Process Instrumentation

and Analytics for Power

Precise process monitoring in tough
environments

usa.siemens.com/power
Reliable and precise process monitoring
Siemens has extensive and in-depth experience of the power industry. Our process instrumentation and

analytics portfolio gives you the precision and integration into the automation system you need to ensure the

best efficiency, reduced emissions, energy optimization and safety, whether you are modernizing existing

operations or developing new facilities.

Siemens instrumentation and analytical products help Ensure environmental compliance and lowest
power producers to efficiently adapt to the ever increas- emissions by:
ing energy demand and also incorporate the flexibility • Intelligent process control for optimal flue gas treatment
needed to support renewable green energy. and CO2 reduction
• Continuous emission monitoring systems
Process control is integral to plant safety and environmen-
tal compliance. Partnering with Siemens provides the Enhance safety and security using:
reassurance of best-in-class products to help you deliver • SIL standard instrumentation giving tighter control and
optimum performance and productivity. improved safety
• Smart instruments reducing the need for field mainte-
Our technology matches to the rigors of power generation
nance and keeping workers safe
where high temperatures and pressures are common
place. Reliability in arduous applications is paramount and
Siemens products are designed to meet the challenge.

Optimize power generation whilst decreasing

operating costs and downtime through:
• Precision measurement for critical application
management
• Reliable devices for safe and efficient power generation

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Comprehensive portfolio to match your
needs
Whether in energy from waste, coal-fired, combined cycle or other power plants, we have process instrumenta-

tion and analytic solutions to match your needs. The following pages provide you with information to select the

best device for your application. To find information about all our application solutions including interactive

process charts, visit: www.siemens.com/sensors/power

Coal-fired power plant

Gas analyzer for optimized

Coal bunkers stock supervision
burner control

For economic fuel management, continuous supervision Power plant efficiency requires continuous monitoring
of the coal stock is essential. Non-contact, high-fre- and optimizing of the combustion process. Optimal fur-
quency radar technology offers a reliable and accurate nace control means continuously monitoring of either
solution for level measurement in harsh, dusty just O2 or O2 together with CO or even CO2 concentra-
environments. tion directly in the combustion chamber.
Preferred device: SITRANS LR560 Preferred device: ULTRAMAT 23 and OXYMAT 61
Alternative device (in-situ): LDS 6
• High-frequency 78 GHz FMCW non-contacting tech-
nology ensures reliable operation in dusty environ- • Low installation costs of the ULTRAMAT 23 through
ments up to 100 m range multi-component design for measuring up to three IR
• Lens antenna eliminates large parabolic or horn an- active constituents and optional electrochemical cells
tennas, providing a narrow 4 ° beam angle for O2
• Unaffected by changing coal characteristics • OXYMAT 61 is an oxygen analyzer for standard
• Reduced maintenance through integrated purge con- applications
nection for easy cleaning of heavy buildup without • LDS 6 is an in-situ real-time laser analyzer for mini-
­removing the sensor mum installation requirements and fast response
• No influence or delay due to gas sampling /conditioning
www.siemens.com/sensors/coal1 • Integrated self-calibration loop for minimal mainte-
nance

www.siemens.com/sensors/coal3
Pulverized coal flow detection

Pulverized coal is pneumatically conveyed to the burner

through distribution lines. To ensure coal is routed cor- Reliable monitoring of main steam
rectly and steadily flowing, monitoring needs to be in
place. Early detection of line blockage allows prompt Ultra-supercritical installations generate temperatures
remedial action. and pressures in excess of 600 °C and 250 bar. To
ensure optimal performance it is vital that pressure and
Preferred device: SITRANS AS100
temperature in the water-steam cycle are monitored
• Flow detection through non-invasive sound detection continuously and accurately.
• Easy mounting and maintenance through multiple
Preferred devices: SITRANS P DSIII and SITRANS T
mounting options such as screw in, bolt on, weld, or
bond in place • Remote mounting capability of the transmitter
• Continuous coal flow detection with high sensitivity allows isolation from high temperatures and vibration
and fast reaction time sources
• High pressure ranges combined with a robust
www.siemens.com/sensors/coal2 transmitter for harsh applications
• Local display and local programming with push
buttons, accessible without opening the enclosure
• Advanced communications, long-term stability and
predictive maintenance functions enable extended
maintenance cycles
• SITRANS P DSIII has high turndown ratio that allows
one transmitter to cover a wide range of applications

www.siemens.com/sensors/coal4

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 COAL HANDLING / HEATING / WATER-STEAM LOOP / GENERATOR / GRID FEEDING
STEAM GENERATION
Coal Gas analyzer for
optimized burner
control Reliable monitor-
ing of main steam

