Control & Instrumentation Process

in Power Plant

- K.J.Rao
SR.MANAGER(C&I-TG)
Control & Instrumentation Process
Control & Instrumentation Process
Control & Instrumentation Process
 Boiler Instrumentation

March 13, 2020 PMI Revision 00 5

 Presentation outline
• Basic Process Measurement
•Level Measurement
•Flow Measurement
•Temp Measurement
•Steam Generator C&I system

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CONTROLS & INSTRUMENTATION
• Control & Instrumentation deals with various
measurement, indication, transmission and
control in different technical fields.
• Instrumentation is for measurement of
various parameters.
• And controlling various parameters from a
remote control room.

March 13, 2020 PMI Revision 00 7

 Instruments
• Instruments for measuring various physical quantities like
– Pressure
– Temperature
– Level
– Flow
– Turbovisory
• Vibration
• Speed etc.
– Analytical
• PH
• Conductivity
• Silica etc

March 13, 2020 PMI Revision 00 8

 Instruments
• Measuring Electrical parameters such as
– Load
– MVAR
– Frequency
– Voltage
– Current etc.
• Indicators
– Local
– Remote
• Recorders
– Single Point
– Multipoint
– Continuous
– Dotted

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 Pressure Measurement

• Manometers for low pressure.

– Water filled
– Mercury Filled
• Bellows for medium pressure
• Bourdon tube gauges for medium and high
pressure measurements

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 Pressure Measurement
• Transducers of different type for all ranges for telemetering
purpose.
– Capacitive type.
– LVDT type.
– Strain gauge type.
• Mode of connection of Transmitters
– Four Wire
– Two Wire

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• Type of Transmitter Microprocessor based 2 wire type,.
• 2. Sensor Type Capacitance/Piezo-electric
• 3. Accuracy ± 0.1% of span
• 4. Output signal range 4-20 mA DC (Analog)
• 5. Turn down ratio 30:1
• Zero and span drift ± 0.015% per deg.C at max span a and
0.11% per deg.C at min. span.

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 Level Measurement
• Floats and liquid displacers
• Head pressure measurement
• DP type
• Ultrasonic
• Direct Viewing
• Strain gauge

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 Level Measurement
• In closed pressurised vessels, Differential pressure measurement is
used to measure the level.
• One side condensate pot is used where constant level is
maintained.
• Other side is connected to the bottom of the vessel.
• Difference between these two heads gives the level.

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 Level Measurement (Closed Vessel)

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 Level Measurement (Closed Vessel)

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 Level Measurement (Float)

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 FLOW MEASUREMENT
• Controlling the flow rate of fluids is a key
control mechanism for any process plant. 
• There are many different types of devices
available to measure flow.

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 Flow Measurement
• HEAD TYPE
– Orifice Plate
– Rotameters
– Venturi Tubes
– Target Meters
• VELOCITY TYPE
– Magnetic
– Vortex
• DISPLACEMENT
– Turbine Meter

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 HEAD TYPE
• Head type devices measure flow by
constricting a stream and measuring the
resulting pressure drop. 
• The pressure drop can then be related to a
flow.

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 Orifice Plates
• An orifice plate is a very simple device
installed in a straight run of pipe. 
• The orifice plate contains a hole smaller than
the pipe diameter. 
• The flow constricts, experiences a pressure
drop, and then the differential pressure can
be related to a flow.

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 Orifice Plates

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 Rotameters
• Rather than using a constant restriction area and a variable
pressure differential, rotometers use a variable restriction
and a constant pressure differential to measure flow.
• Typically, rotometers are used to measure smaller flows and
the reading is usually done locally, although transmission of
the readings is possible.

March 13, 2020 PMI Revision 00 23

Rotameters
• The rotometer consists of a float that moves vertically through a slightly
tapered tube. 
• As fluid enters the bottom of the rotometer, the float is forced upward
until the force is balanced by gravitational forces. 
• Most rotometers are made of glass with markings on the outside so that
flow readings can be taken visually. 
• The advantage to rotometers is the simplicity of the device and a constant
pressure drop. 
• Also, rotometers do not require straight pipe runs for installation so they
can be installed just about anywhere.

