SPPA i3000

Comprehensive Solution meets

All the Instrumentation needs

SPPA i3000
Instrumentation Solution for Power Plant Automation
Answers for energy. s
Preamble:
Comprehensive Field Instrumentation
solution offered by Siemens meets all the
Power plant Process Monitoring and
Control needs. Multiple Instrumentation
package requirement is fulfilled through a
single point interface with Siemens, is the
biggest advantage to the customers.
Offered solution of Field Instrumentation
not only monitor and control the dynamics
of the Processes, but also takes care of the
Control system requirements.
Foundation of the offered Instrumentation
services is on the premise that it is a
“Comprehensive Solution” comprising of
Engineering, Procurement, Installation &
Commissioning services. Process dynamics
under various operating conditions such as
cold start up, load change, plant trip on
catastrophe are visualized while working
out the package solution.
2
In the event of customer preferring to split
the total requirement product wise,
Siemens experts assist the customer to
choose the right option from the product
spectrum on offer. Expert advice on
selection of the right instrument for the
intended application is driven by decades
of experience in power plant automation
business. Over and above, this service
comes as complimentary along with
supply services.
Sensor selection is done to capture wide
spectrum of process conditions as stated
here in. Based on the data captured,
experts can do effective analysis in leisure.
Trip event can be analyzed to pin point the
cause and implement correction at root
level. Additionally, data analysis also
contributes to make the monitoring and
controls effective, enabling to improve the
overall plant performance.
Control elements such as Control valve,
Power cylinder selection and sizing are
given special attention. Under or over
sizing of the control elements adversely
influence effectiveness of the process
control. Also, material and rating selection
of the equipments is done according to
international safety standard to avoid
possibility of an accident. Discerning
approach adopted during detailed
engineering ensures higher plant
availability and safety.
Comprehensive Instrumentation solution
offered by Siemens provides vertical
integration with Control system and
horizontal amalgamation with process
dynamics, is the key factor of the
approach. Holistic approach in providing
solution comes with lot of value addition
in terms of knowledge based engineering
and decades of hands on experience in
Power plant automation industry.

Process parameters in large rating modern
power plants are extremely challenging in
terms of Pressure, Temperature and Flow
velocity. Therefore selection of
Instrumentation equipments needs to be
done cautiously as they are directly
connected to Power plant process and
machinery. Any compromise done on
selection of instruments can lead to
accident which can jeopardize personnel
safety and generation loss. Concerns are
equally loud to safe guard investments in
terms of damages to expensive machinery
arising out of design failure. Siemens pays
due attention in proper selection of
Instruments and associated installation
materials as these aspects play pivotal role
in safe operation of the power plant.
Selection and sizing of Instruments and
associated installation materials is done
with safe design margins as per
international standards like ASME, ANSI,
DIN, EN, IEEE, OHSAS to name a few.
Experience based approach during detailed
engineering and installation planning
eliminates possibility of procurement gaps
which surface during the Installation and
commissioning phase of C&I components.
This task is impeccably fulfilled irrespective
of the Control system chosen by the
customer.
Retrofitting & Upgrade projects:
Siemens expertise is also available for the
Retrofitting and Modernization of C&I
systems in power plants which is a highly
challenging job. Siemens capability in this
field encompasses up gradation of any
existing make of control system with
Siemens offered contemporary C&I
system. Records confirm that Siemens has
successfully upgraded dozens of C&I
system in power plant of varying ratings.
Experts experience is pooled in to study
the existing installation, discuss with
customer to understand the expectations
and then workout a solution meeting
customer satisfaction. Keeping customer’s
budget in focus, the solution is a mix of full
or partial replacement of field devices.
Example of partial replacement is retaining
in line control valve body but replacing
actuator and accessories. Such task can
not be accomplished without the experts
with hands on experience which is one of
the Siemens strength.
3
1. Work scope

Dedicated team of professionally qualified engineers and
designers work closely with customer to understand project
specific requirements to provide customized solutions. Siemens
contribution begins right from review of the basic design
concepts and builds up to commission and handing over the plant
for operation. Offered services comprise of the following:
• Participation in review of basic design concepts
• Detailed engineering
1.1. Design Concept review
Siemens has pioneered Control and Instrumentations concepts
which have over the years become industry practice. Knowledge
driven inherent advantage is de-facto derived by the customer as
Siemens is not only manufacturer of power plant equipments but
is an inventor of electricity generation concept. Stemming from
this lead, following services are extended to the esteemed
customers:

• Procurement • Coordination with Consultant, Customer, Main equipment

manufacturer to decide sensor interface design with process
• Quality control (Ref. Fig-1).
• Site management • Review of process sensor locations on piping, vessel for
• Warranty calls and after sales services obtaining accurate measurement (Ref. Fig-2.1, 2.2).

