Basics of

Instrumentation & Control systems in a TPS

Role of Instrumentation & Control

Case-I
To generate 210 MW we have to introduce steam of 640 TPH at 130 Kg/cm2 and 540 oC 4% of oxygen in the flue gas indicates proper combustion Furnace pressure shall be maintained at -10 mmWcl Water level in the drum shall be maintained to ensure flow of water through boiler tubes

Role of Instrumentation & Control

Case-II
Consider Boiler Feed Pump

To Start the BFP Suction pressure should be adequate Suction valve fully open Recirculation valve fully open Lube oil pressure should be adequate

During Pump Run

Start AOP, if Lube oil pressure falls below 1.5 Kg/cm2 Stop AOP, if Lobe oil pressure reaches 3.5 Kg/cm2 Close the Recirculation valve if the suction flow is >220 TPH Open the Recirculation valve if suction flow is < 110 TPH

BFP should be Tripped if

Suction pressure < 2.5 Kg/cm2 Discharge pressure < 40 Kg/cm2 Lube oil pressure < 0.8 Kg/cm2 Working oil temperature > 130oC Motor bearing temperature > 80oC Discharge water temperature > 175oC Deaerator level < 1520 mm

Role of Instrumentation & Control

Case-III

Drum Level Super heated steam temperature Main steam pressure Deaerator level control Reheated steam temperature Furnace pressure Mill outlet temperature Oxygen percentage in the flue gas Hotwell level Heater levels

Role of Instrumentation & Controls

Monitoring the parameters Permissives and Interlocks & Protections Controlling the Parameters

Monitoring
Most common parameters that are to be monitored are Pressure Temperature Level Flow

Local Remote

Local Monitoring
Pressure - Gauges Temperature - Gauges Level - Gauge glass Flow - Flow meter

Pressure Gauge

Bourdon Type

Pressure Gauge

Bourdon Type

Temperature Gauge

Mercury Gauge

Gauge Glass

See through glass

Remote
Pressure/Flow/Level - Transducers Temperature - Thermocouple, RTD

Transducer
-Converts quantity of physical variable from one form to another -Pressure transducer converts quantity of process pressure in to Electrical quantity -Voltage Transducer (0-5, 0-10, 1-5 etc.,)

-Current Transducer Transmitter=Transduce + Transmit

Pressure Transmitter
-4-wire system of measurement -2-wire system of measurement

-True Zero (0-20 mA) measurement -Live Zero (4-20 mA) measurement

4-wire Transmitter

(0-20/4-20 mA)

+24 V DC

+
mA Load

Control / Monitoring

-Ve

Tx -

Wiring schematic of 4-wireTransmitter

2-wire Transmitter (4-20 mA)

+24 V DC
4-20 mA

+
Tx Load

-Ve

Control / Monitoring

Wiring schematic of 2-wireTransmitter

- Tx drives constant current up to a Load of 600

Transmitter

Power supply Vs Load

40

30

20
400 600 800 1000 1200

Transmitter
- Capacitance based

Thermocouple
-

Junction of two dissimilar metals in contact, produce voltage between the two (unjoined) wire ends Any pair of dissimilar metals will produce a measurable voltage when their junction is heated

Thermocouple
Voltage is directly proportional to the temperature difference between joined and open ends Commonly used thermocouples generate 5 V/oC to 50 V/oC Relationship between temperature and voltage is very much Non-linear

CJC Cold Junction Compensation

Selection of Thermocouple
Which combination gives more V/oC Which combination gives better linear relationship between voltage and temperature

Thermocouple Temp Vs volt

K-Type Thermocouple
K type thermocouple has 41 V/oC Chromel (Nickel-Chromium alloy) Alumel(Ni-aluminium alloy) It can measure in the range of -200 to +1200oC

RTD Resistance Temperature Detector

Electrical resistance of metals changing with temperature temperature coefficient of metals is of the order 0.003 to 0.007 ohms/ohm/C Most common metals used are platinum (Pt-100), nickel, copper and molybdenum

2-wire configuration

Wheatstone Bridge employed to measure the RTD resistance Lead Resistance causes error in the measurement

3-wire configuration

Flow Measurement

P1 Steam Flow

P2

DP across orifice = P1-P2

Level measurement
P1

P2

DP Transmitter

CONTROL SYSTEMS

Control systems
Control system

Open Loop Control

Closed Loop Control

Concentrated control

Distributed control

Distributed Analog control

Distributed Digital Control (DCS)

Open Loop control system

Input

Output

SYSTEM

Closed Loop Control system

Setpoint

CONTROLLER

Final control element

Output

Measurement system

Feedback path

PID controller
Proportional

controller

Controller output Error = Kp * e(t) Where, Kp =Proportional Gain

PID controller
Integral

controller

Controller output e(t) dt = Ki e(t) dt Where, Ki = Integral time constant

PID controller
Derivative

controller

Controller output de(t)/dt = Kd de(t)/dt Where, Kd = Derivative time constant

PID controller

DCS Features

Single Input can be utilized for monitoring/I&P/Control Modifications in the I&P/control can be done easily in software Redundancy Isolated Input / Output modules Remove and insert modules while powered Data Highway speed is 10/100 Mbps Centralized Engineering Station for programming, configuration Point database (Global Data) accessible at any station across the Network Facility for simulation of control logic schemes with virtual processor

Points to Remember
Monitoring Permissives and Interlocks & Protections Controlling Local and Remote monitoring Current transducers/Live-zero system (4-20 mA)/2-wire Thermocouples require Cold junction compensation 3-wire configuration of RTDs eliminate error due to lead wires resistance Distributed control system

Thank You