Basic Principle

 Efficient Operation of the plant.

 Economic Operation of the plant.

 Safe operation of the plant.

 Pollution control
This entire task is often taken up by control & instrumentation or
simply instrumentation system which has following functions:-

a) Measurement
b) Control
c) Operation
d) Monitoring
e) Protection
For a Plant Measurement system needs to be:

 Very accurate
 Reliable
 Delays should be as small as possible
 Should be switched on manually when a overall control
system fails.

 Pressure
 Temperature
 Flow
 Level
 Expansion/ Contraction
 Analysis of (1) Water (2) Steam (3) Flue Gases
And Others
Variables/ Measuring Points Types Of Approx. number
Parameters Sensors/ in the plant
Instruments
(1) Pressure (a) Boiler
(b) Turbine Bourdon Tube,
(c) Turbine Throttle Diaphragm, 375-400
Bellows
(d) Furnace
Bell Gauges
(2)Tempera (a Steam at superheater Thermocouple
ture inlet & outlet
(b Feed Water at
economiser inlet
(c Water at RTD 700-750
condenser
inlet
(d Air Preheater Thermocouple
(e Flue Gases
 (e Bearing of turbine & Thermocouple
generator
(f feed pump, RTD
condensate pump
(3) Flow (a High Pressure Steam Orifice, Venturi, 75- 100
(b Feed water inlet Flow Nozzle,etc.
(c Condensate

(4) Level (a Boiler Drum

(b condensate Differential 75 - 100
tank (c pressure methods
Water line
(5) Expansion Relative 6- 8
(a Turbine Shaft Displacement
(b Turbine casing
(6) Vibration Mass spring with
(a turbine & generator Potentiometric
shafts & bearing shells Capacitive, eddy 30- 50
current, piezo
electric & optical
types are used
(7) Analysis
(i) WATER (a feed water at econ-
-omiser inlet
(b Boiler inlet Conductive cell 8 - 12
(c Condenser with meter
(d Condensate pump
discharge
(ii) STEAM (a Saturated steam Conductive cell 4- 6
(b Main line steam with meter
(c Super heater inlet Na Analyser 1- 2
(iii) FLUE
GASE (a O2 – Economiser Zirconia cell 2-4
S to air
heater CO2 analyser 2-4
(b CO2 – Air heater
inlet CO analyser 2-4
& outlet
(c CO – stack SO2 analyser 1-2

(d SO2 - N - Oxide Analysesr 1-2

Stack
Optical method 2- 3
(e Nitrogen

Oxide- stack (f Dust

 MEASUREMENT

Terminolog
y
 Accuracy : Closeness with which an instrument reading approaches the true
value of the variable being measured.
 Precision : A measure of reproducibility of the measurements; i.e. given a fixed
value of a variable, precision is a measure of the degree which successive
measurements differ from one another. Precision means two or more values of
the measurements are closed to each other
 Sensitivity : The ratio of output signal or response of the instrument to a
change of input or measured variable.
 Resolution : The smallest change in measured value to which
the
instrument will respond.
 Error : Deviation from the true value of the measured variable.
 MEASUREMENT

Repeatability refers to the ability of a pressure sensor to provide the

same output with successive applications of the same pressure.
Hysteresis is a sensor's ability to give the same output at a
given pressure while increasing and decreasing the pressure.
 Pressure : Definitions
 Definition: Force per unit area (P = F/A)
 Absolute pressure
 Atmospheric pressure
 Differential pressure
 Gauge pressure

Importance : Pressure measurement is critical for safe and optimum

operation of processes such as steam generation, hydraulic equipment
operation, air compression, vacuum processing etc.
 Zero Reference , Gauge, Absolute, Atmospheric Pressure
 Any pressure above atmosphere is called gauge pressure
 Any pressure below atmosphere is a vacuum (negative gauge pressure)
 A bsolute pressure (psia) is measured from a perfect vacuum

