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SPPA i3000

Comprehensive Solution meets

All the Instrumentation needs

SPPA i3000
Instrumentation Solution for Power Plant Automation
Answers for energy. s
Comprehensive Field Instrumentation In the event of customer preferring to split Control elements such as Control valve,
solution offered by Siemens meets all the the total requirement product wise, Power cylinder selection and sizing are
Power plant Process Monitoring and Siemens experts assist the customer to given special attention. Under or over
Control needs. Multiple Instrumentation choose the right option from the product sizing of the control elements adversely
package requirement is fulfilled through a spectrum on offer. Expert advice on influence effectiveness of the process
single point interface with Siemens, is the selection of the right instrument for the control. Also, material and rating selection
biggest advantage to the customers. intended application is driven by decades of the equipments is done according to
Offered solution of Field Instrumentation of experience in power plant automation international safety standard to avoid
not only monitor and control the dynamics business. Over and above, this service possibility of an accident. Discerning
of the Processes, but also takes care of the comes as complimentary along with approach adopted during detailed
Control system requirements. supply services. engineering ensures higher plant
availability and safety.
Foundation of the offered Instrumentation Sensor selection is done to capture wide
services is on the premise that it is a spectrum of process conditions as stated Comprehensive Instrumentation solution
“Comprehensive Solution” comprising of here in. Based on the data captured, offered by Siemens provides vertical
Engineering, Procurement, Installation & experts can do effective analysis in leisure. integration with Control system and
Commissioning services. Process dynamics Trip event can be analyzed to pin point the horizontal amalgamation with process
under various operating conditions such as cause and implement correction at root dynamics, is the key factor of the
cold start up, load change, plant trip on level. Additionally, data analysis also approach. Holistic approach in providing
catastrophe are visualized while working contributes to make the monitoring and solution comes with lot of value addition
out the package solution. controls effective, enabling to improve the in terms of knowledge based engineering
overall plant performance. and decades of hands on experience in
Power plant automation industry.

Retrofitting & Upgrade projects:
Process parameters in large rating modern Experience based approach during detailed Siemens expertise is also available for the
power plants are extremely challenging in engineering and installation planning Retrofitting and Modernization of C&I
terms of Pressure, Temperature and Flow eliminates possibility of procurement gaps systems in power plants which is a highly
velocity. Therefore selection of which surface during the Installation and challenging job. Siemens capability in this
Instrumentation equipments needs to be commissioning phase of C&I components. field encompasses up gradation of any
done cautiously as they are directly This task is impeccably fulfilled irrespective existing make of control system with
connected to Power plant process and of the Control system chosen by the Siemens offered contemporary C&I
machinery. Any compromise done on customer. system. Records confirm that Siemens has
selection of instruments can lead to successfully upgraded dozens of C&I
accident which can jeopardize personnel system in power plant of varying ratings.
safety and generation loss. Concerns are
equally loud to safe guard investments in Experts experience is pooled in to study
terms of damages to expensive machinery the existing installation, discuss with
arising out of design failure. Siemens pays customer to understand the expectations
due attention in proper selection of and then workout a solution meeting
Instruments and associated installation customer satisfaction. Keeping customer’s
materials as these aspects play pivotal role budget in focus, the solution is a mix of full
in safe operation of the power plant. or partial replacement of field devices.
Selection and sizing of Instruments and Example of partial replacement is retaining
associated installation materials is done in line control valve body but replacing
with safe design margins as per actuator and accessories. Such task can
international standards like ASME, ANSI, not be accomplished without the experts
DIN, EN, IEEE, OHSAS to name a few. with hands on experience which is one of
the Siemens strength.
1. Work scope

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

Fig. 2.2: Temperature Sensor (TE)