Fig. 1: Pressure Tappings

UD – Upstream Distance
DD – Downstream Distance

Fig. 2.1: Flow Sensor (FE)

Note: Non-Permissible area for Pressure Tapping is indicated by Hatched Zone.

4
Fig. 2.2: Temperature Sensor (TE)
• Selection of Instrument for different applications.
• Participation in developing cabling concepts to achieve
standardization of hardware engineering and cable design
specifications.
• Recommend standard Instrument installation hook-up
schematics. Assist in developing guidelines on selection of
impulse pipe/accessories materials and rating.
1.2. Detailed Engineering
Siemens being leading EPC contractor, customers have reasons to
depend on the engineering capabilities. Detailed engineering
activity is driven by knowledgebase and decades of experience.
Result is highly standardized documentation. Clear output is
delivered for efficient procurement. Subsequently these
documents are valuable resource for the customer during
Installation, Commissioning, Operation and maintenance phase.
Some of the examples of these activities are:
• Developing Master Instrument list based on client provided PID
and design process parameters.
• Selection of appropriate instrument for the application.
• Production of Instrument data sheets complete with Bill of
materials.
• Finalization of Instrument installation hook ups (Tag wise)
along with Bill of materials and their specifications.
• Produce complete field cable termination plan and laying
schedules.
• Develop optimized C&I cable specifications for cost effective
procurement.
• Preparation of Instrument air distribution schematics along
with Bill of materials.
• Produce construction documentation for site activities.
Emphasis is given to installation planning and it’s documentation
which is found highly useful at site. Mainly the documentation
comprises of Control room layout depicting various cabinet
location plan, Cable laying and termination schedule, Instrument
installation hook ups, Field Instruments user manual, Location
plan of Field Junction box and enclosures, Check list for all type of
installation activities, Standard report formats for instrument
calibration & site progress, Safety & Field Quality manual. These
documents are updated during the installation phase to
incorporate site related changes. Finally, marked up site records
are used to produce “As built” documentation for submission to
customer, as part of contractual commitment.
1.3. Procurement
Strategic purchase group in Siemens enables procurement
through efficient supply chain management. Procurement is cost
effective and reliable in delivery because of certain fixed business
commitments between Siemens and vendors. Key procurement
activities comprise of the following:
• Release of firm Purchase Order through SAP on approved
vendors. SAP driven process enables strict monitoring of the
complete procurement progress.
• Continuous coordination with customer and suppliers to meet
project delivery schedules.
• Monitoring dispatch and transportation logistics.
5
1.4. Quality Control
Quality is synonymous with Siemens. Irrespective of the stated
quality requirement in the project, every activity, delivered
material and services has to pass through Quality Gates as per PM
processes. Projects are executed as per the Project Management
Process guide lines ensuring quality check at every critical stage.
Delivering high quality equipments is one of the Siemens
corporate quality objectives. Following are some of the examples
in the direction:
• Engineering and Inspection of Instrumentation packages is
done based on knowledge and time proven procedures.
• Manufacturing release is driven by Siemens approved vendor’s
QAP.
• In stage inspection is a standard procedure during
manufacturing phase of the equipments.
• Pre dispatch inspection is imperative. Equipments cannot be
dispatched in non compliant way, is the internal requirement.
Participation during final inspection is customer’s choice.
1.5. Site Management
Providing professional Site Management services to the esteemed
customers is Siemens inherent strength, being a leading EPC
contractor. Qualified and experienced personnel are deployed for
project and site management activities. Every site activity done is
based on time tested methodology and continually updated
procedures. Efforts result in conducting, monitoring and reporting
of I&C activities in professional manner. Brief details of the various
undertaken activities are as follows.
• Development of Installation and commissioning documents.
• Preparation of time schedules.
• Materials and store management.
• Calibration of Instruments and maintaining reports.
• Supervision of site activities as per Siemens internal Field
Quality Plan.
• Strict implementation of personnel safety norms during routine
activities.
• Preparation of site progress report, to be used by Project
Manager and for customer update.
• Tracking I&C progress through protocol preparation.
• Coordination with customer at site to schedule and priorities
activity to meet project mile stones
• Finalization of the construction documents for handing over to
customer.
• Handing over of plant to customer for operation.
• Inventory reconciliation statements and site closure.
6
1.6. Warranty and After sales service
Many times Instruments are offered from different manufacturers
to meet complex requirement of power plant instrumentation.
Customer require single window interface who meets the
warranty obligation in terms of consumables, spare parts and
repairs services. Siemens provide strong support to fulfill the
customer’s expectation during the committed warranty period. In
order to provide this service Siemens organization supports a
dedicated team of service engineers who take over the project
from Project management group to attend warranty calls. Further,
this group also provides after sales support i.e., beyond warranty
period, depending on customer’s need. Such services are
available round the clock either remotely or by providing full time
deputation of service engineer at site.
1.7. Offered Instrumentation packages
Broadly, services are offered for the following instruments/
packages:-
• Process Transmitters and Switches for pressure, flow, level,
temperature measurement
• Temperature sensors - T/C, RTD
• Flow sensors – Orifice plate assembly, Flow nozzle / ventury,