Differential Pressure has no reference to either absolute vac uum or atmospheric pressure
 Units
 The SI unit for pressure is the Pascal (Pa);1Pa= 1 N·m-2

Non-SI unit pound (Lb) per square inch ( psi) and bar are commonly
used
 Pressure is sometimes expressed in grams-force/cm2or as
kgf/cm2 (KSC)
1 atm=1.03 ksc=14.696 psi=760mmHg=10000 mmWC
=101325 Pa
Standard pressure:Pressure of normal (standard) atmosphere is defined as
standard pressure
 MEASUREMENT OF PRESSURE
Pressure measuring devices are divided into two groups:
 Liquid Columns
 Expansion Elements
Liquid columns:
 Low range pressure measurement
Unknown
e.
 May be of U-Tube type or well-Type Pressure
 Elastic Pressure Sensors
The basic pressure sensing elements:

A: C-shaped Bourdon tube , B: Helical Bourdon tube , C: flat diaphragm

D: Convoluted diaphragm, E: Capsule , F: Set of bellows

Bourden Tube

 C shaped and made into an

0
arc of about 270
Material from which it made
depends upon the pressure range
of the device
 Bourdon tubes are also used
in forms other than C type:-
Spiral element: large
movement than C tube.
Helical element: produce more
or less circular movement which
is useful for driving a recorder
pen directly.
 Bellows:

Manufactured from
Brass, Brass
alloys, Stainless
steel.

Used for low

pressure
measurement.

For high pressure

measurement bellows
are connected with
spring.
Diaphragms
 Commonly corrugated diaphragms are used because large deflection can
be produced without nonlinearity compared with flat type.
 In order to increase the deflection capabilities two or more corrugated
diaphragms are welded at the circumferences--- Capsule element.
 LEVEL MEASUREMENT
 Manual method of level measurement
1. Dipstick
2. Sight Glass/ Gauge Glass

Electrical method of level measurement

3. Pressure
4. Bubbler
5. Weight
6. Conductive
7. Resistance
8. Capacitance
9. Ultrasonic
10. Radar
Dipstick
Pressure Based Level Tx
Capcitance Based Level Tx
 A universal flow meter for all applications in power station is not
available.
 Infect there are more ways of measuring flow than
measuring pressure & temperature.
 Dual function meters usually measure flow rate with linear output &
minimum error.
 Vortex & Ultrasonic meters have become available in recent years
(1986) & their full potential is not still fully developed.
 Two principle measurements are made by flow meters viz. quantity
of flow and rate of flow.
 'Quantity of flow' is the quantity of fluid passing a given point in a
given time, i.e. gallons or pounds.
 ‘Rate of flow' is the speed of a fluid passing a given point at a given
instant and is proportional to quantity passing at a given instant, i.e.
gallons per minute or pounds per hour.
Types of flow meters:
1. Orifice Flow meter
2. Vortex flow meter
3. Ultrasonics flow meter
4. Coriolis Mass Flow meter
5. Major issues for selecting flow meters
Orifice Flow-meters
Several sensors rely on the pressure drop
or head occurring as a fluid flows by a
resistance. The relationship between flow
rate and pressure difference is
determined
by the Bernoulli equation.
 Orifice Flow-meters
•An orifice plate is a restriction with an opening smaller than the pipe

diameter which is inserted in the pipe; the typical orifice plate has a
concentric, sharp edged opening.
•Because of the smaller area the fluid velocity increases, causing
a corresponding decrease in pressure.
•The flow rate can be calculated from the measured pressure drop across
the orifice plate, P1-P3.
•The orifice plate is the most commonly used flow sensor, but it creates a
rather large non-recoverable pressure due to the turbulence around the
plate, leading to high energy consumption.
 Venturi Tube

The change in cro ss-sectional area in the venturi tu be causes a pressure

change between the convergent section and the throat, and the flow rate
be determined can
orifice
from thisplate;
pressure
the venturi tube Although
substantially
more expensive
lower that
recoverable
introduces
drop. pressure drops non- an
 Coriolis Mass Flow-meters
 If a moving mass is subjected to an oscillation perpendicular to
its direction of movement, Coriolis forces occur depending on
the mass flow.
 A Coriolis mass flow meter has oscillation measuring tubes to
precisely achieve this effect.

