Instrumentation and Control in CDQ Power Plant

BY

Pradeep Chotia (CDQ-PP)

 CONTROL AND INSTRUMENTATION

Instrumentation is the branch of science that correlates with the measurement

,monitoring & display of all the process parameters in an Industry.
Control is a vital part of Instrumentation which collects various field data
,Analyze, Compare and change its parameter according to system needs.
Before a condition to be controlled; it has to be measured first
Evolution of Industrial Instrumentation leads to:-
1)Qualitative and Quantitative Production
2)Increased System Efficiency and Availability
3)Reduced Variability in Process
4)Ensuring Human, Machine & Environment Safety.
5) Economical Factor.
 Why we use 4-20 mA as a standard signal?

1)Live Zero or True Zero(4 ma) is standard adopted by ISA over Dead Zero(0 mA) because it
will allow receiver to differentiate between NO INPUT and FAULT CONDITION(Open circuit,
Broken wire)

2)According to ISA Standard 20 mA is Ensuring safety for Field Instruments, I/O Modules &
Human, as 20 mA signal and 24vdc power supply is not enough to produce spark or leakage
current .
 Process Variable:-The specific quantity we are measuring in a process. Examples:
Pressure, Level, Temperature, Flow, Moisture Electrical conductivity,
PH,Voltage,Current,Resistance, Position, Speed, Vibration

,
Temperature Pressure Flow Speed Vibration Position Level PH,
Conductivity,Silica
Measurement is the process of estimating the magnitude, value and attribute of
Process Variables
one can control only what is measured

Continuous Measurement:- A Continuous Discrete Measurement:-A Discrete

Measurement is able to Indicate Infinite Measurement is only able
readings of the measured variable above or to indicate whether the measured variable is
below a predetermined state. above or below a predetermined state

Transmitters (Level, Pressure Flow, Temperature) 1)Limit Switches, Pressure Switches,Level

Speed Probes, Silica Analysers, Position switches,Flow Switches,DP
Switches,Temperature Switch
 Discrete Measuring Element:- Switch is an Instrument that
automatically senses process variable and provides an on/off signal relative to some
reference point.

1)It is Discrete/Binary/Point Signal (1-0)Measurement

2)Send Potential Free Output for Alarm or Tripping via NO, NC Contacts
3)Switches are Always perfect For Accurate and precise Measurement.
4)Discrete Signals are Always taken for Tripping because of their fast Switching action.
5)Applications:-Alarm(Status),Trip(Hi/Low Limits),Control(ON/OFF)

Sensing Switching Binary output to

Process variables Element Set Point
(Temp,Pres,DP,
Circuit DCS
Displacement)
Bourdon Tube Mechanical Switch Calibrated Potential Free Output
Predetermined State
Bellows
Diaphragm
Strain Gauge
 Continuous Measuring Device
1)SMART Defines:-SIGNAL MODULATION ,AMPLIFICATION AND REMOTE TRANSDUCER
2)Easy calibration and Troubleshooting,Fast Response time.
3) Smart transmitters can perform noise filtering and can provide different signal characterizations
4) Smart transmitters also have self-diagnostic capability and can report malfunctions that may indicate
erroneous process values.
5)Smart transmitters can be configured with a handheld terminal(HART) and store the configuration settings in
non- volatile memory.
Sensing Element Transducer convert Detector or Indicator will provide
Convert Process Mechanical Signal to Microprocessor circuit Indication of the
variable Signal to corresponding will Amplify and corresponding Process
Mechanical signal Electrical Signal Transmit the signal variable signal

Memory will save the Aspects/Properties of

Transmitter(Ranges, Tags etc)
 Pressure is defined as the force per unit area applied to an
object in a direction Perpendicular to the surface.

Pressure

Gauge pressure Absolute Pressure Differential Pressure

Gauge pressure is the pressure relative to the local

atmospheric or ambient pressure.

Absolute Pressure is the sum of the available

atmospheric pressure and the gauge pressure.

Absolute Pressure = Gauge Pressure + Atmospheric Pressure

Differential Pressure is the difference between

Pressure measured at two different points.
 Pressure Transmitter

1)When Pressure is applied to Transmitter, its diaphragm will compress and its
Piezoelectric sensor(quartz) changes its vibration frequency with reference to change in pressure.