Impact head flow meter, Rota meter, Magnetic and Ultrasonic
flow meter
• Level sensor- Ultrasonic and Radar type
• Steam and Water Analysis System
• Analyzers for Continuous Emission Monitoring
• Ambient air Quality Monitoring System
• Furnace Flame Monitoring System
• Furnace Flame Camera system
• Furnace Temperature Monitoring System
• Boiler Tube Leak Detection System
• Vibration Monitoring System
• Turbine Supervisory Instrumentation (TSI)
• Close Circuit Television System
• Public Address System
• Power supply System – UPS, Charger, Battery bank
• Control and Instrumentation cables
• Enclosure and Racks for field instruments
• Impulse piping complete with valves, manifold, fittings,
siphon, snubber, condensate pot, dust chamber etc.
• Instrument air distribution system
• Cable trays
2. Instrumentation - Key packages
Some of the Instrumentation packages are specific to the plant
equipment application where as other packages are common to
the entire power plant process. Prominently the Instrumentation
packages can be divided in three categories, for better
understanding of the subject. These are related to
• Steam generator
• Turbo generator
• Common to the plant
2.1. Steam generator
Huge pressing demands of energy at base load has set trend to
build large capacity power generation plants. Installation of large
capacity unit in multiple numbers can only be the answer to the
emerging challenge. Continuous availability of the Steam
Generator under varying fuel quality level and operating
conditions need to be reckoned while deciding on the type of
Instrumentation solution. In corollary to human body where eye
and ear provide input to mind, similarly Instrumentation of steam
generator collects information on internals of the furnace and
enables control system for appropriate action. In addition, this
information is proactively used for scheduling maintenance, avoid
abrupt shut down and increase plant availability.
Fig. 3: Boiler Tube Leakage Detection
Steam generator specific packages are:
2.2. Boiler Tube Leak Detection system (BTLD)
Enables monitoring and early detection of boiler tube leakage in
water walls. Air borne noise, emanating from water wall tube
leak, is picked up by acoustic sensors as an early warning signal.
Noise developed from boiler’s fatigued structure is also detectable
by another type of acoustic transducer. Information provided by
the system is useful for scheduling maintenance. Advantage to
the utility is eliminating generation loss and expensive
maintenance caused by severe tube leakage or structural failure
detected in advanced stage. Typical system schematic is depicted
by Fig-3.
2.3. Furnace Temperature Monitoring System (FTMS)
System provides information on thermal profile of the flue gas in
side the furnace. Commonly recommended location for
monitoring the temperature is at the furnace and economizer exit
point in the steam generator. Details are made available in the
form of thermal image at the point of monitoring. Acoustic
sensors (transceivers) are installed in required numbers,
depending on the boiler design. These sensors pick up the
thermal behavior of the flue gas constituents which has direct
7
Fig. 4: Sensors Location Plan
relation to the heat energy carried by them. Data gathered by the
sensors help in plotting thermal profile at the monitoring cross
section of the boiler. Study of the thermal image pattern depicts
uniformity or imbalance of flue gas heat distribution inside the
boiler. Corrective action is taken by control system to change the
gun firing combinations so that heat is uniformly distributed
throughout the flue gas path. Uniform heat distributed by the Flue
gas improves heat exchangers performance to super heat the
steam.
System also helps in providing information on possible hot spots
inside the furnace which can lead to boiler tubes failure caused by
overheating. Further, Combustion control loop can be fine tuned
by using the information provided by the system. Typical
schematic is depicted by Fig-4.
2.4. Furnace Camera System
System monitors the fuel flame pattern inside the boiler furnace
by directly looking at it. Data collected by the camera is used to
plot heat dissipation pattern from the flame formed inside the
furnace zone. Adverse information picked up by the system can
be used by control system to take corrective action to balance out
the flame formation. Complementary information on hot spots
and boiler tube condition can also be observed by the cameras.
Typical system schematic is depicted by Fig-5.
8
2.5. Furnace Flame Monitoring System
Furnace flame monitoring is an essential component of Boiler
Management System. Requirement to monitor furnace flame
begins from the first step to successfully establish flame inside the
furnace by lighting oil/gas and subsequently building up full load
firing where coal is the main fuel. Flame monitoring scanners are
deployed to establish “Flame” or “No flame” status inside the
boiler under all the operating conditions. Based on the
information provided by the scanners, boiler operation safety
logic is built according to the manufacturer specifications.
Flame scanners task, after establishing flame, is to subsequently
provide authentic information on existence of the subject flame
based on discrimination capability w.r.t., adjacent flame or
ambience sources. Combination of flicker frequency and intensity
signal of the subject flame is the criteria to discriminate with other
illuminated sources. Scanners performance is adjudged by the
discriminating and flame evaluation capability under various type
of conditions prevailing inside the furnace e.g., variations in the
fuel quality like dust contents, high humidity level during rainy
season, fly ash surrounding flame zone to name a few. Such
gathered information through the scanners system enables the
operators to decide on course of action to be taken for regulating
the firing to meet generation target.
Scanner sensing head is suitable for monitoring UV/Visible/IR
source of light. Suitable type of scanners needs to be selected
depending on the type of fuel firing to be monitored. Smart
scanners capable of flame evaluation based on FFT (Fast Fourier
Transforms) intelligence are available. Inputs provided by the
flame scanners also help in improving combustion efficiency of
the boilers. Typical schematic is depicted by Fig-6.
Fig. 5: Furnace Camera System