Coriolis forces are generated when a fluid (= mass) flows through

these oscillating tubes. Sensors at the inlet and outlet ends register
the resultant phase shift in the tube's oscillation geometry.
 Major issues for selecting flow-meters

Accuracy
Repeatability
Linearity
Reliability
Range/Span
Dynamics(Response
time) Safety
Maintenance
Cost
 Measurement Devices
 Thermocouples
 Resistance Thermometers
 Thermistors
 Bimetallic Thermometers
 Acoustic Pyrometers
 Local Instruments
 Thermocouple
IT IS BASED ON ‘SEEBECK’ EFFECT WHICH SAYS THAT
WHEN HEAT IS APPLIED TO A JUNCTION OF TWO
DISSIMILAR METALS AN ‘EMF’ IS GENERATED WHICH CAN
BE MEASURED AT THE OTHER JUNCTION
T/C Connection
COMPENSATING CABLE
HOT JUNCTION

TO DDC CARDS

TERMINAL END CJC BOX

 Thermocouple
Types of T/C:E,J,K,T,R,S,B
K (Chromel & Alumel; Ni-Cr &Ni-Al) Type: mostly used in power plant for
low temp. application )
R (Platinum & Platinum-Rhodium) Type: Used for high temp. application.
Highly
resistant to oxidation & corrosion
Advantages: - Disadvantages: -
- Low Cost - Sensitivity low & low voltage
- No moving parts, less likely to be broken. output susceptible to noise
-Wide temperature range. - Accuracy not better than 0.5 °C
-Reasonably short response time. - Requires a known temperature
- Reasonable repeatability and accuracy. reference
 RESISTANCE THERMOMETER (RTD)
THE RESISTANCE OF A CONDUCTOR CHANGES WHEN ITS
TEMPERATURE IS CHANGED .THIS PROPERTY IS UTILISED TO
MEASURE THE TEMPERATURE.
Rt = Ro (1+βdT)
β = TEMP CO- EFFICIENT OF RESISTANCE ; dT = TEMPERATURE DIFFERENCE
WHERE

When discussing RTDs, following must be considered:

• Wiring configuration (2, 3 or 4-wire)
• Self-heating
• Accuracy RTD types:
• Stability 1. Platinum (Range -00 °C to 200 °C
• Repeatability )
• Response time 2. Copper (Range -100 °C to 100 °C )
3. Nickel (Range -60 °C to 180 °C )
 THERMISTORS

THERMISTORS ARE GENERALLY COMPOSED OF SEMICONDUCTOR

MATERIALS.THEY HAVE A NEGATIVE COEFFICIENT OF TEMPERATURE SO
RESISTANCE DECREASES WITH INCREASE IN TEMP.
Making use of Negative Temperature
Coefficient characteristics, thermistor and can be applied in
temperature compensation, inrush current
limit, precision temp. control (temp. coefficient very large compared to
RTC & T/C) etc.
BIMETALLIC THERMOMETERS
 ALL METALS EXPAND OR CONTRACT WITH TEMPERATURE
 THE TEMPERATURE COEFFICIENT OF EXPANSION IS NOT THE SAME FOR
ALL METALS AND SO THEIR RATES OF EXPANSION AND CONTRACTION ARE
DIFFERENT
USAGE: IN PROCESS INDUSTRIES FOR LOCAL TEMPERATURE MEASUREMENTS
OVERLOAD CUTOUT SWITCH IN ELECTRICAL APPARATUS
 Control and instrumentation in any process industry, can be compared
to the nerve system in the human being.
 The way the nerve system controls the operation of various limbs of
human beings, C&I in the same way controls and operates various
motors, pumps, etc and thus helps us to achieve our targets.
 C&I, as the name indicates, is a branch in engineering which deals
with various measurement, indication, transmission and control in
different technical field.
 The main work of C&I department is to observe, control and
manipulate electrical as well as non-electrical quantities like
temperature, pressure, vibrations.
DCS system is a process control system which

includes regulating controls, interlocks, sequential

control, operator interface, close loop controls and

open loop controls .