2) Change in frequency is sensed by microprocessor and convert it into proportional voltage signal and
signal conditioning unit to convert it into electrical signal(4-20 ma) which is proportionally equivalent to the
Input Process Variable

3)Application:-Turbine Inlet MS Pressure

 Pressure Gauges

Pressure Gauge is Measuring the Total Stress in an Elastic Medium(HOOKS LAW)

The Bourdon Tube is a no liquid pressure measurement device. It is widely used in

applications where inexpensive static pressure measurements are needed.

When pressure is applied at the Primary End of Gauge, deformation of Bourdon take Place
which is Directly proportional to the applied deforming or applied force.

After Removal of Pressure it will regain its original position.

 Definition:-Level is defined as the difference between
two heights.

Level Transmitter:-Guided Wave Radar

Guided Wave RADAR Transmitters based on the Principle of Time of Flight
It Generates Microwaves of High frequency range upto 10 GHZ .
It measures the distance from transmitter to the surface of a process material by measuring
Time of Flight(Transmitting and Receiving Time Interval) of a travelling wave.
Speed of Signal is very fast.
When properly selected, radar can overcome many of the limitations of ultrasonic level
probes.
Be unaffected by temperature changes in the tank air space.
Unaffected by heavy foam and Vapors to detect the true material level.
It can give more than 70readings/sec
Application in CDQ power Plant:-MOT Level & Sump Level measurement
Hydrostatic Head Level Measurement

It is a level measurement Technique that a Liquid filled Tank will exert a

pressure whose value depends on HEIGHT,DENSITY and ACCELERATION
of Liquid and Totally Independent of Cross sectional area of Tank.
A Pressure Measuring devices can be used for HYDROSTSTIC LEVEL
MEASUREMENT.
DENSITY and GRAVITY is uniform above the transmitter tapping results in
PRESSURE directly proportional to Height at constant density and Acc. Due
to gravity(g)
(P=Height x Density x Acc due to Gravity.)
Level measurement by pressure requires a constant density for accurate
measurements.
If the Static head pressure in the tank can be other than atmospheric, we
must use a differential pressure sensor.
Application:-MOT Level, DM Tank Level
 Flow is defined as the quantification of bulk fluid
movement in a closed or open medium
Flow is measured as volume per unit time.

Measurement of Flow is based on two types:-

1)volumetric flow rate is the volume of fluid ,which passes through a given surface per unit time. is
applicable for compressible liquids only. Example:-metre cube/sec.
2)Mass flow rate :-It provide a flow rate that is in units of mass per unit time by referencing volumetric
flow and density. Example:-TPH.
Relationship:-Vol flow x Density= Mass flow(M=xV)
Factors Affecting Flow Measurement:-
1)Temperature, Pressure, Density, Viscosity, Flow Element, Medium, Type of flow.
 Differential pressure flow transmitter

It requires Primary sensing element (an Orifice or flow nozzle) to create a pressure difference for measuring
flow.
2)Differential pressure created is directly proportional to the square of flow.(DP is directly prop to square of flow)
2)That pressure difference created by flow element is given to DP transmitter.
4)Differential pressure applied between two diaphragm in transmitter directly proportional to the change in
capacitance ,Inductance, piezoelectric voltage which will be converted into equivalent electrical signal(4-20mA)
Application:-Turbine inlet MS Flow.
.
 Magnetic Float Level Switch

Principle:-When a free moving Dual magnetic Float cum switch

assembly placed in a enclosure In a non magnetic material to
achieve undisturbed magnetic flux ,a change in liquid level bring the
like poles opposite to each other resulting repulsion force tend to
change over the contacts by snap action switch

Application:- Hot well Level, GSC

 Magnetic owmeters

1)It is based on Faradays Law of Electromagnetic Induction

2)When an Electrical Conductor(water) moves perpendicular to magnetic field ,a voltage is induced in the
conductor perpendicular to both magnetic flux lines and direction of motion which is proportional to the average
flow velocity - the faster the flow rate, the higher the voltage. This voltage is picked up by sensing Metal
electrodes mounted in the meter tube and sent to the transmitter which takes the voltage and calculates the flow
rate based on the cross sectional area of the meter tube making it readable to an electronic circuit(4-20 mA)
3)It is velocity based Flowmeter which doesnt require Primary Flow Element as opposite to DP flow.
4)It is not suitable for Measurement of Flow measurement in non conductivity medium.
5)Application:-DM Plant(DMF outlet flow meter).
.
 Rotameter.

1)Rotameter is a Field Mounted Flow Measuring

Instrument used to measurement flow directly.

