A

Report On
Industrial Training

SUBMITTED BY
Shruti Vinod Gadge (2181750)

DEPARTMENT OF INTRUMENTATION ENGINEERING

INSTITUTE OF PETROCHEMICAL ENGINEERING,
LONERE-RAIGAD-402103
(2019-2020)

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 Dr. Babasaheb Ambedkar technological university, Lonere
Institute of petrochemical engineering
Lonere – Raigad 402301

CERTIFICATE
This is to certify that Shruti Vinod Gadge (2181750), a student of
instrumentation engineering has been submitted this report after
satisfactory completion of training in siemens power plant as
prescribed by I.O.P.E. Lonere.
This work is approved for the award of instrumentation.

Prof. D.S. karanjkar. Dr. M.A. Dabhade

(Head of dept.) (principal)

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 ABSTRACT

This report is prepared based on the 4 weeks duration training in the

course of power plant and steam turbine Instrumentation.
The training was obtained at SIEMENS POWER PLANT for the period of
4 weeks duration.
A brief introduction to the company along with its features is
introduced further the products of company and power plant are
covered.
A report includes vision mission, technical details, various department
information, different products of company application of steam
turbine, quality policy and features of the company.

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 ACKNOWLEDGEMENT

Firstly, I would like to thank Dr. D.S. karanjkar sir (head of department)
of instrumentation engineering for their support. Further, I like to
express my special thanks of gratitude to all who guide and support me
in the training . I would like to extend my gratitude to the principal sir
Dr. Dabhade sir to give me this opportunity. I want to thank my mentor
for their support and useful guidelines. And I also thanks to all who
support me in this training.

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 INDEX

SR.NO. CHAPTERS PAGE NO.

1. CHAPTER 1: Company History and Product Basics 6-17

2. CHAPTER 2: Company departments & products 18-41

3. CHAPTER 3: Quality policies 42

4. CHAPTER 4: Conclusions 43

5. CHAPTER 5: References 44

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 CHAPTER 1: Company History and Product Basics

SIEMENS an MNC which was first started in Germany and founded by

WORNER VON SIEMENS in 1847. It has 190 branches in different
countries and more than 4,75,000 employees all over the world.
Siemens the 55% Indian subsidiary is a leader in Electrical and
Electronic Engg. Sector.
It offers products, systems, solution & services in Power generation,
Power Transmission & Distribution, Automation & Distribution, IT,
Transportation system, Health care, Communication, etc. In India it was
established in 1922.

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History
Siemens was founded in Berlin by Werner von Siemens in 1847. As an
extraordinary inventor, engineer and entrepreneur, Werner von
Siemens made the world's first pointer telegraph and electric dynamo,
inventions that helped put the spin in the industrial revolution. He was
the man behind one of the most fascinating success stories of all time -
by turning a humble little workshop into one of the world's largest
enterprises.

As Werner had envisioned, the company he started grew from strength

to strength in every field of electrical engineering. From constructing
the world's first electric railway to laying the first telegraph line linking
Britain and India, Siemens was responsible for building much of the
modern world's infrastructure.

Siemens is today a technology giant in more than 190 countries,

employing some 4,75,000 people worldwide. Our work in the fields of
energy, industry, communications, information, transportation,
healthcare, components and lighting have become essential parts of
everyday life.

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 VISION AND MISSION

MISSION:-

• We will seek global market leadership

• Development and growth in oriented firms will be our focus
• We will continue to create a winning culture, operating in the
highest standards of ethics and values
• We will strive for excellence in customer service, quality and R&D

VISION :-

1. A world of proven talent

2. Delivering break through innovation

3. Giving our customers a unique competitive edge

4. Enabling societies to master their most vital challenges

and creating sustainable value.

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PRODUCT AND PROCESS BASICS
Product: Siemens SST-300 Industrial Steam Turbine

Steam turbine
A steam turbine is a device that extracts thermal energy from
pressurized steam and uses it to do mechanical work on a rotating
output shaft.
The steam turbine is a form of heat engine that derives much of its
improvement in thermodynamic efficiency from the use of multiple
stages in the expansion of the steam, which results in a closer approach
to the ideal reversible expansion process.

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During heating , water gets converted into its gaseous form i.e. Steam.
based on boiler pressure water will start evaporating at a certain
temperature (saturation temperature )to form steam and that steam
contains large quantity of steam which eventually gets converted to
electrical energy through steam turbines.