 I
Switch A D I I I /
P O O O
Switch B
U
O
D I I I S
P O O O
U I
G
I I I I N
O O O O A
L
S
 FSSS
FUNCTIONS OF F.S.S.S

1. FURNACE PURGE SUPERVISION

2. OIL GUNS ON/OFF CONTROL
3. PULVERISERS/FEEDERS ON/OFF CONTROL
4. SECONDARY AIR DAMPERS CONTROL
5. FLAME SCANNER INTELLIGENCE
6. BOILER TRIP PROTECTIONS
 FSSS
COMBUSTION-THE PROBLEM : WHEN THIS CONTROLLED BURNING
GOES OUT OF CONTROL DUE TO AN IMBALANCE IN THE FUEL/AIR
RATIO, THERE IS EITHER A FUEL RICH MIXTURE OR A FUEL LEAN
MIXTURE. IN BOTH CASES THE FLAME QUALITY BECOMES POOR. THERE
IS A CHANCE OF FUEL ACCUMULATION WHICH CAN LATER ON IGNITE
SUDDENLY AND CAUSE EXPLOSIONS.
SO FSSS IS USED FOR SAFE AND ORDERLY STARTUP AND
SHUTDOWN OF BOILER THROUGH VARIOUS INTERLOCKS AND
PROTECTIONS
THE PROTECTIVE SYSTEM IN THE BOILER IS DESIGNED
BASICALLY TO PREVENT OCCURRENCE OF SUCH SITUATIONS BY
TAKING ADVANCE ACTIONS.
 AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL
LOOP OPEN LOOP CONTROL:
Open Loop Control is accomplished by the following means:

 Group Control
 Sub-Group Control
 Sub-Loop Control
 Drive Level Control
 Programmable Logic Control(PLC)

 Group Control : Start and Stoppage of a Group of equipment is

accomplished by Group Control(GC).
Ex. :CEP GC, Equipment Cooling GC etc.
AUTOMATIC CONTROL SYSTEM & POWER PLANT CONTROL LOOP
Important Closed Loop Controls in a Thermal Power Plant:
a) Furnace Draft Control
b) Boiler Drum Level Control
c) HOT well & D/A level control
d) Main Steam Temperature Control
e) Air and Fuel Flow to Boiler Control
f) SH & RH spray control
g) Coordinated Master Control(CMC)
h) Turbine Speed, Pressure and Load Control
 DDCMI
S

SG-C&I SYSTEM
 BURNER MANAGEMENT SYSTEM (BMS)
 SOOT BLOWER CONTROL SYSTEM (SBC)
 SECONDARY AIR DAMPER CONTROL SYSTEM (SADC)
 AUXILIARY PRDS CONTROLS (APRDS)

TG-C&I SYSTEM
 ELECTRONIC TURBINE PROTECTION (ETP)
 AUTOMATIC TURBINE RUN-UP SYSTEM (ATRS)
 AUTOMATIC TURBINE TESTING SYSTEM (ATT)
 ELECTRO- HYDRAULIC TURBINE CONTROL SYSTEM (EHTC)
 TURBINE STRESS CONTROL SYSTEM (TSC)
 LP BYPASS SYSTEM (LPBP)
 HP BYPASS SYSTEM(HPBP)
 GLAND STEAM PRESSURE CONTROL
 GENERATOR AUXILIARY MONITORING PANEL (GAMP)
THANK YOU