Fig. 6: Furnace Flame Monitoring System

9
2.6. Turbo Generator
Turbo generator specific Instrumentation package is:
Turbine Supervisory Instrumentation (TSI)
Most critical Instrumentation need in the entire power plant,
beyond debate, is to monitoring operating condition of the
Turbine Generator machine. TG set is extremely fast acting
machine and operates under thin tolerance band. Sluggish control
of the machine can lead to devastating situation exposing human
life to unprecedented danger. Fine control and safe operation of
the TG set is dependent on the information provided by TSI
deployed to monitor the operating conditions of the machine.
Therefore, importance of right selection of TSI can be well
understood by one and all in power plant environment.
Function of the TSI is to closely monitor the operating parameters
of the TG set under all operating conditions i.e., right from a) Cold
start up to synchronization; b) Load ramp up to load throw off; c)
Hot role back to load change; d) Normal running to trip condition,
are some of the routine situation in power plant. Instruments
selected shall be sensitive to situation change and report it to the
Fig. 7: Turbine Supervisory Instrumentation
10
control system quickly for corrective action. Also information
gathered by the system is useful to the experts to do online health
monitoring and diagnosis of the running machine.
Information on machine operating close to or crossing operating
limits is provided by the system for operator action. Information
provided by the system is also used to schedule the preventive
maintenance.
Typical measurement associated with TG set are Rotor shaft and
bearing vibration, Differential expansion of rotor and casing,
Casing expansion, Thrust bearing pressure, Rotor eccentricity, Key
phaser and Temperature monitoring of Bearing, Turbine casing,
Generator winding, Governor valve position. Turbine speed
monitoring is most important parameter for turbine protection
interlock which is measured with multiple redundant sensors.
Siemens being leading manufacturer of the turbo-generators
worldwide, genuinely understands the imperatives of condition
monitoring needs of the machine. Therefore, TSI solution offered
by the Siemens is comprehensive and comes with lot of
innovative value addition for the customers benefit. Typical
schematic is depicted by Fig-7.
3. Instrumentation Common to plant
Instrumentation packages elaborated below are common to the
entire plant.
3.1. Process Transmitters
are used to generate analog signals to monitor various process
values such as Pressure, Level, Flow etc. Transmitters can be
mounted local or remote to the process. Care needs to be taken so
that range selected of the transmitter is suitable to cover entire
spectrum of the operating conditions. Right from cold start up to
extremely disturbed process condition related measurement shall
fall with in the selected range, is the right approach
3.2. Process switch
are used to generate binary signals. These signals are indicators of
change in process conditions to depict either abnormality or a
permissive status. Set point differential is important parameter
and same shall be selected depending on the process behavior.
Low differential is preferred for Level and Temperature signal
where as high differential is the right choice for Pressure and Flow
measurement.
3.3. Temperature sensor
Thermocouple and RTD are the most commonly used devices.
Different types of thermocouple and RTD are available to choose
from, depending on the process temperature and location
environment. Mechanical design of the process stub, Thermowell
design and immersion length are extremely important parameters
associated with selection of the temperature sensor. Relaxation in
meeting the stated requirement can lead to accident and may be
plant shut down. Location and orientation of the sensor in piping
system influences the reliability and accuracy of the measured
signal.
3.4. Flow Sensor
Mostly these are line mounted devices. Commonly used sensors
are Orifice plate assembly, Flow nozzle, Ventury, Rota meters,
Impact head meters, Magnetic and Ultrasonic flow meters.
Criterion influencing selection of sensor is Line size, Process
media, flow rate, Pressure and temperature parameters,
permissible pressure drop and measured rangeability.
11
3.5. Level Sensor

