insights
Through these interactions and observations, I acquired several key learnings and insights:
Operational Efficiency: Understanding the importance of operational efficiency in maximizing
power output while minimizing environmental impact.
Team Collaboration: Recognizing the significance of effective teamwork and communication in
ensuring safe and reliable plant operations.
Technical Skills Development: Enhancing my technical skills in equipment troubleshooting,
maintenance practices, and safety protocols.
Professional Conduct: Learning about professional conduct in an industrial setting, including
adherence to regulations and standards.
Overall, my internship experience at MTPS-I was enriching and transformative. It deepened my
appreciation for the complexities of thermal power generation and equipped me with practical
skills that are invaluable for a career in the energy sector.
Internship Work Diary: Immersive Experience at Mettur Thermal Power Station-1
My internship at Mettur Thermal Power Station-1 (MTPS-I) was a transformative journey into
the heart of thermal power generation, marked by hands-on learning, technical immersion, and
invaluable exposure to industry best practices. This digital diary encapsulates my day-to-day
experiences, challenges encountered, and insights gained during this enriching internship.
Week 1: Introduction to Coal Handling
The first week commenced with an orientation to coal handling processes at MTPS-I. I
shadowed operations engineers and technicians involved in unloading coal from rail wagons,
transportation to the primary crusher, and subsequent pulverization. Witnessing the efficient
handling of large quantities of coal was awe-inspiring, underscoring the critical role of this initial
stage in power generation.
Week 2: Boiler Operations and Steam Generation
As I delved deeper into my internship, I had the privilege of observing boiler operations and
steam generation processes. I learned about the combustion of pulverized coal, heat transfer
mechanisms within the boiler, and the generation of high-pressure steam. Witnessing the
synchronization of various systems to achieve optimal steam conditions was a testament to the
precision and complexity of thermal power plant operations.
Week 3: Turbine Systems and Electrical Generation
In the third week, I focused on turbine systems and electrical generation. I closely observed high-
pressure turbines (HPT), intermediate-pressure turbines (IPT), and low-pressure turbines (LPT)
in action. Understanding the conversion of thermal energy into mechanical energy, followed by
electrical generation through turbo generators, provided a holistic view of the power generation
process.
Week 4: Control Room Operations and SCADA Systems
My immersion into plant operations culminated in an exploration of the control room and
SCADA systems. I gained insights into real-time monitoring of critical parameters, data
visualization, and decision-making processes. Collaborating with control room operators
underscored the importance of technology-driven efficiency in ensuring safe and reliable plant
performance.
Challenges Encountered and Overcome
Throughout my internship, I encountered several challenges that tested my problem-solving
skills and resilience. These included:
Equipment Malfunctions: Addressing minor equipment malfunctions and participating in
troubleshooting exercises under the guidance of experienced technicians.
Safety Protocols: Adhering to stringent safety protocols while navigating operational areas and
understanding emergency response procedures.
Learning Curve: Overcoming the initial learning curve associated with complex industrial
processes and terminology.
Key Learnings and Personal Growth
My internship at MTPS-I was not just a professional endeavor but a transformative learning
experience that contributed significantly to my personal and career development. Key learnings
and insights include:
Technical Proficiency: Acquiring practical skills in coal handling, boiler operations, turbine
systems, and control room operations.
Team Collaboration: Appreciating the importance of teamwork, effective communication, and
interdisciplinary collaboration in industrial settings.
Problem-Solving Skills: Developing adaptive problem-solving skills and the ability to think
critically in dynamic operational environments.
Industry Exposure: Gaining a comprehensive understanding of thermal power generation
practices, regulations, and sustainability initiatives.
Conclusion: A Foundation for Future Endeavors
In conclusion, my internship at Mettur Thermal Power Station-1 was a rewarding experience that
solidified my passion for the energy sector and equipped me with invaluable skills and insights.
The hands-on exposure, mentorship from industry experts, and immersion in real-world
operations have laid a strong foundation for my future endeavors in the field of power generation
and energy management.
Software and Hardware Utilized in Thermal Power Plant Operations
During my internship at Mettur Thermal Power Station-1 (MTPS-I), I had the opportunity to
familiarize myself with a variety of software and hardware systems integral to power generation
and plant operations. This exposure enriched my technical skill set and provided insights into the
technological infrastructure supporting thermal power plants.