• Selection of Instrument for different applications. • Preparation of Instrument air distribution schematics along
with Bill of materials.
• Participation in developing cabling concepts to achieve
standardization of hardware engineering and cable design • Produce construction documentation for site activities.
Emphasis is given to installation planning and it’s documentation
• Recommend standard Instrument installation hook-up which is found highly useful at site. Mainly the documentation
schematics. Assist in developing guidelines on selection of comprises of Control room layout depicting various cabinet
impulse pipe/accessories materials and rating. location plan, Cable laying and termination schedule, Instrument
installation hook ups, Field Instruments user manual, Location
1.2. Detailed Engineering plan of Field Junction box and enclosures, Check list for all type of
installation activities, Standard report formats for instrument
Siemens being leading EPC contractor, customers have reasons to calibration & site progress, Safety & Field Quality manual. These
depend on the engineering capabilities. Detailed engineering documents are updated during the installation phase to
activity is driven by knowledgebase and decades of experience. incorporate site related changes. Finally, marked up site records
Result is highly standardized documentation. Clear output is are used to produce “As built” documentation for submission to
delivered for efficient procurement. Subsequently these customer, as part of contractual commitment.
documents are valuable resource for the customer during
Installation, Commissioning, Operation and maintenance phase.
1.3. Procurement
Some of the examples of these activities are:
• Developing Master Instrument list based on client provided PID Strategic purchase group in Siemens enables procurement
and design process parameters. through efficient supply chain management. Procurement is cost
effective and reliable in delivery because of certain fixed business
• Selection of appropriate instrument for the application. commitments between Siemens and vendors. Key procurement
• Production of Instrument data sheets complete with Bill of activities comprise of the following:
materials. • Release of firm Purchase Order through SAP on approved
• Finalization of Instrument installation hook ups (Tag wise) vendors. SAP driven process enables strict monitoring of the
along with Bill of materials and their specifications. complete procurement progress.

• Produce complete field cable termination plan and laying • Continuous coordination with customer and suppliers to meet
schedules. project delivery schedules.

• Develop optimized C&I cable specifications for cost effective • Monitoring dispatch and transportation logistics.

1.4. Quality Control 1.6. Warranty and After sales service

Quality is synonymous with Siemens. Irrespective of the stated Many times Instruments are offered from different manufacturers
quality requirement in the project, every activity, delivered to meet complex requirement of power plant instrumentation.
material and services has to pass through Quality Gates as per PM Customer require single window interface who meets the
processes. Projects are executed as per the Project Management warranty obligation in terms of consumables, spare parts and
Process guide lines ensuring quality check at every critical stage. repairs services. Siemens provide strong support to fulfill the
Delivering high quality equipments is one of the Siemens customer’s expectation during the committed warranty period. In
corporate quality objectives. Following are some of the examples order to provide this service Siemens organization supports a
in the direction: dedicated team of service engineers who take over the project
from Project management group to attend warranty calls. Further,
• Engineering and Inspection of Instrumentation packages is
this group also provides after sales support i.e., beyond warranty
done based on knowledge and time proven procedures.
period, depending on customer’s need. Such services are
• Manufacturing release is driven by Siemens approved vendor’s available round the clock either remotely or by providing full time
QAP. deputation of service engineer at site.
• In stage inspection is a standard procedure during
manufacturing phase of the equipments. 1.7. Offered Instrumentation packages
• Pre dispatch inspection is imperative. Equipments cannot be Broadly, services are offered for the following instruments/
dispatched in non compliant way, is the internal requirement. packages:-
Participation during final inspection is customer’s choice.
• Process Transmitters and Switches for pressure, flow, level,
temperature measurement
1.5. Site Management
• Temperature sensors - T/C, RTD
Providing professional Site Management services to the esteemed
customers is Siemens inherent strength, being a leading EPC • Flow sensors – Orifice plate assembly, Flow nozzle / ventury,
contractor. Qualified and experienced personnel are deployed for Impact head flow meter, Rota meter, Magnetic and Ultrasonic
project and site management activities. Every site activity done is flow meter
based on time tested methodology and continually updated • Level sensor- Ultrasonic and Radar type
procedures. Efforts result in conducting, monitoring and reporting
of I&C activities in professional manner. Brief details of the various • Steam and Water Analysis System
undertaken activities are as follows. • Analyzers for Continuous Emission Monitoring
• Development of Installation and commissioning documents. • Ambient air Quality Monitoring System
• Preparation of time schedules. • Furnace Flame Monitoring System
• Materials and store management. • Furnace Flame Camera system
• Calibration of Instruments and maintaining reports. • Furnace Temperature Monitoring System
• Supervision of site activities as per Siemens internal Field • Boiler Tube Leak Detection System
Quality Plan.
• Vibration Monitoring System
• Strict implementation of personnel safety norms during routine
activities. • Turbine Supervisory Instrumentation (TSI)

