Power Plant

SPPA i3000 Comprehensive Solution meets All the Instrumentation needs

SPPA i3000 Instrumentation Solution for Power Plant Automation

Answers for energy.

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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.

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.

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.

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.

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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.

Retrofitting & Upgrade projects: 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.

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 • Procurement • Quality control • Site management • Warranty calls and after sales services

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: • Coordination with Consultant, Customer, Main equipment manufacturer to decide sensor interface design with process (Ref. Fig-1). • Review of process sensor locations on piping, vessel for 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.

• 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:

• Finalization of Instrument installation hook ups (Tag wise) along with Bill of materials and their specifications.

• Release of firm Purchase Order through SAP on approved vendors. SAP driven process enables strict monitoring of the complete procurement progress.

• Produce complete field cable termination plan and laying schedules.

• Continuous coordination with customer and suppliers to meet project delivery schedules.

• Develop optimized C&I cable specifications for cost effective procurement.

• Monitoring dispatch and transportation logistics.

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1.4. Quality Control

1.6. Warranty and After sales service

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:

• Manufacturing release is driven by Siemens approved vendor’s QAP.

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.

• In stage inspection is a standard procedure during manufacturing phase of the equipments.

1.7. Offered Instrumentation packages

• Engineering and Inspection of Instrumentation packages is done based on knowledge and time proven procedures.

• 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.

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

• 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 Quality Plan.

• Boiler Tube Leak Detection System

• Strict implementation of personnel safety norms during routine activities.

• Turbine Supervisory Instrumentation (TSI)

• Vibration Monitoring System

• Preparation of site progress report, to be used by Project Manager and for customer update.

• Close Circuit Television System

• Tracking I&C progress through protocol preparation.

• Power supply System – UPS, Charger, Battery bank

• Coordination with customer at site to schedule and priorities activity to meet project mile stones

• Control and Instrumentation cables

• Finalization of the construction documents for handing over to customer. • Handing over of plant to customer for operation. • Inventory reconciliation statements and site closure.

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• Public Address System

• 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.

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

Fig. 3: Boiler Tube Leakage Detection 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.

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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

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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

3.3. 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.

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.

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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 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 interface point.

Field Instrument Enclosure 3.7. Instruments Installation Hook ups 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, 1/2" NPT(M) X ½" OD COMP.

2

3

SEAMLESS TUBE, SS, 1/2" OD X 0.065" WT

4

5 VALVE MANIFOLD, SS, ½" NPT(F)

1

5

BLOW DOWN VALVE, SS, CLASS 800, 1/2" OD COMP. END

2

6

DP TRANSMITTER

1

7

CONDENSATION POT, 3"NB, SS, 1/2" x 1/2" WELD END

1

20mtr ~

Fig. 8: Instrument Hook Up

Isolation Valve

TEE

Male Connector

2-Valve Manifold

3-Valve Manifold

5-Valve Manifold

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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 common place in instrumentation package. Wide spread Instrument air distribution network is needed to meet the requirement. Typical schematic is depicted by Fig-9.

Smart Positioner SIPART PS2

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 modulation or ON/OFF type. Siemens make of smart positioners are fitted which have nearly zero air consumption in steady state of operation. Design selection criterion of the control elements is dependent on the following: • Process medium chemistry for body material selection. • Design Pressure & Temperature parameters for body rating. • Operating conditions for Trim design selection. • Piping interface for end connection.

3.10. Plant Engineering Based on the plant layouts, piping isometrics or layout drawings and PID, Siemens can assist the customers in developing Instruments grouping for Field Junction box and Instrument Enclosure/Racks according to functional requirement. Location plans are also recommended keeping in mind the ease of operation and maintenance activities. 3.11. Vital Power supply system

• Fail safe operating condition

Normally two types of power supply systems needed for 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 and LP bypass control valves for TG island where Siemens offer expert solution. Along with HP, LP bypass control valves, solution includes control system and complimentary packages.

• 24V DC

Combined Aux PRDS station to meet customized requirement is also engineered and delivered. 14

Indeed, Power supply system is the life line of automation system engaged in monitoring and controlling the power plant generation. Therefore, reliability of the power supply system is of paramount importance.

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 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.

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.

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.

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

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)

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

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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

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.

Fig. 12: System Configuration CCTV 17

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 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.

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.

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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.

• 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.

• 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

management group. Professional approach of Project Management Procedures ensures timely delivery to meet project mile stones. The biggest advantage to the customer is:

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

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Regional Sales Offices

NORTH - Gurgaon

EAST - Kolkata

Siemens Ltd. Energy sector 3rd Floor, Plot 6A, Sector 18, Maruti Industrial Area Gurgaon, Haryana - 122015 India Contact Person: Mr. I.K. Rai Tel. (Dir.): +91 124 4697376 Mobile: +91 9818018701 E-mail: [email protected]

Siemens Ltd. Energy sector 43, Shantipalli Eastern Metropolitan Bypass R B connector, Kolkatta West Bengal - 700042 India Contact Person: Mr. Ashoke Roy Tel. (Dir.): +91 33 24449000 Mobile: +91 9830006653 E-mail: [email protected]

WEST - Mumbai Siemens Ltd. Energy sector 3rd Floor, R&D Tech Centre, Thane Belapur Road, Thane - 400601 India Contact Person: Mr. Sachin Jaguste / Mr. Neenad Wilankar Tel. (Dir.): +91 22 24987341 Mobile: +91 9819155056 E-mail: [email protected] Mobile: +91 9867665588 E-mail: [email protected]

SOUTH - Chennai Siemens Ltd. Energy sector 144, Mahatma Gandhi Road Chennai (Madras) Tamil Nadu- 600034 India Contact Person: Mr. Muralidharan Krishnan Tel. (Dir.): +91 44 28334608 Mobile: +91 9962592826 E-mail: [email protected]

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: [email protected]

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 [email protected]

Siemens Ltd. Energy Sector - Fossil Plot - 6A, Sector - 18, Maruti Industrial Area Huda, Gurgaon - 122 015. Tel.: +91 124 2846000 Fax: +91 124 2846141 E-mail: [email protected] www.siemens.co.in

Contact Person: Mr. Kuldeep Tickoo / Mr. Aditya Dubey E-mail: [email protected], [email protected]

Customer Care Toll free no. 1800 419 7477 Email: [email protected]

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.