Coal silo
Boiler
Steam turbine

Mains
Transformer

Generator

Ignition gas
Cooling water

Heating fuel Condensor

River
Feeding pump Flow measure- Cooling tower

ment at the
Coal bunkers stock cooling water inlet
supervision
FLUE GAS TREATMENT
Ammonia
water
Coal Intake
mill heater Electrostatic Induced draught
filter fan

Pulverized coal DeNOx plant

Slag removal
flow detection
Ambient air
Slag storage

Effective DeNOx
DeSOx
air supply control plant

Stack

Level control of
Fly ash limestone
Limestone suspen- silo
suspension supply
sion flow and density Level

measurement Flow

Pressure

Gypsum
storage Temperature
Lime silo

Weighing

Process protection
Process
water CGA

In-situ
Limestone
suspension
Positioning

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 Flow measurement at cooling Level control of limestone
water inlet suspension supply

Sufficient cooling water flow strongly influences the Flue Gas Desulfurization (FGD) is typically used to
performance of a power plant. Flow measurement has remove SO2 from the flue gas. Lime suspension is used
to cope with large pipe diameters, high water velocity as a reagent in FGDs, produces vapor, dust and depos-
and the risk of abrasion. Considering this criteria, non- its which can make measurement difficult. For efficient
intrusive, clamp-on flow measurement is the ideal SO2 removal, the reliable and steady supply of lime sus-
solution. pension in the FGD is vital. This can be achieved by
non-contacting level measurement.
Preferred device: SITRANS FUS1010
Preferred device: SITRANS LR200
• Suitable for pipes up to 5 m diameter and larger
• Easily retrofitted as it is non-intrusive and can also be • Continuous level measurement offers a cost-effective
calibrated without stopping the flow solution with a high immunity to buildup, vapor and
• Unaffected by changing characteristics of the medium condensation
• Low maintenance costs due to external, simple • Process intelligence and Auto False-Echo Suppression
clamp-on installation as standard, giving superior performance in process
vessels
www.siemens.com/sensors/coal5 • Low maintenance costs and reduced cleaning due to
the non-contacting principle

www.siemens.com/sensors/coal7
Effective DeNOx air supply control

The DeNOx plant of modern units is characterized by a

Limestone suspension flow
hot environment with high vibration. For sustainable
and density measurement
NOx reduction, the ratio between air flow and ammo-
nia is essential. A reliable solution for the control of Density and flow of limestone suspension in flue gas
air supply is to equip the pneumatic valve with the desulfurization need to be measured to ensure a stable
SIPART PS2 intelligent valve positioner and a remote- scrubbing process for efficient SO2 removal. Using the
mounted non contacting sensor (NCS), keeping the coriolis principle for flow metering, both density and
positioner away from the harsh environment. flow are available in one device, minimizing installation
and maintenance costs.
Preferred device: SIPART PS2
Preferred device: SITRANS FC430
• The industry benchmark for linear and rotary valves,
double- and single-acting actuators • Offers high accuracy over a wide range of flow rates
• Easy retrofit with a variety of mounting options • Low life cycle costs due to multi-variable measure-
including remote mounting ment in one device
• Simplified programming due to automated • Advanced communications allow access to multiple
spanning capability process variables
• Advanced diagnostics including predictive • Easy retrofit due to the compact size
maintenance
• Extremely low air consumption www.siemens.com/sensors/coal8

www.siemens.com/sensors/coal6

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Combined cycle power plant
STEAM GENERATION Stack

Steam
Steam drum level drum

control Boiler
Steam drum level control

As a result of the fast-growing renewable energy gen-

eration, the demand for fast load changes in traditional
power plants is significantly rising. Therefore a reliable
drum level control is vital for ensuring the operation in
Feed water tank
all load cases. Feed water pump

A too low level will trip the boiler to avoid overheated

Calorific value
boiler tubes, or a too high level can cause damage in Condensate
polishing measurement of
the steam turbine through insufficient moisture separa-
fuel
tion within the drum. Mixed bed
filter Cation Gas turbine
Preferred device: exchanger