2) Based on Force balance Principle:-

As fluid enters the tube, the higher density of the float will cause the float to remain on the bottom .As flow
increases in the tube, the pressure drop increases. When the pressure drop is sufficient, the float will rise to
indicate the amount of flow. The higher the flow rate the greater the pressure drop. The higher the pressure drop
the farther up the tube the float rises
3)Application:-DM Plant ,Ejector flow..
 Vortex Flow meters

1)Basic Principle:-Vortex meters

operate on the principle that when a
non-streamlined(Rigid) object is
placed in the middle of a flow stream,
vortices are shed alternately
downstream of the object. The
Frequency of the vortex shedding
is directly proportional to the velocity
of the liquid flowing in the pipeline.
2)Fluid should be NON Viscous and
clean.
2)Application:-DM Plant(SBA-
1,2,Outlet)
 Ultrasonic Level Transmitter

Ultrasonic makes use of sound waves.

Sound waves are in the range of MHZ.
Not suitable for Measuring level of powder material.
A transducer mounted in the top of a tank transmits sound waves in
bursts onto the surface of the material to be measured. Echoes are
reflected back from the surface of the material to the transducer and
the distance to the surface is calculated from the burst-echo timing.
Application in CDQ Power Plant:-Neutralizing Pit Level
measurement.
Limitations of ultrasonic transducer are:
The speed of sound varies with temperature.
Heavy foam on the surface of the material interferes with the echo.
Heavy vapor in the air space can distort the sound waves resulting in false reading.
 Temperature:-It is defined as the degree of Coldness and
Hotness of a body.

Thermocouple It is a Temperature Measuring device Based on see back effect which

K Type(Chromel - Alumel) states that When two dissimilar metal wires are joined together at one
Range:(0-1260 Deg C) end(Hot Junction) a voltage is produced at the other end(cold junction)
that is proportional to temperature
RTD(4 wire,3 wire) THE RESISTANCE OF A CONDUCTOR CHANGES WHEN ITS
PT-100(Platinum) TEMPERATURE IS CHANGED .THIS PROPERTY IS UTILISED TO
(-200 to 850 Deg C) MEASURE THE TEMPERATURE.(Rt=R0(1+T)

a)Temperature ALL METALS EXPAND OR CONTRACT WITH TEMPERATURE

Gauges(Mercury filled) THE TEMPERATURE COEFFICIENT OF EXPANSION IS NOT THE SAME
FOR ALL METALS AND SO THEIR RATES OF EXPANSION AND
b)BimetallicTemperature CONTRACTION ARE DIFFERENT
Switches(Brass-Nickel)
 PLC DCS
1)It is Programmable Logic Controller 1) It is Distributed control system.
2) PLC used for particular machine/section of plant. 2) DCS is used for whole plant control system.
Example:-DM plant control system. Example:- Turbine Control system

3)PLC is a single dedicated controller, network and 3) DCS offer redundant controllers, networks, and large
limited number of I/Os capability. I/o capability .
4)PLC is FAST(Input-Compute-output Time) 4)DCS is slow (Input-Compute-output Time) as
compared to PLC.

5)PLC doesnt allow Inter controller communication 5) DCS allow Inter-controller communications
6)PLC is a Sequential Logic Controller, which will affect 6) DCS is Distributed Control System, where control
or stop the whole system if any process variation occur. elements are distributed in such a manner such that
change in particular process will not Stop the whole
system.
7)PLC Is Mostly used for Discrete Control System 7) DCS is used with Continuous and Discrete Control
System
8) PLC doesnt require too much operator intervention 8)DCS is operation need continuous monitoring by
and monitoring. operator.
9) PLC is Economical . 9)DCS is Costlier than PLC.
SFD(DCS to Field and Vice Versa)
 Communication Architecture
1) Redundant Ethernet Switches(1+1) are provided for Uninterrupted Communication between operating
stations(HMI) and Hardware ( DPUs. DPU) at high speed of 100mbps
2)All Max station can communicate with any other Maxstation(OWS or ESOS) through NET A and
NET B.
OWS-04 ESOS-01 LINK ESOS-02
OWS-03

OWS-01
OWS-02

NET B (HMI B)

NET A (HMI A)