Contemporary sensors for Level measurement are driven by Radar

or Ultrasonic based technology. These sensors do not have any
moving parts which make them drift free and reliable in
performance. Displacer or float type sensors are no more the
choice of designers.

3.6. Field Instruments Enclosure and racks

Process transmitters, Switches and local Gauges can be mounted

in field installed Enclosures and Racks. Harsh plant environment,
protection against inadvertent operation, functional grouping of
instruments for ease of operation, saving on installation time at
site, are some of the reasons to go for this option. Enclosure and
Racks are delivered to site pre-tubed, wired up to integral Junction
box, hydro tested for safe pressure rating/leakage. These are
Field Instrument Enclosure
suitable for installation at the pre identified locations in the boiler
and TG area. Impulse pipe needs to be field routed from process
tapping and can be terminated at the enclosure/rack respective 3.7. Instruments Installation Hook ups
interface point.
Detailed engineering exercise also includes developing Instrument
installation hook ups, preparing bill of materials and Installation
drawings for the offered Field Instruments. Hook ups are prepared
tag wise. Impulse pipe, tube, instrument valves, manifolds,
various types fittings form part of the bill of materials.

Siemens contribution is to recommend field proven hook up

schemes, selection of materials according to the pressure and
temperature parameters of the respective tag number and
quantification of bill of materials. Design margins of the selected
material of impulse pipe and components is specified inline with
the guidelines of international standards like ANSI, ASME, DIN.
Refer Fig-8 as an example of instrument hook up diagram.

Special Instrument installation arrangement for Coal bunker level,

CW sump level, Boiler tube leak detection sensor, Furnace
temperature acoustic sensor and Flame scanners are seamlessly
coordinated with mechanical equipment supplier.

Field Instrument Rack

12
 BILL OF MATERIALS

ITEM No. DESCRIPTION QTY.

1 EQUAL TEE, SS, 1/2" OD COMP. END 2

2 MALE CONNECTOR, SS, 2

1/2" NPT(M) X ½" OD COMP.

3 SEAMLESS TUBE, SS, 20mtr ~

1/2" OD X 0.065" WT

4 5 VALVE MANIFOLD, SS, ½" NPT(F) 1

5 BLOW DOWN VALVE, SS, 2

CLASS 800, 1/2" OD COMP. END

6 DP TRANSMITTER 1
7 CONDENSATION POT, 3"NB, SS, 1
1/2" x 1/2" WELD END

Fig. 8: Instrument Hook Up

Isolation Valve TEE Male Connector

2-Valve Manifold 3-Valve Manifold 5-Valve Manifold

13
Fig. 9: Instrument Air Distribution
3.8. Instrument Air Distribution system

Instrument air requirement for Pneumatic actuators, Air purge to

Furnace measurement Transmitters in a coal fired power plant is a
Smart Positioner
common place in instrumentation package. Wide spread
Instrument air distribution network is needed to meet the SIPART PS2
requirement. Typical schematic is depicted by Fig-9.

Siemens contribution comprises of developing instrument air

consumers list, air distribution scheme, sizing of air headers,
preparation of pneumatic hook ups and material take off.