• Blade and stage design

Turbine blades are of two types, blades and nozzles. Blades move
entirely due to the impact of steam on them and their profiles do not
converge. This results in a steam velocity drop and essentially no
pressure drop as steam moves through the blades. a turbine composed
of blades alternating with fixed nozzles is called an impulse turbine.
Except of low-power applications, turbine blades are arranged in
multiple stages in series, called compounding, which greatly improves
efficiency at low speeds.

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 • Barring & sealing
Barring of shaft is done after a trip/during start up to ensure
uniform heat dissipation/distribution throughout the shaft cross section
to prevent bowing or unwanted shaft deformation. It is for this very
purpose that the gland sealing steam needs to be introduced only after
turning gear/barring starts.
It is also requiring to remove the inertia of the and prevent sagging of
the rotors.
Sealing: it is required to isolate the turbine flow-path from exposure of
atmospheric air. It will prevent thermal shocks and also will enable
faster vacuum pulling.

• Reheat and non-reheat turbines

If high pressure, high temperature steam is partially expanded
through a turbine, the efficiency can be increased by returning the
steam to the steam generator and reheating it to approximately its
original temperature before feeding it back to the turbine. Single reheat
turbines are common in the electric utility industry. for very large units,
double reheating may be employed.

• Control wheel
- Pressure difference between life steam and steam before the
first blades dependent on the mass flow.

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 - Several nozzle groups to increase the efficiency at partial load
(reducing throttling)
- Impulse design to allow partial admission
- Relative big enthalpy gradient.
- Reduced wheel chamber conditions.
- Lower efficiency.
- High static and dynamic load.

• Steam turbine features

- Condensing and back pressure applications
- Extractions possible, e.g. controlled or uncontrolled extractions,
single or multiple extractions.
- Operational flexibility features, e.g. daily starts and stops.
- Various valve configurations possible to achieve an optimal
performance in different operation regimes.
- Symmetrical casing or nozzle casing, for fast start up time.
- Remote monitoring system (RMS) for predictive maintenance
possible.
- Advance technology features, e.g. 3d blades.

• Applications of the steam turbine

1. Sugar mills
2. Pulp and paper mills
3. Cogeneration
4. Biomass plants
5. Energy from waste plants
6. Coal-fires

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Thermal Power plant process
In the power plant steam is used to drive electric generator. When
water is heated it turns into steam and spins a steam turbine. After it
passes through the turbine, the steam is condensed in condenser.

Power plants use a surface condenser cooled by water circulating

through tubes. the steam which was used to turn the turbine is
exhausted into the condenser and is condensed as it comes in contact
with the tubes full of cool circulating water. the condensed steam is
withdraw from the bottom of the condenser. the condenser
temperature can always be kept significantly below the 100deg c
where the vapor pressure of the water is much Less than atmospheric
pressure, the condenser generally works under vacuum. If a good
source of cooling water is not available, cooling towers may be used
to reject waste heat to the atmosphere. A large river or lake can also
be used as a heat sink for cooling the condensers.

Feedwater heater
in the case of a conventional steam-electric power plant using a
drum boiler ,the surface condenser removes the latent heat of
vaporization from the steam as it changes states from vapor to liquid.
The condensate pump then pumps the condensate water through a
feedwater heater, which raises the temperature of the water by using
extraction steam from various stages of the turbine.
preheating the feedwater reduces the irreversibilities involved in
steam generation and therefore improves the thermodynamic
efficiency of the system .this reduces plant operating costs and also
helps to avoid thermal shock to the boiler metal when the feedwater is
introduced back into the steam cycle.

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 Boiler
Once this water is inside the boiler or steam generator, the process of
adding the latent heat of vaporization begins. The boiler transfers
energy to the water by the chemical reaction of burning some type of
fuel. The water enters the boiler through a section called economizer.
From the economizer it passes to the steam drum, from where it goes
down the downcomers to the lower inlet waterwall headers. From the
inlet headers the water rises through the waterwalls. Some of it is
turned into steam due to the heat being generated by the burners
located on the front and rear waterwalls. From the waterwalls, the
water/steam mixture entersthe steam drum and passes through a
series of steam and water separators and then dryers inside the stem
drum. The steam separators and dryers remove water droplets from
the steam; liquid water carried over into the turbine can produce
destructive Erosion of the turbine blades. And the cycle through the
waterwalls is repeated. This process is known as natural circulation.

superheater
after the steam is conditioning by the drying equipment inside the
drum, it is piped from the upper drum area into an elaborate set up of
tubing in different areas of the boiler, the areas known as superheater
and reheater. The steam vapor picks up energy and is superheated
above the saturation temperature. The superheated steam is then
piped through the main steam lines to the valves of the high-pressure
turbine.