DAVR BOP-03 EHTC

BOP-01 BOP-02 TSE +TP + GSPC ATRS
 Hardware Configuration and Communication
1)Control Panels:-It is a group of equipment that provides the control, Data acquisition &I/O Processing
functions for DCS consisting DPUs, I/O cards, Terminal Blocks, relays, Comm. N/W and Power supply.
DPU and Modules are mounted on Max PAC Backplane in 4 Racks
Each Rack is equipped with 8 slots for I/O modules and DPUs. SCADA
Sixteen Control Panels are provided for Turbine, Generator& BOP Control systems. Level-2

2) DPU:-It is a self contained microprocessor based ,rack mounted HMI

(Operating Stations)
Distributed Processing Unit which performs primary data acquisition,
Control and data processing function & act as a Hardware processing engine of DCS(Max DNA).
1)Redundant DPU /Controllers (7+7) are provided for each Functions Group units
AUTOMATION
2) Each DPU can Control Up to 60 I/O modules and 256 I/o Addresses. Level 1
3) I/O redundancy is provided in Rack-1&2 for critical Input outputs
3)Power Supply:- (DPU,I/O Modules, Relays

110VAC Supply is taken from UPS and converted into 24VDC by PSU Field Instrumenta
Separate PSUs for DC Supply distribution :-
1)System Power Supply:-24vdc For(Panel Auxiliaries){PSS-10,PSS20}
Level-0
(Transmitters, Actuators, SO
2) Field Power Supply:-24vdc For(Field Instruments){PSF-10,PSF-20} Dampers Switches etc.
4)I/O Modules:- Input Output Modules provides a method for transferring and exchanging
information(Interface) between internal storage devices (DPU) and external I/O Devices(Field Instruments) .
Max DNA DCS has following I/O Modules :-
1)Analog Input Modules: It will Transfer Analog Input Signals from Field to DPU.(Example:-Transmitters,
speed & vibration signals ,CV position Feedbacks)
2)Analog Output Modules:- It will Transfer Analog Output Signals from DPU to Field(Analog Commands
for opening and closing to Control valves.
3)Digital Input Module:-It will Transfer Digital Input signal(Binary) from Field to DPU(Position Feedbacks
of MOV,Limit Switches) Pump/Motor Run &Trip Status, RTS.
4)Digital Output Module:- it will Transfer Digital Output signal from DPU to Field(Digital Commands from
DPU to MOV, SOV, RELAY, Annunciator for alarms, Pump/Motor start & stop .
5)RTD Module:- It will Transfer RTD Signal from Field to DPU
6)TC Module:- It will Transfer TC signal from Field to DPU
 MAX DNA DCS
(CDQ Power Plant)
BOP Turbine Generator
Control Control Control

BOP01 BOP02 BOP03 ATRS

TSE+TP+GSPC
B01CRE01, B04CRE04 B07CRE07, EHTC CCA01
CJJ02 DAVR
B01CRE02, B05CRE5, B08CRE08, CJJ01 CCA03
CJJ03
B03CRE03 B06CRE06 B09CRE09 CCA03

1)ACW-A Pump, 1)APRDS System 1)MOP&AOP

2)DC EOP
2)CWP-A, 1)ACW Pump-B 2)CWP-C
3)AC-DC JOP
3)CT Fan-(1,3,4), 2)CWP-B 2)CDQ(1&2),(3&4) 1)HP and LP
4) Turning
4)SWBP-A, 3)CT Fan-(2,5) Comm HDR V/vs 1)Governing Extraction sys
Gear MOV
5)HWMKP A 4)SWBP-B 3)Ext Temperature Valves, 2)GSPC Control,
5)Turbine
3)TSE
6)Hot well Level 5)HWMKP B Control, 2)Speed I/P parameters(MS,
Drain Vlvs 1) Excitor
Makeup Control 6)Condensate B 4)MS Stop Valves 3)MS Pres., 6)CEP-A&B
ESV
7)Hotwell
2) PMG
valves(Low & isolation valves to PRDS 4)Governing Temperatures)
&Lube Oil &
High Capacity. 7)CDQ-3&4 MS 5) MS Line to system SOVs 4) TG Vibrations
OHT Level
7)CDQ-1&2 MS Line Valves Dump Valves switches
Line Valves 8)Compressor B 6)HP By pass 8)Vacuum
8) Compressor-A System Breaker Vlv
 Control Valves
1)Based on Actuator Input Signal:-
a.)Hydraulic Operated b.)Electrical Motor Operated C.) Pneumatic Operated
2) Based on Actuator Movement
a.)Linear b.) Rotary DCS(AI,AO Module)
3) Based on Fail Safe Condition

