INTRODUCTION
TO C&I
-Gajendra Singh Rathore
Deputy Manager(C&I)
C&I
Control- Brain of the power
plant.
Instrumentation- Sense
organ of the power plant
Functions of C&I In A Power
Plant
• TO MONITOR THE PARAMETERS AND DISPLAY THE
INFORMATION
• TO CONTROL THE PARAMETERS
• TO ENABLE THE SMOOTH RUNNING OF
EQUIPMENTS (AUTO OPERATION)
• TO GIVE FEEDBACK ABOUT ANY EVENTUALITY
THROUGH ALARMS AND ANNUNCIATIONS
• TO ENSURE THE SAFETY OF THE EQUIPMENT AND
THE UNIT AND IF REQUIRED GENERATE NECESSARY
TRIP/SHUTDOWN COMMANDS
AREAS OF INVOLVEMENT OF C&I
IN A POWER PLANT
• BOILER • HYDROGEN PLANT
• TURBINE • SWITCHYARD
• GENERATOR • ASH DISPOSAL SYSTEM
• COMPRESSED AIR • HFO PUMP HOUSE
SYSTEM • CT/CW PUMP HOUSE
• DM PLANT • MGR SYSTEM
• COAL HANDLING PLANT
FUNCTIONAL BLOCK OF AN
INSTRUMENT
PRIMARY SECONDARY FINAL
ELEMENT ELEMENT ELEMENT
Primary element converts small part of process energy
into a suitable form.
Secondary element is signal converter
Final element is used for actualization or display etc
INSTRUMENTATION
• MEASUREMENT
- PRESSURE
- TEMPERATURE
- FLOW
- LEVEL
- POSITION
- ANALYTICAL MEASUREMENT LIKE O2, CO,
SILICA,PHOSPHATE, PH,SODIUM, CONDUCTIVITY ETC
• SIGNAL PROCESSING AND CONDITIONING
• DISPLAY & CONTROL
Pressure Measurement
• Pressure is measured as force per unit area
(pounds per square inch or Kg/cm2)
Force (F)
Pressure (P) =
Area (A)
• There are four basic scales used to measure
pressure:
– Gauge pressure
– Absolute pressure
– Differential pressure
– Vacuum pressure
Comparison of Pressure Scales
Pressure Definition
Standard pressure
Pressure of one normal
(standard) atmosphere
– 1013.25 mbars
–101325 Pa / 101.325 kPa
– 14.696 psia
– 29.921 [Link] / 760 mmHg @
0oC (32oF)
– 407.5 in.H2O / 33.958 [Link]
Manometers
• The most common liquid column device to measure
pressure is the manometer
• Each column is exposed to a different pressure source
• Read the rise of liquid in one column and the drop in the
other, and add them together
Mechanical Gauges
• Mechanical gauges are more rugged than liquid-
filled gauges and are often preferred
• They are relatively inexpensive and reliably
accurate
• Major types of mechanical gauges include:
– Bourdon tube
– Diaphragm gauge
– Bellows gauge
Bourdon Tube Gauge
• The Bourdon tube is a
C-shaped metal tube
• As pressure increases,
the tube coil unwinds
• As it unwinds, a needle
attached to the end
will move to indicate a
higher pressure
reading
PRESSURE MEASUREMENT
SENSORS
• BOURDON TUBE
PRESSURE MEASUREMENT
SENSORS
• BOURDON TUBE
As the pressure inside the Bourdon tube increases, the tube
deflects and this action, through a linkage and a pinion gear,
rotates the needle on the gauge.
Types of Bourdon Tube
Diaphragm Gauge
• Diaphragm gauges are
quite common in
industrial pressure
systems
• Diaphragm gauges are
typically spring-loaded as
a means of setting the
range and sensitivity
• Diaphragm gauges can be
used to measure
absolute, gage, and
differential pressures
Diaphragm Gauge
PRESSURE MEASUREMENT SENSORS
• DIAPHRAGM
• CAPSULE
• BELLOWS
Bellows Gauge
• Bellows gauges have wider
ranges of operation than do
diaphragm gauges because of
the pleated sides of the bellows
• Bellows material may be brass,
phosphor bronze, or stainless
steel
• An opposing spring is used to
control range and sensitivity
Pressure Gauge Accessories
As the Bourdon tube may be damaged by high
temperatures, it is common practice on steam systems
to install the gauge at the end of a syphon tube.