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1.Turbine Casing
Short, long and extralong turbine casing are available for the turbine.
These arrangements of turbine casings are used for condensing,
backpressure and heating turbines.
The single casing- turbine with horizontal split has a nearly symmetrical
casing. Which allows short start-up timers and quick load changes.
Internal valve arrangements or adaptive stages control the steam flow
to the back end of the turbine and are used to maintain constant
process steam extraction pressures over a wide flow range.

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2. Rotor and Reaction Blading

The rotor is fitted with resonance-proof fully shrouded blading. The last
stage of the blading is free standing with a damping wire(condensing
steam turbine).

The blading design guarantees high efficiency over the whole operation
range, including rapid changes of load for smooth plant operation.

The reliability of the blading is achieved primarily through a low total

stress load on the blades.

3. Gearbox
The turbine is most often delivered with a gearbox.
The reduction gears are taken from the existing range of world-class
gear manufacturers and have proven high reliability and performance.
Single or double helical toothing is applied based on application and
power output of machine.

4. steam turbine arrangement

Different arrangements are possible:
• Simple base frame for steam turbine, oil type base frame for gear
box and generator which is places directly a concrete foundation.
• Full package solution: base frame with integrated oil unit, carrying
the turbine, gear box and generator.
• Semi package solution: one base frame with integrated oil unit,
carrying turbine and gear box; but the generator is directly place
on concrete.
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Control
A turbine driving an electric generator must run at constant speed. In
the unites states where 60 cycle per second alternating current is used,
this usually means 3,600 or 1,800 revolutions per minute. When electric
power demand on the generator, or the load, charges, the turbine
must respond immediately to keep the speed constant

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 CHAPTER 2: Company Departments & products

Following is the department structure in Siemens -

1. Human resource department
2. Commercial department
3. Purchase department
4. Store department
5. Production department
6. Quality assurance department
7. Marketing department

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 Human resource department

Management is to “manage - men - tactfully” through there are other

major organizational function such as financial management of the
human resources that provides all other organizational function.

In short human resources department is that part of the total

management of an organization which specifically deals with human
resources in respect of :-
a) Their procurement
b) Their Development in terms of skills, knowledge & attitude
c) Their motivation towards the attainment of organizational
objectives by creating and maintaining an organizational limit
conducive to such development.

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 FUNCTIONS OF HR DEPARTMENT
1. Human Resource Planning
2. Budgeting
3. Job analysis
4. Recruitment:-

Empowerment
a) Internal Recruitment

b) External Recruitment

a) Internal Recruitment :- Promotion

Empowerment

Transfer

Training and
Development

Performance appraisal
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b) External Recruitment :- Advertisement
On the gate
Sourcing
Screening
Interview
Offer
Reff. Check

Medical

Line mgt.
Decision

Recruitment

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 COMMERCIAL DEPARTMENT

Commercial department acts like oil in the machine for the

organization. It has to be perform various activities related to the
money required for running the business successfully, also it has to take
various important decision which are mostly irreversible in nature.

The commercial dept. of company is totally handled by the higher

authority of the corporate. Basically it includes different financial
concept like : Excise duty, service Tax, dispatching of products .

Commercial department is very keen and sensitive department because

it is concerned with the each and every department. In commercial
dept. the transactions related to the co. are done.

When the orders are given by the customers ,the process of transaction
starts. There are some documentation which is very important to do in
the commercial dept. It deals with the accounts , dispatching, indirect
taxes etc.

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 PURCHASE DEPARTMENT

The Purchase department of SIEMENS LTD. Plays a very important role,

because purchasing has its effect on every vital factor concerning the
manufacture, quality, cost, efficiency, and prompt delivery of goods to
customers. Its function is to procure materials, supplies, services,
machines and tools at the most favorable terms consistent with
maintaining the desired standard of quality.

The main function of the purchasing department is firstly register

suppliers and secondly placing the purchase order.

Registration of suppliers :-

# The suppliers are sent the registration form

# The respective buyers are identified
# Scrutinize the information provided by the supplier
# Arrange for a visit by concerned personnel if necessary
# Include the name of approved suppliers in the list of
Suppliers.

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 Functions of purchase dept. :-

# Maintains relationship between co. and vendor

# It works on vendor evaluation
# Helps in finalization of price of products and cost reduction
# Supports to custom clearance
# helps in rates amendment process
# Executives of the dept. go for vendor visit, prepare contract
letters with its vendors.