AO
a.) Air TO Open(Air Fail to Close)
b.) Air to Close( Air Fail to Open)
I/P

AI
AFR convertor
Instrument Air
C.Valve
AFR Air Lock
Supply Air Controlled Air Relay
Positioner

Feedback Link

Air Line Tubing

 Process Control Loops
A) Process Control Loops are Broadly Classified into Two Types
I)An Open Loop Control(OLCS)
II)Closed Loop Control System(CLCS)
B) The process control schemes are:
I. Feedback II. Feed forward III. Back-pressure IV. Ratio V. Cascade VI. Split Range Control VII)ON-OFF
The above control schemes can be applied to the following generic applications:
I. Temperature II. Flow III. Level IV. Pressure

C) There are Three elements that must be defined by the user for the control process.
I. Process Variable Sensing device
a.) Flow transmitter b.) Level transmitter c)Pressure transmitter d.) D.P Transmitter e.) Temp. Transmitter
II. Controller Type
a.)Proportional b.)Proportional Integral c.) Proportional Integral Derivative
III. Final Control Element (Final controlling mechanism)
a) Control valve b.) Actuator (MOV)
 Sense
Decide
Control schemes in CDQ Measuring controller
device
Influence
React
Final control
process device

1)Feedback control scheme:- Feedback control is the simplest control scheme where Process variable is
measured and the controller output is calculated based on its deviation from set point .It is applied to those
applications where disturbances are not severe. Example:- PRDS Control

2)Split range Control:- In Split range control scheme, Process variable is controlled by using two FCE (final
control elements),by splitting the range of controller output .(4-12mA/0-50%) &(12mA-20mA/50-100%) .It is
used to control critical process variable where slightly exceeding and reducing a process variable limit can
adversely affect the process. Ex:-Gland sealing pressure control
3)Backpressure Feedback control:-The most common application for a Back pressure feedback control
scheme is the elimination of Sudden high pressure from a process that will effect the process.
Example:- HP Bypass pressure control.
 Process control is the act of controlling a final control element to
change the manipulated variable to maintain the process variable at a
desired set point.
CONTROL SYSTEM: An arrangement of elements interconnected and interacting in such a way that it can
maintain some condition of a process or machine in a prescribed manner
Process is broadly defined as an operation that uses resources to transform inputs into outputs.
Set Point (SP):- The set point is a value for a Process variable that is desired to be maintained.
Transducer:-It is a sensing device used to convert one form of energy to another.
Feedback:-It is a function of Process Variable sent to summing point to identify the deviation from its
desired Set point to obtain the actuating signal.
Controlled Output Signal(CO) :-It is the processed and controlled signal (4-20ma) sent by the controller to
the Final control element to bring the process variable at desired SET POINT.
Manipulated Variable :- The factor that is changed by FCE to keep the Process Variable at its set point is
called the manipulated variable.
A final control element (FCE) is a device changes the value of the manipulated variable in accordance to
Controller output Signal to change the process output.
Disturbance (D):-It is defined as uncontrolled changes in the process inputs or resources.
Actuating signal:-It is the Difference between reference input signal(SP) and feedback signal(PV) also known
as ERROR Signal. It can be positive, negative or zero.
Controller:-It is a microprocessor based device used to monitor and physically alter the operating condition at
a given dynamic system by its controlled output.
Process Variable (PV):-It is a measure of the Process output that changes in response to changes in the
manipulated variable and disturbances.
Summing Point: It is the Junction where difference between SET POINT and PROCESS VALUE
to produce an Actuating Signal
 Closed Loop Control System:-A Closed Loop Control (CLCS) is one
where a Process Variable is measured, compared to a Set Value and action is taken to
correct any Deviation or Error from Set Value. The continuous Measurement of PV and its
comparison to Set Point closes the Loop.

Disturbances

Summing Point

Set Point Actuating Controlled FCE(Final

Controller MV Process
Signal O/P Signal control element)

PV
Transducer
Feedback Signal (Process sensing
Element)
 In open loop control:- An Open Loop Control(OLCS) is one where
the PV is not compared with Set Value and action taken, but action
is taken without regard to conditions of PV

In open loop control we are not concerned that a particular set point to be maintained, the
controller output is fixed at a value until it is changed an operator
Many processes are stable in an open loop control mode and will maintain the process variable
at a value until a DISTURBANCE(uncontrolled change in the process inputs or resources)
Occur.
Example :- SWBP Suction Pressure Control, Manual Mode, CBD& IBD operation.