• Preparation of site progress report, to be used by Project • Close Circuit Television System
Manager and for customer update. • Public Address System
• Tracking I&C progress through protocol preparation. • Power supply System – UPS, Charger, Battery bank
• Coordination with customer at site to schedule and priorities • Control and Instrumentation cables
activity to meet project mile stones
• Enclosure and Racks for field instruments
• Finalization of the construction documents for handing over to
customer. • Impulse piping complete with valves, manifold, fittings,
siphon, snubber, condensate pot, dust chamber etc.
• Handing over of plant to customer for operation.
• Instrument air distribution system
• Inventory reconciliation statements and site closure.
• Cable trays

2. Instrumentation - Key packages

Some of the Instrumentation packages are specific to the plant Steam generator specific packages are:
equipment application where as other packages are common to
the entire power plant process. Prominently the Instrumentation 2.2. Boiler Tube Leak Detection system (BTLD)
packages can be divided in three categories, for better
Enables monitoring and early detection of boiler tube leakage in
understanding of the subject. These are related to
water walls. Air borne noise, emanating from water wall tube
• Steam generator leak, is picked up by acoustic sensors as an early warning signal.
Noise developed from boiler’s fatigued structure is also detectable
• Turbo generator
by another type of acoustic transducer. Information provided by
• Common to the plant the system is useful for scheduling maintenance. Advantage to
the utility is eliminating generation loss and expensive
2.1. Steam generator maintenance caused by severe tube leakage or structural failure
detected in advanced stage. Typical system schematic is depicted
Huge pressing demands of energy at base load has set trend to by Fig-3.
build large capacity power generation plants. Installation of large
capacity unit in multiple numbers can only be the answer to the
2.3. Furnace Temperature Monitoring System (FTMS)
emerging challenge. Continuous availability of the Steam
Generator under varying fuel quality level and operating System provides information on thermal profile of the flue gas in
conditions need to be reckoned while deciding on the type of side the furnace. Commonly recommended location for
Instrumentation solution. In corollary to human body where eye monitoring the temperature is at the furnace and economizer exit
and ear provide input to mind, similarly Instrumentation of steam point in the steam generator. Details are made available in the
generator collects information on internals of the furnace and form of thermal image at the point of monitoring. Acoustic
enables control system for appropriate action. In addition, this sensors (transceivers) are installed in required numbers,
information is proactively used for scheduling maintenance, avoid depending on the boiler design. These sensors pick up the
abrupt shut down and increase plant availability. thermal behavior of the flue gas constituents which has direct