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 STORE DEPARTMENT

Store keeping is an important function of material management . It is a

primarily service function in which the store keeping acts as a custodian
of all the items kept in the store . Store is the connecting link between
the shops as work place and the production control department.

Functions of store Department :-

1. Requesting from purchasing department economical quantity of
material for delivery at the most appropriate time.
2. Exercising control and quality of material received.
3. Storing and protection of material against hazards, condition ,
weather & pilferage .
ABC Method for Maintaining Stock :-
A) It is usually founds that 5 to 10% of item cost for 70-75% of the
total money. These items are stocked in smaller quantity due to
high cost.
B) These items are generally of 10 to 15% of the total items which
represents 10 to 15 % of total expenditure. Controlling these
items are not so difficult.

C) These items are 70 to 80% of total item and 5 to 10 expenditure.

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These items procured in bulks hence helps in price discounts .
ABC analysis helps in storage of all items in to three
Categories.

PRODUCTION DEPARTMENT
Incoming

Stores

Material issued on sub assembly

Testing

Unloading

Packing

Dispatching

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 QUALITY ASSURANCE DEPARTMENT

Quality assurance department actually deals with final product that is

assuring its quality or rather maintain its quality to the best this
assurance of quality to the best. This assuring of quality is given either
in process of manufacturing itself or after the completion of the
product. Thus there are two main types of quality assurance namely :-

1. Line quality assurance

2. Inward inspection

Line Quality assurance :-

In line quality assurance, frequent checking or inspection is done of

any part during the manufacturing process. Here any part is taken and
then tested, if it gives positive or desired result then it is proceeded
further. But if the result is not positive then there is a through
inspection is tested again & again. In this checking process eight to ten
people are involved.

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Inward inspection :-

The inward inspection is done when the parts are purchased from the
vendors. The parts which come from vendors, are inspected properly by
the inspector or engineer or technician and then if it is ok then the part
is allowed to go to the production department. If the part is found
faulty in the first inspection, the whole bunch of the parts are sent back
to the vender and asked for new one.

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 MARKETING DEPARTMENT

Marketing has its origins in the fact that man is a creature of needs and
wants. Needs and want create a state of discomfort in persons and they
tend to get object those needs and wants. The size of the market
depends upon the number of persons who have both:

1) An interest in the product and

2) Are willing to offer something in exchange of products

Functions of marketing Department :-

A) Marketing
# Product management
# Product promotion
# Market Intelligence

B) Sales co-ordination
# Price conformation
# Sales statistics
# Co-ordination with regions for sales & execution

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C) After Sales service
# Complaint Registration
# Co-ordination with QA for site
# Commissioning support

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SEIMENCE power generator products:-
1. SST - 050
2. SST - 060
3. SST – 150
4. SST – 2OO
5. SST – 300
6. SST – 400
7. SST – 500
8. SST – 600
9. SST – 800
10. SST - 700\900

1. SST – 050
Design size AF 3,5 AF 4 Gs
Output (kW) 300 750
Speed (r.p.m.) 11000 10500
Live steam 101 101
pressure (bar abs.)
Live steam 500 500
temperature(deg.c)
Outlet steam 1-17 1-17
pressure(bar abs.)

2. SST - 060

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 Design size AF 3.5 AFA 4 AFA6 CFA 4
Output (kW) 600 2200 6000 1600
Speed (r.p.m.) 13600 118000 11400 10500
Live steam 101 131 41 41
pressure (bar abs.)
Live steam 500 530 450 450
temperature(deg.c)
Outlet steam 1-17 0,08-25 0,08-11 1-17
pressure(bar abs.)

3.SST – 150
Power Output Up to 20 MW
Speed Up to 13,000 rpm
Live steam parameters
Inlet pressure Up to 103 bar/1,495 psi
Inlet temperature Up to 505 deg.c/940 deg.F
Exhaust steam parameters
Back-pressure Up to 10 bar/145psi
Condensing Up to 0.25bar/3.6 psi
Steam extraction
Controlled(up to 4) 16 bar/230psi/350deg.c/560
deg.F
Uncontrolled 25 ar/365 psi

4.SST - 200

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 Power output Up to 10 MW
Speed Up to 14,600rpm
Live steam
parameters
Inlet pressure Up to 110 bar/1,595psi