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 Rotameters

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 Venturi Tubes
• A venturi tube also measures flow rates by constricting fluids and
measuring a differential pressure drop.
• Venturi tubes allow for flow measurement with lower head losses than
orifice plates.

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Target Meters
• A target flowmeter operates just as the name implies.
• A small "bullseye" is placed inside the pipe and is connected
to a pneumatic transmitter.
• Typical applications include flow measurement of steam and
outdoor liquids.
• In a target flowmeter, the square of the force exerted on the
target is proportional to the volume or mass flow through the
pipe.

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 Target Meters

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 Flow measurement
• Differential pressure flow meters • Orifice plate is a circular metal plate with a
center hole.
– Orifice pattern • In venture tube there is a gradual change in
– Venture & nozzle pattern the area.
– Pitot tube pattern • Nozzle is similar to a orifice but with a curved
form of approach
– Dall tube pattern
• Variable area flow meters
• Displacement and interferential flow
meters
• Electromagnetic flow meters.
• Ultrasonic Flow meters

March 13, 2020 PMI Revision 00 29

 Temperature Measurement

• Expansion of Solids
– Thermostats
• Expansion of Liquids
– Temperature Gauges
• Expansion of gases
– Temperature Gauges
• Thermal Electricity Thermocouples
– Type K Chromel Alumel etc.
• Change of Electric Resistance (RTD)
– Pt100
– Cu53
• Intensity of total radiation
– Optical Pyrometer
– Radiation Pyrometer

March 13, 2020 PMI Revision 00 30

 Temperature Measurement
• Expansion of Liquids and gases are used for local gauges.
• Thermocouples and RTDs are used for most of the remote
temperature measurements and controls.
• RTDs are used for low temperature applications.
• Pyrometers are used for high temperature measurements.
(NON Contact type).

March 13, 2020 PMI Revision 00 31

 Temperature Measurement

• (a) Type of Thermocouple 16 AWG wire of

chromel-Alumel (Type K) or 24 AWG wire Pt-
Rhodium Pt (Type R); ungrounded type
depending on operating temperature range.
• (b) Type of RTD 3/4 wire - Pt RTD 100 ohm
(as per DIN-43760)

March 13, 2020 PMI Revision 00 32

 Temperature Measurement
• C J C Boxes
• a) Ref. temp. 60°C ± 1.3 °C for Thermocouple
• b) Effect of ambient temp. ± 0.1% per 10°C
variation
c) Material 4 mm thick fibre glass reinforced polyster
d) Protection class of IP 55

March 13, 2020 PMI Revision 00 33

 Temperature Measurement

• Outlput signals: Analog : 4-20 mA DC

Binary : 2 NO + 2 NC for
high alarm
2. Zero & span Adjustment : Available
• 3. Ambient temp. : 60°C
• 4. Indication : Digital
• 5. Enclosure Type/Material : Weather &
Dust proof (IP 55) Die cast Aluminium/SS

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 SG RELATED CONTROL & INSTRUMENTATION
SYSTEM/EQUIPMENTS
• FLAME MONITORING SYSTEM
• COAL FEEDERS CONTROL AND INSTRUMENTATION
• ELECTROMATIC SAFETY VALVES
• FURNACE TEMPERATURE PROBES
• ACCOUSTIC PYROMETERS
• BOILER FLAME ANALYSING SYSTEM (IN LATEST ADVANCE
BOILER )

March 13, 2020 PMI Revision 00 35

 SG RELATED CONTROL & INSTRUMENTATION
SYSTEM/EQUIPMENTS
• COAL BUNKER LEVEL MONITORING SYSTEM
• ELECTRONIC REMOTE DRUM LEVEL
MONITORING SYSTEM(Hydra step)
• CONDUCTIVITY TYPE LEVEL SWITCHING
SYSTEM
• ASLD SYSTEM
• APH FIRE SENSING

March 13, 2020 PMI Revision 00 36

 THANK YOU

March 13, 2020 PMI Revision 00 37

 EHC: position controller

 Position Controller is the Final Element in the EHC. It receives

Set Point from the Transfer Circuit.