SITRANS P DSIII Differential pressure transmitter Universal flow

Alternative device: measurement
SITRANS LG200 Guided wave radar Filter

• Standard devices offer comprehensive diagnostics DEMINERALIZATION

and simulation functions with high reliability Cation Anion Mi
• Suitability for use in SIL circuits and redundancy Regeneration
exchanger Degasser exchanger filt

• SITRANS LG200 measures accurately in applications Neutralization

of corrosive vapors, saturated steam with quick fill/ Raw

water
empty rates and vacuum
HCI NaOH
• Suitable for high pressure and temperature
applications Level measure-
ment in water
www.siemens.com/sensors/combined1 treatment

Calorific value measurement of fuel

Accurate water-steam cycle flow
To provide optimum control of the gas burners, contin-
uous information on natural gas quality and physical Steam flow is often measured using differential pres-
properties, such as calorific value and density, are sure (DP with an orifice plate as the primary element)
required. Timely, accurate and reliable measurement or with a Vortex flowmeter because of high pressure
of gas quality ensures a more efficient combustion and temperature conditions as well as the non-
process. conducting nature of the medium.
Preferred device: SITRANS CV Preferred device: SITRANS FO Orifice flowmeter
Alternative device: SITRANS FX300 Vortex flowmeter
• High separation performance of gas components with
low detection limits • Orifice flowmeters are very robust and can be used in
• High linearity over the entire measuring range reduc- a wide range of pipe diameters
ing the need for expensive calibration gases • Accredited to international standards
• Mounted directly at the sample extraction point re- • No calibration required as system is standardized
ducing the need for expensive shelters and sample • Remote mounting capability
conditioning • Vortex flowmeters provide three process variables
in one device (flow, temperature, pressure)
www.siemens.com/sensors/combined2 • Easy installation
• System redundancy available with a dual transmitter
version

www.siemens.com/sensors/combined3

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 GENERATOR / WATER-STEAM LOOP /
GRID FEEDING

Level measurement in water treatment

Transformer Complex water treatment systems are installed to supply

Mains the power plant not only with high-quality demineralized
water, but also with service water for cleaning or for fire
Accurate water-
fighting in emergency cases.
Air
steam cycle flow
Level measurement on inlets, basins, process vessels,
Gas pump stations, filter beds and storage tanks are all
required to ensure the water supply of the plant.
Steam
turbine Makeup water Preferred device: SITRANS Probe LU
Alternative device: SITRANS P200
Generator
Condensate pump • SITRANS Probe LU is an entry-level 2-wire loop-
Condensor
Cooling water
powered ultrasonic transmitter for level and flow
Leakage control monitoring of liquids, providing cost-effective high
of makeup water performance
• The SITRANS P200 transmitter is a compact single-
ixed bed
range transmitter for hydrostatic measurements of
ter Level Weighing aggressive and non-aggressive media
• Price-effective compact units with easy installation
Flow CGA
and simple start-up
Pressure In-situ

River www.siemens.com/sensors/combined5
Temperature GC

Positioning

Universal flow measurement

The water treatment process contains many flow

measurements e.g. raw water, chemical dosing, back
Leakage control of makeup water washing. A universal flo meter with a large variety of
liners and diameters ensures a perfect fit for
Power plants operate with high-quality demineralized almost every water application with a minimum of
water. It is used to feed the water steam cycle to make conductivity.
up for losses due to blow-down or sealing issues. By
Preferred devices: SITRANS F M MAG 3100 / MAG 6000
continuously monitoring the makeup water flow rate,
abnormal conditions can be detected and operating • SITRANS F M MAG 3100 is an electromagnetic flow
costs can be controlled. Water is demineralized to sensor with a large variety of liners, electrode materi-
remove impurities that will effect the process. Its al and with grounding electrodes as standard. All this
characteristic low conductivity makes the ultrasonic ensures a perfect fit for almost every flow application
flow principle the ideal choice. • The SITRANS F M MAG 6000 transmitter is engineered
for high performance, easy installation, commissio­n­
Preferred device: SITRANS F US SONO 3100/FUS060
ing and maintenance. It is robust, suitable for general
• Reliable flow measurement on non-conductive liquids applications and can be fitted with communication
• Wide measuring range with high accuracy modules
• No pressure drop keeping system pressure standard
• Long-time stability www.siemens.com/sensors/combined6
• Transducers can be replaced under pressure, reducing
maintenance costs

www.siemens.com/sensors/combined4

9
Energy from waste plant
ENERGY FROM WASTE PLANT

Ensuring raw material fuel supply

Intake bunkers and cranes play a crucial role in modern Ensuring raw material
energy from waste power plants. It is important that the fuel supply
continuous material handling system, from waste arrival, Feed water
pump
through separation, to combustion, is controlled effec- Steam
drum
tively. Level measurement in bunkers and automated
crane positioning both play a critical part in this process. Boiler