3.9. Control elements

Control valve, Power cylinder, Solenoid valve are the prominent

control elements known in the power plant application. These
control elements are fitted with Pneumatic, Hydraulic or Electric
Actuators depending on the automation requirement. Duty can be 3.10. Plant Engineering
modulation or ON/OFF type. Siemens make of smart positioners
Based on the plant layouts, piping isometrics or layout drawings
are fitted which have nearly zero air consumption in steady state
and PID, Siemens can assist the customers in developing
of operation. Design selection criterion of the control elements is
Instruments grouping for Field Junction box and Instrument
dependent on the following:
Enclosure/Racks according to functional requirement. Location
• Process medium chemistry for body material selection. plans are also recommended keeping in mind the ease of
operation and maintenance activities.
• Design Pressure & Temperature parameters for body rating.
• Operating conditions for Trim design selection.
3.11. Vital Power supply system
• Piping interface for end connection.
Normally two types of power supply systems needed for
• Fail safe operating condition automation system are:
• Interlock and feed back signals requirement for the accessories. • 1 phase, 50/60 Hz, 230/110V AC and
One of the important and critical applications in this family is HP • 24V DC
and LP bypass control valves for TG island where Siemens offer
expert solution. Along with HP, LP bypass control valves, solution Indeed, Power supply system is the life line of automation system
includes control system and complimentary packages. engaged in monitoring and controlling the power plant
generation. Therefore, reliability of the power supply system is of
Combined Aux PRDS station to meet customized requirement is paramount importance.
also engineered and delivered.
14
Fig. 10: SLD of Parallel Redundant Ups
3.12. Uninterrupted Power Supply system
Broadly 1 phase, 50/60 Hz, 230/110V AC power supply is required
to power operating and monitoring system. Good UPS system
provides reliable and quality power supply in uninterrupted
manner. Quality of UPS output is adjudged by the regulation
tolerance of Voltage, wave formation, frequency, transient load
change variations etc. to be better than the specifications of the
connected loads.
Parallel redundant with maintenance bypass is a well accepted
UPS configuration. System normally operates in equal load
sharing mode. Failure of one UPS stream bump less transfer the
100% load to the second stream. Common battery bank is the last
resource to deliver power supply. Bypass line can be cut in to feed
the demand under scheduled maintenance period of UPS. Bypass
connection is established in make before break manner to avoid
any brown outs. Isolating transformers are provided to arrest the
fault arising from loads or UPS to protect higher level of raw
power supply system. Refer Fig-10 for single line diagram of
parallel redundant UPS.
3.13. Charger system - 24V DC power supply
Automation system power supply requirement is generally of 24V
DC. Rectifier cum chargers complete with battery bank fulfills the
requirement. SMPS based rectifiers is the favorite choice of the
designers because of the higher overall efficiency. Dual parallel
configuration with common battery bank is common in demand.
Besides feeding the loads, chargers also provide window to boost
or float charge the batteries.
3.14. Battery bank
Depending on customer’s choice, batteries can be maintenance
free Lead Acid or NiCad type. Single or block cells can be offered
according to the available space. Battery health monitoring
system is integral part of the battery bank. Health monitoring is
done at each cell level and information can be interfaced to
control room for operator’s information.
Battery bank engineered by Siemens has in built provision to cater
full load requirements under all operating conditions for the life
time of the power plant. While sizing the battery bank, aging,
design margin, temperature compensation etc are factored in to
deliver robust solution.
3.15. Water chemistry
Requirement of water and steam in power plant processes is of a
specific quality. Health and availability of the power plant
equipments is directly influenced by the contamination level of
the water and steam quality. Higher level of contamination simply
deteriorate the power plant overall efficiency. Conductivity, pH,
Dissolved oxygen, Residual Sodium and Hydrazine, Dissolved
Silica, Hydrogen are the main constituents to be monitored and
controlled in water and steam cycle.
Stated measurements are monitored online on continuous basis.
Preferred concept is to collect samples at a central place near
control room in chemist’s laboratory. These samples need to be
conditioned in terms of Pressure, Temperature and Flow rate to
meet microprocessor based electronic analyzer requirement, is
important factor in system design and engineering.
15