U-shaped Ring type
syphon syphon
Electronic Pressure Sensors
• Electronic pressure sensors are more
reliable, more accurate, and less expensive
than many mechanical measuring
instruments
• Two types of pressure sensors are:
– Strain Gauge
– Variable Capacitor Pressure Detector
Strain Gauge
• Strain gauges measure pressure with changing its
resistance by detecting the strain on an object
caused by pressure
• In Place of Strain of piezoelectric semiconductor
material also used as Pressure sensor
• Pressure on the elements of a strain gauge causes
the elements to expand or contract
Strain Gauge Configuration
Variable Capacitor Pressure Detector
• Uses two conductive plates
oriented adjacent to one
another and separated by air
• One plate is fixed, and the
other is attached to a bellows
• The charge of the capacitor is
influenced by the distance
between the plates, and
therefore, the pressure being
exerted on the bellows
TEMPERATURE MEASUREMENT
GUAGES
Increasing the temperature expands
the liquid and increases the
pressure
• Liquid filled systems
- GAS FILLED (nitrogen)
- LIQUID FILLED (mercury,
alcohol, xylene)
Mercury in steel thermometer
Principle of bimetallic strip
The bimetallic type temperature gauge - Consists of a coiled
bimetallic element. The gauge is based on the principle of the
bimetallic strip, which consists of two metal strips, made from
different materials, bonded to each other. The two materials are
selected so that they have different thermal coefficients of
expansion. The two metals expand by different amounts when
heated, and since they cannot move relative to each other, the
bimetallic strip bends.
Bimetallic temperature guage
TEMPERATURE MEASUREMENT
• Resistance temperature
detectors (RTDs)
• Thermocouples
RESISTANCE TEMPERATURE DETECTORS (RTDs)
Rt =Ro (1+α Δt )
Rt= Resistance at temp. “t”
Ro=Resistance at zero deg temp.
α = temp. coefficient of resistance
Δt= difference in temp.
TYPES OF RTDs : Pt-100
Cu-53
THERMOCOUPLES
Seebeck effect :--
The Seebeck effect is a phenomenon in which a temperature
difference between two dissimilar electrical conductors or
semiconductors produces a voltage difference between the
two substances. When heat is applied to one of the two
conductors or semiconductors, heated electrons flow toward
the cooler one.
TYPE T COPPER + CONSTANTAN 300ºC
TYPE E CHROMEL + CONSTANTAN 700ºC
TYPE J IRON + CONSTANTAN 800ºC
TYPE K CHROMEL + ALUMEL 1100ºC
TYPE S/R PLATINUM + RHODIUM 1600ºC
FLOW MEASUREMENT
• ORIFICE FLOW METER
• VENTURI TUBE
• FLOW NOZZLE
• PITOT TUBE
• ULTRASONICS FLOW METER
• CORIOLIS MASS FLOWMETERS
• VORTEX FLOW METER
• AEROFOIL
• ANNUBAR
FLOW MEASUREMENT
• ORIFICE
FLOW MEASUREMENT
• ORIFICE
FLOW MEASUREMENT
• VENTURI TUBE
FLOW MEASUREMENT
• FLOW NOZZLE
FLOW MEASUREMENT
PITOT TUBE
• The pitot tube measures the static and dynamic (or impact) pressures of the
fluid at one point in the pipe.
• The flow rate can be determined from the difference between the static and
dynamic pressures which is the velocity head of the fluid flow.
FLOW MEASUREMENT
• ULTRASONIC FLOW METER
• Ultrasonic flow meters measure
the difference of the propagation
time (transit time) of ultrasonic
pulses propagating in (normally
an inclination angle around 30 to
45° is used) flow direction and
against the flow direction.