Inlet temperature Up to 520deg.c/970deg.F

Exhaust steam
parameters
Back- pressure Up to 16 bar/230psi

Condensing Up to 0.25 bar/3.6psi

Steam extraction

Controlled(up to 4) 16
bar/230psi/350deg.c/560deg.F
Uncontrolled 60 bar/870psi

5.SST - 300
1. Power output Up to 45 MW
Speed Up to 12,000rpm
Live steam
parameters

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Inlet pressure 140 bar/2030psi

Inlet temperature 540deg.c/1004deg.F

Exhaust steam
parameters
Back- pressure Up to 16 bar/232
psi
Condensing Up to 0.3 bar/4.4psi

District Heating UP TO 3.0

BAR/43PSI
Controlled
extraction (up to 2)
Single or
double,adaptive
stage,nozzle
control,throttle
control
pressure Up to 25 bar/362psi

temperature 400deg.c/752deg.F

Uncontrolled
extraction (up to 6)
pressure Up to 60 bar/870
psi

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 6.SST – 400

Power output Up to 60 MW
Speed Up to 8000rpm
Live steam
parameters
Inlet pressure 140 bar/2030psi

Inlet temperature 540deg.c/1004deg.F

Exhaust steam
parameters
Back- pressure Up to 25 bar/363
psi
Condensing Up to 0.3 bar/4.4psi

Steam extraction

Uncontrolled Up to 60 bar/870
psi

7. SST - 500

Power output Up to 100 MW

Speed Up to 15000rpm

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Live steam
parameters
Inlet pressure 30 bar/435psi

Inlet temperature 400deg.c/750deg.F

Exhaust steam
parameters
Back- pressure Up to 1.5
bar/21.75psi
Condensing Up to 0.5
bar/7.25psi
Steam extraction

Uncontrolled(up to Various pressure

2) levels

8.SST - 600

Power output Up to 200 MW

speed 3000 to 18000rpm
Live steam
parameters
Inlet pressure 165 bar/UP TO
2393psi
Inlet temperature 565deg.c/1050deg.F

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 Exhaust steam
parameters
Back- pressure Up to 80 bar/1160
psi
Condensing Up to 1.0 bar/15psi

District heating Up to 3.0 bar/43 psi

Controlled
extraction(up to 2)
Pressure,ext.valve Up to 72
bar/1044psi
Pressure,int.valve Up to 45 bar/798psi

Temperature Up to
480deg.C/895deg.F
Uncontrolled
extractions(up to
6)
Up to 85
bar/1233psi

9. SST - 800

Power output Up to 250 MW

Speed 3000 to 3600rpm
Live steam
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 parameters
Inlet pressure 165 bar/UP TO
2393psi
Inlet temperature 565deg.c/1050deg.F

Exhaust conditions

Back- pressure Up to 72
bar/1044psi
Controlled
extractions(up to
2)
Pressure,ext.valve Up to 65bar/942psi

Uncontrolled
extractions(up to 7
)
Various pressure
levels

10.SST – 700/900

Power output Up to 250 MW

Speed 3000to 3600rpm
Live steam
parameters

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Inlet pressure 180bar/2611psi

Inlet temperature 565deg.c/1050deg.F

Exhaust steam
parameters
Back- pressure 0.3 bar/4.4 psi

Steam extraction

Controlled 72bar/1044psi

Uncontrolled Up to 7
uncontrolled
extractions possible

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 CHAPTER 3: Policies

QUALITY POLICY

Siemens Metering Services (SES) vision is to be trusted as the leading

independent provider of innovative services. Siemens Metering
Services provides flexible, innovative products, services and solutions
enabling our customers to improve their quality and cost to serve.
Through this we seek to gain customer loyalty, maintain market
leadership and deliver profitable and sustainable growth.

In order to achieve our vision and deliver shareholder expectations,

Siemens Metering Services executive management team is committed
to enhancing customer satisfaction and overall business performance.
This will be achieved through the active development of our people,
working in partnership with key contractors and suppliers and by the
continual improvement of processes, products and services.
Strategic objectives are established by the Executive Management
Team for delivery of business goals within a quality framework - the
"SES Quality House".

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 CHAPTER 4: Conclusion

CONCLUSION

In these 4 weeks of industrial training, I have learned a lot about

different things in the industry. I learned about the different
departments in the company and how the industry works. What are the
vision and mission of the industry . The quality policy of the industry.
I also learn about steam turbine. How steam turbine works, what
are the different parts of the turbine, various application of the steam
turbine.

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 CHAPTER 5: References

REFERENCE

1. https://youtu.be/SPg7hOxFItI

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