Siemens engineered solutions ensure continuous availability of
samples in safe manner to provide reliable data. Analyzer
selection is based on sample location and sensitivity to monitor
ingress of actual contamination possibilities. Sample conditioning
components are selected to ensure safe availability of samples for
the life time of power plant.
3.16. Gas Analytic
Chemistry of the Flue gases escaping furnace provide vital data
on fuel combustion efficiency and concentration of effluents
escaping to the environment through chimney. Deviation in
Carbon monoxide and Oxygen % in the flue gas sample is a direct
indicator of the combustion efficiency where as quantum of
Sulfur and Nitrogen oxides provides information on environment
pollutant level. Particulate emission rate through chimney
indicates ESP efficiency.
Siemens offer complete range of analyzers to monitor flue gas
chemistry and provide required information for corrective action.
Both line mounted and extractive type of analyzers are available.
Skid mounted solution containing sample conditioning
equipments are available from Siemens for the extractive type of
analyzers. Alternatively, gas analyzers installed in air conditioned
containers suitable for field mounting can also be the option to
choose from.
Multi Component Gas Analyzer - ULTRAMAT
16
3.17. Ambient air Quality Measurement System (AAQMS)
Environment pollution control is a necessity in today’s challenges.
Power plants are one of the major contributors in adding
pollutants to the atmosphere. AQMS is very effective in
monitoring pollution level surrounding power plant environment.
Air quality monitoring stations are set up preferably in all the four
directions of power plant in a radius of 2 to 4 kilometers to
measure Oxides of Sulfur, Nitrogen, Carbon and Particulate level.
These stations are connected to the central monitoring station via
LAN/WAN/Wireless communication link to pool the so collected
information. Experts analyze the data offline and suggest for the
corrective actions.
3.18. Vibration Monitoring System (VMS)
Every plant has certain number of rotating equipments in the
shape of fans, pumps and motors. Count of these equipment
depends on size/rating of the plant and the type of process
followed. Most of the rotating equipments need vibrations
monitoring system during the commission phase and
subsequently to track it’s wear and tear condition.
Depending on the type of bearing and RPM of the rotating
equipment, Siemens can recommend the sensor type suitable for
the machine. Measurement can be configured as velocity/
acceleration or absolute displacement. VMS offered comprises of
the sensors along with mounting pads, monitors, diagnostic suite
and optional interface to the third party. Besides Siemens own
system, it can also be offered from the customer’s preferred
manufacturer.
3.19. Control and Instrumentation cables
Role of cables in automation package is like importance veins in
human body. Signal transfer or say communication among all the
C&I components is mainly through cable network. Therefore,
technically correct type of cable is needed to transmit the signals
while taking care of distance of transmission and associated noise
attenuation requirements in power plant environment. Higher use
of multipair / multicore cable can help in cable package cost
optimization.
Siemens participation help customers in developing cable
specification to meet the stated requirements. Value addition
includes developing cable block diagrams to standardize cable
application. Procurement of a few types of cables in large
quantities provides substantial cost reduction through
standardization concept. Refer Fig-11 as an example of the cable
block diagram.
Fig. 11: Cable Block Diagram
3.20. CCTV system
Considering vast expanse of power plant premise and access
difficulty in attending all the plant machinery, it is extremely
challenging to arrange for round the clock surveillance all over by
deploying personnel. Event capturing and monitoring difficult
locations in power plant can be effectively managed by installing
Close Circuit TV system at the pre identified locations. Entire
Fig. 12: System Configuration CCTV
station can be under surveillance from central monitoring control
room where operators can keep watch round the clock.
Event capturing can be pre engineered to arrest happening
sequence with pan tilt and zoom functions for each camera
location. Data collected from all the cameras can be used for
instant analysis or can be archived for future use. Refer Fig-12 for
system configuration of CCTV.
17
Fig. 13: Block Diagram PAS
3.21. Public address system
All the personnel present in the plant at various locations need to
communicate with each other. In addition, certain safety related
or otherwise important information, whenever required to be
announced/broad casted in the power plant, public address
system fulfills the required role. Adequate number of Telephone
handsets and speakers are installed at the predefined locations.
These equipments are wired to local telephone exchange each
area wise. Such geographically distributed exchanges are
networked through Fiber-optic /wireless link to provide integrated
communication connectivity. It is also possible to interface
internal network with external network by taking permission from
the local authority. Refer Fig-13 for block diagram of PAS.
18
3.22. Lab Instruments
Instrument laboratory is a standard requirement in every power
plant. Large spectrum of complex instruments of different
manufacturers is required for the testing and calibration of the
various Instruments installed in the plant. Electronic and
Mechanical test benches are the major components among the
total requirement portable devices are also needed to monitor the
operating conditions of plant machinery.
Siemens can provide single window solution to set up modern
Instrument laboratory along with other offered Instrumentation
solution and services for the plant.
3.23. Miscellaneous packages
Some of the complementary packages falling between
Instrumentation and Control system are also offered for specific
applications.
– Field Interface Modules (FIM) are available to provide
customized signal conditioning functions for the field
generated signals to make them compatible to the control
system. FIM is a compact electronic module suitable for DIN rail
mounting. Typical functionality provided by the FIM is as
follows:
• Signal multiplication of single field sensor output for
redundancy purpose.
• Provision of optical/electrical isolation between field signals
and control system.
• Field signal isolation through knife switches for testing
purpose during commissioning phase.
• Compact Power supply distribution (24V DC) for automation
system.
• Diode auctioneering for redundant power supply feeders.
4. Inference
Instrumentation solutions offered by Siemens are comprehensive,
world class and tailored to meet power plant specific needs.
Return on customer’s investment is rewarded instantly through
the cost effective bulk procurement efforts by Supply chain
“Siemens offer One Stop Shop Solution for all Power Plant Instrumentation needs”.
• Interface between high voltage (110V/220V AC) field input
to low voltage (24V DC) control system signal.
• Any other customized application can be offered
– Control room furniture for the Control system.
– Development of customized control panels.
3.24. International Standards
Design engineering of various instrumentation packages is done
in accordance with International Standards; IEC, IEEE, ANSI, ASME,
DIN. These products are delivered with UL, CE certification
depending on application. Any other conformance according to
application specific need can also be considered during the
design engineering phase.
Installation & commissioning is carried out in line with jointly
accepted Field Quality Plan. Special emphasis is given to
personnel safety working at site. Audit check by certified
engineers related to installation practices & personnel safety is a
routine activity.
management group. Professional approach of Project
Management Procedures ensures timely delivery to meet project
mile stones. The biggest advantage to the customer is:
19
Regional Sales Offices