Preferred device: SITRANS LUT400

• Compact, long-range ultrasonic controllers for contin-
uous level or volume measurement of liquids, slurries,
and solids
• Fast and reliable response with integral digital over-
ride
• Low life cycle costs based on easy installation and fast
commissioning
• Minimum spare parts due to compatibility with all Recycled waste

Echomax® transducers Fly ash

www.siemens.com/sensors/waste1 Pit Grate

Bottom ash
Accurate weighing of by-products Accurate weighing
of by-products
When using waste to generate energy, by-products
such as ash, metals and aggregates are produced. To
optimally manage these products, they are weighed in
flight due to the continuous nature of the process. An
accurate beltscale mounted on a conveyer provides the
Monitoring of fly ash loadout
necessary information about the feed rate and total
weight to enable resale.
Fly ash is a valuable by-product from power generation
Preferred device: Milltronics MSI and is often used as a cement substitute. Being able to
accurately measure the bulk solid flow of fly ash with a
• 0.5 % accuracy with a single idler system
solids flowmeter is critical to the downstream handling
• Outstanding accuracy and repeatability
process.
• Unique parallelogram style load cell design minimizes
external mechanical influences Preferred device: SITRANS WF330
• Fast reaction to product loading; capable of monitor-
• Continuous monitoring of the material flow without
ing fast-moving belts with light product loading
interrupting the process
• Rugged construction, reducing maintenance needs
• Requires minimal maintenance or recalibration after
www.siemens.com/sensors/waste2 the initial installation and material tests
• Performs in situations where other weighing devices
cannot be integrated into an existing process: the
compact size makes them easy to install without
major modifications

www.siemens.com/sensors/waste3

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 GENERATOR AND GRID FEEDING

Emission monitoring
Steam turbine Generator

District The Gasmet CEMS FTIR measuring system is designed

heating
for continuous emission monitoring (CEM). By use of
r
Fourier Transform Infrared (FTIR) spectroscopic tech-
Accredited heat
nology it typically monitors H2O, CO2, CO, NO2, SO2,
metering Transformer Mains
HCl, HF, and NH3 in emission gases.
Preferred device: Gasmet CEM
Filter level • A standardized emission monitoring system which
detection reliably covers all requirements associated with
Cyclone / Scrubber

Level sampling, sample preparation, and gas analysis

Bag house • It contains the Gasmet FTIR gas analyzer, an industrial
Flow
computer and a sampling system, it may be enhanced
Pressure with an optional ZrO2 oxygen analyzer and/or a total
Monitoring of fly ash organic carbon analyzer FIDAMAT 6
loadout Temperature
• Depending on the configuration, certified measure-
Weighing ments according to European WID and LCPD guide-
Stack
lines as well as compliance to US EPA guidelines are
Process protection
supported
CGA • The operation of the system is fully automatic and
In-situ
controlled by the Calcmet software ensuring reliability

GC www.siemens.com/sensors/waste5
Emission
monitoring Positioning

Accredited heat metering

Frequently cogeneration of power and heat is found in

energy from waste plants. Following power generation
Filter level detection
the exhaust steam supplies district heating systems via
a heat exchanger. To ensure efficient performance, the
Bag filters and ESPs remove particulates from the flue
monitoring of the heated water flow is the key process
gas prior to entering the stack. The particulates are
for metering delivered thermal power. The ability to
deposited in the dust collectors below the filters. Col-
accurately monitor and control water flow and derive
lectors overfill often require manual labors to clear and
energy usage is paramount for optimal operation.
will trip the flue gas cleaning process. Each collector is
equipped with a high-level switch to automate the Preferred device: SITRANS FUE380
emptying process. For high reliability, the level sensors Ancillary device: SITRANS FUE950
need to be resistant to high temperature and abrasion.
• SITRANS FUE380 is a high-performance ultrasonic
Preferred device: Pointek CLS300 flowmeter ideal for high-volume water-based
applications
• Unaffected by material buildup in the active shield
• Available in a wide range of sizes and approved for
section ensures reliable operation
custody transfer
• Operates in extremely abrasive conditions because
• Low maintenance costs due to proven measuring
of the solid rod construction reducing maintenance
principle and welded construction
requirements
• SITRANS FUE950 is a universal custody transfer
• High-temperature version for applications up to 400 °C
approved energy calculator, designed for use in
• Digital version: integral LCD display, and PROFIBUS PA
cooling / heating applications
communication
www.siemens.com/sensors/waste6
www.siemens.com/sensors/waste4