Software Systems
SCADA (Supervisory Control and Data Acquisition): SCADA systems play a pivotal role in
real-time monitoring and control of plant processes. I gained hands-on experience with SCADA
software, visualizing critical parameters, alarms, and trends. The ability to navigate SCADA
interfaces enhanced my understanding of plant operations and data-driven decision-making.
Computerized Maintenance Management System (CMMS): I utilized CMMS software for asset
management and maintenance scheduling. This system enabled efficient tracking of equipment
status, work orders, and maintenance histories. Understanding CMMS functionalities was
instrumental in optimizing maintenance workflows.
CAD (Computer-Aided Design) Software: I explored CAD software used for drafting and
designing plant layouts, equipment configurations, and piping systems. Learning CAD
fundamentals enhanced my ability to interpret engineering drawings and visualize plant
components.
Hardware Systems
Turbine and Boiler Components: I observed various turbine and boiler components, including
high-pressure turbines (HPT), intermediate-pressure turbines (IPT), boiler drums, economizers,
and condensers. Hands-on exposure to these critical hardware systems deepened my
understanding of energy conversion processes.
Instrumentation and Control Devices: I interacted with instrumentation devices such as pressure
gauges, flow meters, temperature sensors, and control valves. Learning about instrumentation
principles and their role in process control was essential for operational insights.
Electrical Systems: I gained insights into electrical systems encompassing generators,
transformers, switchgear, and control panels. Observing electrical installations and safety
protocols underscored the importance of electrical infrastructure in power generation.
Key Takeaways
Integration of Software and Hardware: The synergy between software systems (SCADA,
CMMS) and hardware components (turbines, boilers) is critical for efficient plant operations.
Data-Driven Decision-Making: Software tools enable data visualization and analysis,
empowering operators to optimize performance and respond to operational challenges promptly.
Interdisciplinary Skills Development: Exposure to both software and hardware systems nurtured
interdisciplinary skills essential for a successful career in power generation and industrial
automation.
The comprehensive exposure to software and hardware systems at MTPS-I broadened my
technical expertise and underscored the importance of technology in driving efficiency and
reliability in thermal power plant operations.
Summary
My internship at Mettur Thermal Power Station-1 (MTPS-I) was an enriching experience that
significantly contributed to my professional development. Through hands-on exposure to thermal
power plant operations, I enhanced both my technical competencies and interpersonal skills,
gaining invaluable insights into the energy sector.
Technical and Behavioral Skill Development
Technical Skills Enhancement
Operational Understanding: I acquired a comprehensive understanding of coal handling, boiler
operations, turbine systems, and control room functionalities. This technical knowledge
deepened my appreciation for the intricacies of thermal power generation.
Software Proficiency: Exposure to SCADA, CMMS, and CAD software enhanced my ability to
leverage technology for data visualization, asset management, and design tasks. These skills are
invaluable for efficient plant operations and maintenance.
Hardware Familiarity: Interacting with turbine components, instrumentation devices, and
electrical systems provided practical insights into equipment functionality and maintenance
practices.
Behavioral Skills Enhancement
Team Collaboration: Working alongside experienced engineers and operators fostered effective
teamwork and communication. I learned the importance of collaboration in achieving operational
excellence.
Problem-Solving Abilities: Addressing equipment malfunctions and operational challenges
honed my problem-solving skills and resilience in dynamic industrial environments.
Safety Awareness: Adhering to strict safety protocols heightened my awareness of occupational
hazards and the importance of prioritizing safety in all operational tasks.
Comments for Improvement
Continual Learning and Adaptation
Continuous Skill Development: To further enhance my technical proficiency, I plan to pursue
additional training in power plant operations and maintenance practices.
Adaptability: Building on my internship experience, I aim to cultivate greater adaptability and
flexibility to thrive in diverse professional settings.
Communication and Leadership
Effective Communication: I aspire to refine my communication skills to articulate technical
concepts and collaborate seamlessly with multidisciplinary teams.
Leadership Development: Developing leadership qualities will be a focus area to assume greater
responsibilities and contribute to organizational success.
Conclusion
In conclusion, my internship at MTPS-I was a transformative journey that equipped me with a
robust skill set and a deeper understanding of thermal power generation. The experience has
inspired me to pursue a career path aligned with energy management and sustainable
technologies, driven by a commitment to innovation and continuous improvement.