NORTH - Gurgaon EAST - Kolkata

Siemens Ltd. Siemens Ltd.
Energy sector Energy sector
3rd Floor, Plot 6A, Sector 18, 43, Shantipalli
Maruti Industrial Area Eastern Metropolitan Bypass
Gurgaon, Haryana - 122015 R B connector, Kolkatta
India West Bengal - 700042
Contact Person: Mr. I.K. Rai India
Tel. (Dir.): +91 124 4697376 Contact Person: Mr. Ashoke Roy
Mobile: +91 9818018701 Tel. (Dir.): +91 33 24449000
E-mail: indra.rai@siemens.com Mobile: +91 9830006653
E-mail: roy.ashoke@siemens.com
WEST - Mumbai
Siemens Ltd. SOUTH - Chennai
Energy sector Siemens Ltd.
3rd Floor, R&D Tech Centre, Energy sector
Thane Belapur Road, Thane - 400601 144, Mahatma Gandhi Road
India Chennai (Madras)
Contact Person: Mr. Sachin Jaguste / Mr. Neenad Wilankar Tamil Nadu- 600034
Tel. (Dir.): +91 22 24987341 India
Mobile: +91 9819155056 Contact Person: Mr. Muralidharan Krishnan
E-mail: Sachin.jaguste@siemens.com Tel. (Dir.): +91 44 28334608
Mobile: +91 9867665588 Mobile: +91 9962592826
E-mail: neenad.wilankar@siemens.com E-mail: Krishnan.muralidharan@siemens.com

WEST - Baroda
Siemens Ltd.
Energy sector
3rd Floor, Ohm Business Park
Opp. Balaji Hospital, Ellora Park
Subhanpura, Vadodara - 23
Gujarat, India
Contact Person: Mr. Mandar Pagedar
Tel. (Dir.): +91 265 6692123
Mobile: +91 9925004384
E-mail: mandar.pagedar@siemens.com

For any Technical Documentation, pls visit

www.siprotec.com
www.reyrolle-protection.com
For any general queries and technical support, pls write to us at
support.energy@siemens.com

Siemens Ltd. Contact Person: Mr. Kuldeep Tickoo / Mr. Aditya Dubey
Energy Sector - Fossil E-mail: kuldeep.tickoo@siemens.com,
Plot - 6A, Sector - 18, Maruti Industrial Area aditya.dubey@siemens.com
Huda, Gurgaon - 122 015.
Tel.: +91 124 2846000
Fax: +91 124 2846141
E-mail: efie.in@siemens.com Customer Care Toll free no. 1800 419 7477
www.siemens.co.in Email: service.energy.in@siemens.com Product upgradation is a continuous process. Hence, data in
this catalog is subject to change without prior notice. For the
latest information, please get in touch with our Sales Offices.