Position controller is a PID controller

Error signal is generated by comparing the selection circuit

output with the position feedback obtained from Collins
transmitter.

There are two Collins transmitters which gives output voltage

corresponding to piston position.
EHC: position controller
 EHC: position controller

Plunger coil
 EHC: position controller
 The output of the two Collins transmitter passes through a
selection gate( max/median) and the selected value is fed to
the controller.
• Plunger coil is an integrator type. Note this

• The balance position of the pilot v/v piston is achieved if -1.0V is

fed to the plunger coil.

• For moving the piston in open direction the voltage has to be

increased. Say -0.9V is fed to the coil, then piston will keep on
moving towards opening direction till the voltage again made
-1.0V.
 EHC: position controller

• Similarly if the voltage is made -1.1V, then the piston will keep
on moving towards closing direction till voltage is again
brought back to -1V.

• If at any time during operation plunger coil wire breaks, the

piston will go to full open position and plunger coil fault alarm
will be generated.

• As the piston goes to full open position, the control v/vs also
will open fully.
 EHC: position controller @recent
modification at simhadri

• Since from the inception, in simhadri stage#1:EHC System the

selection among the Collins transmitters (selection gate/ card)
is median selection.
• NOW IT IS CHNAGED TO MAX SELECTION.

• In the recent times a logic has been introduced that if there is

deviation in the EHC Collins transmitter 1&2 out put is more
than 10% and GCB on, the plunger coil will get off.
• This logic is removed now.
 EHC: position controller @recent
modification at simhadri
Now let us try to under stand the results
of it

Input set point

Out put
controller

Collins
transmitter
Max
gate

in case failure Collins transmitter gives an o/p of 5V

 EHC: position controller @recent
modification at simhadri

Suppose input is 25%

25% 2.5V 2.5V
Input set point
E=0 Out put
controller

Collins
transmitter
Max
2.5V gate

in case failure Collins transmitter gives an o/p of 5V

 EHC: position controller @recent
modification at simhadri
If now one transmitter fails
Valve will try to close
25% 2.5V 2.5V
Input set point
E=-2.5v Out put
controller

Collins
transmitter
Max
5V gate

in case failure Collins transmitter gives an o/p of 5V

 EHC: position controller @recent
modification at simhadri

Suppose input is 50%

50% 5V 5V
Input set point
E=0 Out put
controller

Collins
transmitter
Max
5V gate

in case failure Collins transmitter gives an o/p of 5V

 EHC: position controller @recent
modification at simhadri
If now one transmitter fails
Valve will stay same
50% 5V 5V
Input set point
E=0v Out put
controller

Collins
transmitter
Max
5V gate

in case failure Collins transmitter gives an o/p of 5V

 EHC: position controller @recent
modification at simhadri

Suppose input is 75%

75% 7.5V 7.5v
Input set point
E=0 Out put
controller

Collins
transmitter
Max
7.5V gate

in case failure Collins transmitter gives an o/p of 5V

 EHC: position controller @recent
modification at simhadri
If now one transmitter fails
Valve will stay same
75% 7.5V 7.5V
Input set point
E=0v Out put
controller

Collins
transmitter
Max
7.5V gate

in case failure Collins transmitter gives an o/p of 5V

 EHC: position controller @recent
modification at simhadri
 If at any time during operation plunger coil
wire breaks, the piston will go to full open
position and plunger coil fault alarm will be
generated.
 As the piston goes to full open position, the
control v/vs also will open fully.
 POSITION CONTROLLER

We expect further feedback

from operation department
to make it better -------kjrao