Fig. 3: Boiler Tube Leakage Detection

Fig. 4: Sensors Location Plan

relation to the heat energy carried by them. Data gathered by the 2.5. Furnace Flame Monitoring System
sensors help in plotting thermal profile at the monitoring cross
section of the boiler. Study of the thermal image pattern depicts Furnace flame monitoring is an essential component of Boiler
uniformity or imbalance of flue gas heat distribution inside the Management System. Requirement to monitor furnace flame
boiler. Corrective action is taken by control system to change the begins from the first step to successfully establish flame inside the
gun firing combinations so that heat is uniformly distributed furnace by lighting oil/gas and subsequently building up full load
throughout the flue gas path. Uniform heat distributed by the Flue firing where coal is the main fuel. Flame monitoring scanners are
gas improves heat exchangers performance to super heat the deployed to establish “Flame” or “No flame” status inside the
steam. boiler under all the operating conditions. Based on the
information provided by the scanners, boiler operation safety
System also helps in providing information on possible hot spots logic is built according to the manufacturer specifications.
inside the furnace which can lead to boiler tubes failure caused by
overheating. Further, Combustion control loop can be fine tuned Flame scanners task, after establishing flame, is to subsequently
by using the information provided by the system. Typical provide authentic information on existence of the subject flame
schematic is depicted by Fig-4. 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
2.4. Furnace Camera System illuminated sources. Scanners performance is adjudged by the
discriminating and flame evaluation capability under various type
System monitors the fuel flame pattern inside the boiler furnace
of conditions prevailing inside the furnace e.g., variations in the
by directly looking at it. Data collected by the camera is used to
fuel quality like dust contents, high humidity level during rainy
plot heat dissipation pattern from the flame formed inside the
season, fly ash surrounding flame zone to name a few. Such
furnace zone. Adverse information picked up by the system can
gathered information through the scanners system enables the
be used by control system to take corrective action to balance out
operators to decide on course of action to be taken for regulating
the flame formation. Complementary information on hot spots
the firing to meet generation target.
and boiler tube condition can also be observed by the cameras.
Typical system schematic is depicted by Fig-5. 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

2.6. Turbo Generator control system quickly for corrective action. Also information
gathered by the system is useful to the experts to do online health
Turbo generator specific Instrumentation package is: monitoring and diagnosis of the running machine.
Turbine Supervisory Instrumentation (TSI) Information on machine operating close to or crossing operating
limits is provided by the system for operator action. Information
Most critical Instrumentation need in the entire power plant,
provided by the system is also used to schedule the preventive
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 Typical measurement associated with TG set are Rotor shaft and
of the machine can lead to devastating situation exposing human bearing vibration, Differential expansion of rotor and casing,
life to unprecedented danger. Fine control and safe operation of Casing expansion, Thrust bearing pressure, Rotor eccentricity, Key
the TG set is dependent on the information provided by TSI phaser and Temperature monitoring of Bearing, Turbine casing,
deployed to monitor the operating conditions of the machine. Generator winding, Governor valve position. Turbine speed
Therefore, importance of right selection of TSI can be well monitoring is most important parameter for turbine protection
understood by one and all in power plant environment. interlock which is measured with multiple redundant sensors.
Function of the TSI is to closely monitor the operating parameters Siemens being leading manufacturer of the turbo-generators
of the TG set under all operating conditions i.e., right from a) Cold worldwide, genuinely understands the imperatives of condition
start up to synchronization; b) Load ramp up to load throw off; c) monitoring needs of the machine. Therefore, TSI solution offered
Hot role back to load change; d) Normal running to trip condition, by the Siemens is comprehensive and comes with lot of
are some of the routine situation in power plant. Instruments innovative value addition for the customers benefit. Typical
selected shall be sensitive to situation change and report it to the schematic is depicted by Fig-7.

Fig. 7: Turbine Supervisory Instrumentation

3. Instrumentation Common to plant

Instrumentation packages elaborated below are common to the 3.3. Temperature sensor
entire plant.
Thermocouple and RTD are the most commonly used devices.
3.1. Process Transmitters Different types of thermocouple and RTD are available to choose
from, depending on the process temperature and location
are used to generate analog signals to monitor various process environment. Mechanical design of the process stub, Thermowell
values such as Pressure, Level, Flow etc. Transmitters can be design and immersion length are extremely important parameters
mounted local or remote to the process. Care needs to be taken so associated with selection of the temperature sensor. Relaxation in
that range selected of the transmitter is suitable to cover entire meeting the stated requirement can lead to accident and may be
spectrum of the operating conditions. Right from cold start up to plant shut down. Location and orientation of the sensor in piping
extremely disturbed process condition related measurement shall system influences the reliability and accuracy of the measured
fall with in the selected range, is the right approach 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.

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

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





1/2" NPT(M) X ½" OD COMP.