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A comprehensive portfolio for
all applications
Siemens process instrumentation and analytics has a comprehensive, proven product portfolio suitable for

arduous environments. This overview shows the entire spectrum of our process instrumentation and analytics

portfolio for the power industry.

Level
Whether you are measuring liquids, slurries or bulk solids, Siemens provides
the right level measuring technology for both continuous and point level
measurements. Regardless of the application, we provide the optimum
­solution, whether the technology is radar, ultrasonic, capacitance, electro-
mechanical or hydrostatic pressure. One of our product highlights is the
SITRANS LR560, which is the ideal solution for level measurement in coal
bunkers and dusty environments.

Weighing
The comprehensive Siemens weighing portfolio includes beltscales, weigh-
feeders, solids flowmeters and static weighing. Our SIWAREX PLC-based
weighing electronics also allow direct integration into the Siemens range of
PLCs, providing unparalleled flexibility and ease of use. Milltronics MSI
beltscales are the preferred solution for accurate weighing of by-products.

Flow
Our flowmeters meet the toughest challenges and are available for a wide
variety of applications. Highly accurate and reliable, they measure and
­monitor flow rates of gas, steam and liquids with varying consistencies.
Technologies include electromagnetic, ultrasonic, coriolis and vortex.

Pressure
Siemens offers a comprehensive range of devices for pressure measurement –
relative, differential and absolute. The outstanding accuracy, robustness and
ease-of-use make these instruments the preferred choice.

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Temperature
Siemens temperature measurement devices offer you a comprehensive
solution. They are designed to support all common RTDs, thermocouples,
resistance and millivolt sensors. The range covers head, rail and field
transmitters and includes industry-specific sensors to match all common
applications.

Process protection
A wide range of rugged and reliable process protection devices. SITRANS
AS100 acoustic sensors help operators detect blockages in pneumatic
conveying systems, while our motion sensor range ensures that mechani-
cal conveying systems maintain their set speed – informing operators in
the case of breakdown or failure and helping to increase availability.

Positioner
The electropneumatic valve positioner SIPART PS2 offers easy integration,
as well as extensive diagnostic functions and minimum loss of process
air by only using air when required. This enables operators to gain cost-
effective and accurate control over typical applications.

Gas analysis
Siemens offers a comprehensive range of products and systems for
­process analytics. It includes in-situ and extractive continuous gas
­analyzers for stand-alone and system solutions, as well as process gas
chromatography.

WirelessHART communication components

Our WirelessHART portfolio includes battery-powered transmitters, adapt-
ers as well as a gateway. With our WirelessHART solutions, users profit
not only from lower total cost of ownership but also from significantly
improved process diagnostics, productivity and security.

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Measuring everything that matters:
usa.siemens.com/pi

Siemens Process Instrumentation offers

best-in-class measurement and seamless
integration into your automation system.
We are the total solution provider for flow,
level, pressure, temperature, weighing,
positioners and more.

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Siemens Industry, Inc.

Process Industries and Drives
100 Technology Drive
Alpharetta, GA 30005
1-800-365-8766
[email protected]

Subject to change without prior notice

Order No.: PIBR-A280-1019
All rights reserved
Printed in USA
© 2018 Siemens Industry, Inc.

Subject to changes and errors. The information given in this document

only contains general descriptions and/or performance features which
may not always specifically reflect those described, or which may
undergo modification in the course of further development of the
products. The requested performance features are binding only when
they are expressly agreed upon in the concluded contract.

All product designations may be registered trademarks of Siemens AG.

All other designations in this document may represent trademarks
whose use by third parties for their own purposes may violate the
proprietary rights of the owner.