• This time difference is a measure
for the averaged velocity of the
fluid along the path of the
ultrasonic beam.
LEVEL MEASUREMENT
• ULTRASONIC TYPE
• FLOAT TYPE
• LOAD CELL TYPE
• DISPLACER TYPE
• DP METHOD
• HYDRASTEP
• DIP STICK METHOD
Level Measurement (Closed Vessel)
• 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.
Level Measurement (Float)
Ultra sonic type
• Ultra sonic sensors emit high frequency (20kHz to
200kHz) acoustic waves that are reflected to and
detected by the transducer.
Radar Type
MEASUREMENT DEVICES
• TRANSMITTERS
- PRESSURE
- TEMPERATURE
- FLOW
- LEVEL
• SWITCHES
- PRESSURE
- TEMPERATURE
- FLOW
- LEVEL
CONTROL SYSTEM
COMPONENTS
• CONTROLLERS (P,PI,PID)
• ACTUATORS
- ELECTRICAL
- HYDRAULIC (OIL)
- PNEUMATIC (AIR)
• POSITIONERS
-ELECTRONIC
-PNEUMATIC
ELECTRICAL ACTUATOR
PNEUMATIC ACTUATOR
PNEUMATIC SYSTEM COMPONENETS
• E/P CONVERTERS
• POSITIONERS
• POWER CYLINDERS
• DIAPHRAGM TYPE
ACTUATORS
• SOLENOIDS
E/P CONVERTER
PNEUMATIC POWER CYLINDER
SOLENOIDS
DISPLAY DEVICES
• INDICATORS
• RECORDERS
• MONITORS
• LVS
• PRINTERS
INDICATORS
RECORDERS
LVS
MAJOR C&I SYSTEMS IN A
POWER PLANT
• FURNACE SAFEGUARD SUPERVISORY SYSTEM (FSSS)
• CLOSED LOOP CONTROL SYSTEM (CLCS)
• AUTOMATIC TURBINE RUN UP SYSTEM (ATRS)
FSSS SYSTEM
• Furnace Safeguard supervisory system is designed
to ensure the execution of safe, orderly, operating
sequence in start-up and shutdown of boiler to
prevent error of omission in following operating
procedures.
• It is a logic system and interlock which is specially
meant for increasing safety, reliability, flexibility,
and overall performance of boiler and protection
against malfunctioning of fuel firing equipments
and associated air system.
FSSS SYSTEM FUNCTIONS
• Furnace purge supervision
• Secondary air damper control
• Heavy oil control and supervision
• Mills & feeders control and supervision
• Flame scanner intelligence and checking
• Boiler trip protection in case of some abnormality
which may threaten boiler safety
FSSS PANEL AT NTPC-KORBA
FSSS PANEL AT NTPC-KORBA
AUTOMATIC TURBINE RUN- UP SYSTEM
• It is a system for acquisition and analysis of a wide
variety of information pertaining to various
parameters like speed, steam temperature, vacuum
and oil pressure warm up conditions of turbine and
associated pipelines.
• It does proper sequencing of logical steps
• Eliminates chances of mal-operation due to error,
improper judgments of the operator
AUTOMATIC TURBINE RUN- UP SYSTEM
• It is based on “Functional Group Control” philosophy
• Each Functional group is sub divided into Sub Group Control
(SGC) and Sub Loop Control (SLC).
• SGC TURBINE, SGC OIL, SGC EVACUATION
CLOSED LOOP CONTROL SYSTEM
• Air Flow Control
• Firing Rate control
• Furnace pressure control
• Feed water control /Drum level control
• PA header pressure control
• Superheater & Reheater temperature control
• Hotwell level control
• Deaerator level control
• Mill air flow & temperature control
• Coordinated Master Control (CMC)
ANALOG CONTROL SYSTEM PANEL AT
NTPC-KORBA
DDCMIS
NTPC-KORBA
Centralized Control room with back
up analog panels and DAS system
THANK YOU