3 SEAMLESS TUBE, SS, 20mtr ~

1/2" OD X 0.065" WT



CLASS 800, 1/2" OD COMP. END

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

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.
Fig. 10: SLD of Parallel Redundant Ups

3.12. Uninterrupted Power Supply system 3.14. Battery bank

Broadly 1 phase, 50/60 Hz, 230/110V AC power supply is required Depending on customer’s choice, batteries can be maintenance
to power operating and monitoring system. Good UPS system free Lead Acid or NiCad type. Single or block cells can be offered
provides reliable and quality power supply in uninterrupted according to the available space. Battery health monitoring
manner. Quality of UPS output is adjudged by the regulation system is integral part of the battery bank. Health monitoring is
tolerance of Voltage, wave formation, frequency, transient load done at each cell level and information can be interfaced to
change variations etc. to be better than the specifications of the control room for operator’s information.
connected loads.
Battery bank engineered by Siemens has in built provision to cater
Parallel redundant with maintenance bypass is a well accepted full load requirements under all operating conditions for the life
UPS configuration. System normally operates in equal load time of the power plant. While sizing the battery bank, aging,
sharing mode. Failure of one UPS stream bump less transfer the design margin, temperature compensation etc are factored in to
100% load to the second stream. Common battery bank is the last deliver robust solution.
resource to deliver power supply. Bypass line can be cut in to feed
the demand under scheduled maintenance period of UPS. Bypass
3.15. Water chemistry
connection is established in make before break manner to avoid
any brown outs. Isolating transformers are provided to arrest the Requirement of water and steam in power plant processes is of a
fault arising from loads or UPS to protect higher level of raw specific quality. Health and availability of the power plant
power supply system. Refer Fig-10 for single line diagram of equipments is directly influenced by the contamination level of
parallel redundant UPS. the water and steam quality. Higher level of contamination simply
deteriorate the power plant overall efficiency. Conductivity, pH,
3.13. Charger system - 24V DC power supply Dissolved oxygen, Residual Sodium and Hydrazine, Dissolved
Silica, Hydrogen are the main constituents to be monitored and
Automation system power supply requirement is generally of 24V controlled in water and steam cycle.
DC. Rectifier cum chargers complete with battery bank fulfills the
requirement. SMPS based rectifiers is the favorite choice of the Stated measurements are monitored online on continuous basis.
designers because of the higher overall efficiency. Dual parallel Preferred concept is to collect samples at a central place near
configuration with common battery bank is common in demand. control room in chemist’s laboratory. These samples need to be
Besides feeding the loads, chargers also provide window to boost conditioned in terms of Pressure, Temperature and Flow rate to
or float charge the batteries. meet microprocessor based electronic analyzer requirement, is
important factor in system design and engineering.

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
Siemens engineered solutions ensure continuous availability of followed. Most of the rotating equipments need vibrations
samples in safe manner to provide reliable data. Analyzer monitoring system during the commission phase and
selection is based on sample location and sensitivity to monitor subsequently to track it’s wear and tear condition.
ingress of actual contamination possibilities. Sample conditioning
components are selected to ensure safe availability of samples for Depending on the type of bearing and RPM of the rotating
the life time of power plant. 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
3.16. Gas Analytic the sensors along with mounting pads, monitors, diagnostic suite
and optional interface to the third party. Besides Siemens own
Chemistry of the Flue gases escaping furnace provide vital data
system, it can also be offered from the customer’s preferred
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 3.19. Control and Instrumentation cables
Sulfur and Nitrogen oxides provides information on environment
pollutant level. Particulate emission rate through chimney Role of cables in automation package is like importance veins in
indicates ESP efficiency. human body. Signal transfer or say communication among all the
C&I components is mainly through cable network. Therefore,
Siemens offer complete range of analyzers to monitor flue gas technically correct type of cable is needed to transmit the signals
chemistry and provide required information for corrective action. while taking care of distance of transmission and associated noise
Both line mounted and extractive type of analyzers are available. attenuation requirements in power plant environment. Higher use
Skid mounted solution containing sample conditioning of multipair / multicore cable can help in cable package cost
equipments are available from Siemens for the extractive type of optimization.
analyzers. Alternatively, gas analyzers installed in air conditioned
containers suitable for field mounting can also be the option to Siemens participation help customers in developing cable
choose from. 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.

Multi Component Gas Analyzer - ULTRAMAT

Fig. 11: Cable Block Diagram

3.20. CCTV system station can be under surveillance from central monitoring control
room where operators can keep watch round the clock.
Considering vast expanse of power plant premise and access
difficulty in attending all the plant machinery, it is extremely Event capturing can be pre engineered to arrest happening
challenging to arrange for round the clock surveillance all over by sequence with pan tilt and zoom functions for each camera
deploying personnel. Event capturing and monitoring difficult location. Data collected from all the cameras can be used for
locations in power plant can be effectively managed by installing instant analysis or can be archived for future use. Refer Fig-12 for
Close Circuit TV system at the pre identified locations. Entire system configuration of CCTV.

Fig. 12: System Configuration CCTV

Fig. 13: Block Diagram PAS

3.21. Public address system 3.22. Lab Instruments

All the personnel present in the plant at various locations need to Instrument laboratory is a standard requirement in every power
communicate with each other. In addition, certain safety related plant. Large spectrum of complex instruments of different
or otherwise important information, whenever required to be manufacturers is required for the testing and calibration of the
announced/broad casted in the power plant, public address various Instruments installed in the plant. Electronic and
system fulfills the required role. Adequate number of Telephone Mechanical test benches are the major components among the
handsets and speakers are installed at the predefined locations. total requirement portable devices are also needed to monitor the
These equipments are wired to local telephone exchange each operating conditions of plant machinery.
area wise. Such geographically distributed exchanges are
networked through Fiber-optic /wireless link to provide integrated Siemens can provide single window solution to set up modern
communication connectivity. It is also possible to interface Instrument laboratory along with other offered Instrumentation
internal network with external network by taking permission from solution and services for the plant.
the local authority. Refer Fig-13 for block diagram of PAS.

3.23. Miscellaneous packages • Interface between high voltage (110V/220V AC) field input
to low voltage (24V DC) control system signal.
Some of the complementary packages falling between
Instrumentation and Control system are also offered for specific • Any other customized application can be offered
– Control room furniture for the Control system.
– Field Interface Modules (FIM) are available to provide
– Development of customized control panels.
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 3.24. International Standards
mounting. Typical functionality provided by the FIM is as
follows: Design engineering of various instrumentation packages is done
in accordance with International Standards; IEC, IEEE, ANSI, ASME,
• Signal multiplication of single field sensor output for DIN. These products are delivered with UL, CE certification
redundancy purpose. depending on application. Any other conformance according to
• Provision of optical/electrical isolation between field signals application specific need can also be considered during the
and control system. design engineering phase.

• Field signal isolation through knife switches for testing Installation & commissioning is carried out in line with jointly
purpose during commissioning phase. accepted Field Quality Plan. Special emphasis is given to
personnel safety working at site. Audit check by certified
• Compact Power supply distribution (24V DC) for automation
engineers related to installation practices & personnel safety is a
routine activity.
• Diode auctioneering for redundant power supply feeders.

4. Inference

Instrumentation solutions offered by Siemens are comprehensive, management group. Professional approach of Project
world class and tailored to meet power plant specific needs. Management Procedures ensures timely delivery to meet project
Return on customer’s investment is rewarded instantly through mile stones. The biggest advantage to the customer is:
the cost effective bulk procurement efforts by Supply chain

“Siemens offer One Stop Shop Solution for all Power Plant Instrumentation needs”.

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: Mobile: +91 9830006653
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: Tel. (Dir.): +91 44 28334608
Mobile: +91 9867665588 Mobile: +91 9962592826
E-mail: E-mail:

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

For any Technical Documentation, pls visit
For any general queries and technical support, pls write to us at

Siemens Ltd. Contact Person: Mr. Kuldeep Tickoo / Mr. Aditya Dubey
Energy Sector - Fossil E-mail:,
Plot - 6A, Sector - 18, Maruti Industrial Area
Huda, Gurgaon - 122 015.
Tel.: +91 124 2846000
Fax: +91 124 2846141
E-mail: Customer Care Toll free no. 1800 419 7477 Email: 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.