Process Variable
Set Point FCE Process
Vacuum Breaker Open Loop Control System

TG
Set Point Controller

Exhaust Pressure Control

PSHH

1oo2
PSHH

Condensor
 1)HP Bypass Pressure Control Valve Closed Loop
Significance:-
1)Used to Control Upstream TG Inlet MS Pressure during Turbine Trip and Normal Condition.
2) Used to Save Precious Steam During Cold Startup and Turbine Trip Condition
Process Sensing Elements(Transducers):- Two Pressure Transmitter-(MSTPT008A-,PT-MSTPT008A)
Upstream HP bypass PCV. One Pressure Transmitter (PT-) at Downstream HP bypass PCV
Final Control Element:-HPPCV
Set Point:- 90 KSC
Controling Scheme:-Back pressure Closed Loop Feedback Control .
Controller Direction&CV Action:-Direct(PV increases ,Controller Output Increases),
Control valve action:-Air to Open
Override Control:-Under given conditions override the Loop and CLOSE the Valve Immediately
a)Exhaust Pressure above 0.2 Abs
b) Instrument Air Failure(Auto Shut off thru air Cylinder output)
c) HP by pass line Temperature More than 200
d)Both CEP Pump Trips
e)Downstream Pressure more than 6 KSC
f) Maximum Permissible Flow Capacity to Condenser exceed 162.5 TPH.
 HP Bypass Pressure Control Loop

Controller
1oo2

PT PT PT FT

Main Steam Turbine Inlet

HP Bypass Dump Line

Condensor
 HP Bypass Temperature Control Valves-(Main and Dump TCV)
Significance:-
1)Used to Control Downstream Temperature when HP PCV is in Operation( condenser tubes Protection)
2) It will Not allow to Dump Steam to condensor at high temperature otherwise vacuum will drop abruptly.
4)It will Decrease the temperature from 530 to less than 200 degree during Turbine Trip.
Process Sensing Elements:-Two Temperature Transmitter(TT001A,TT001B) at Downstream of HP Bypass
Temp Control Valve
Set Point:-62 deg C
Final Control Element:-TCV 1617 and TCV 1616
Control Scheme:- Closed Loop Feedback Control
Controller Direction:-Direct (PV Increases, Controller Output Increases)
Control valve Direction:-Air to Open(without Air lock Relay)
Over ride Control:-1)Instrument Air or Control Signal Fail
2)Both CEP Pump Trips
HP Bypass Temperature Control Loop

CEP Discharge Line

HP Bypass Line
TT

1oo2
Controller
TT

Condensor
 PRDS Pressure Control Valve
Significance:-
1)It is utilized for Auxillary Steam Pressure distribution to (GSPC, Ejectors) for Maintaining Vaccum
2) It will be in line during Cold startup or low load condition(0-21MW approx) for providing steam to
auxillary equipments(Ejectors,Gland sealing,GSC and four boilers(Drum and Deaerators)
Process Sensing Elements:-Two Pressure transmitter (MSTPT009A,MSTPT009B)
Final Control Element:-PRDS PCV01
Set Point:-(11.5-12.5 KSC)
Controller Direction:-Reverse (PV Increases, Controller Output Decreases)
Control Valve Action:-Air to open(Fail to close)
Control Loop:- 1) It is Closed loop feedback Process Control .
Override control Interlocks:-
1)Instrument Air Failure
2) When Differential pressure Across Wander Extraction and HP Extraction will be more than 0.7 KSC, it
will give close command to PRDS PCV ,it will happen when load is Approx 21 MW.
 PRDS Pressure Control Loop

Controller
Main steam Line to TG

1oo2

LP Header Line
PT PT

PRDS to LP Header Line

 PRDS Temperature Control Loop

Significance:-
1) It is used to control the PRDS Steam Temperature after Desuperheater.
Process Sensing Elements:-Two Temperature transmitters :-(ASTT001A,ASTT001B)
Final Control Element:-PRDS TCV01
Set Point:-(250 Deg C)
Controller Direction,:-Direct (PV Increases, Controller Output Increases)
Control valve action:-Air to open(no Air lock relay)
Control Loop:- 1) It is Closed loop feedback Process Control
Override Control:- 1)Control system fault
3)Instrument Air Failure
 PRDS Temperature Control Loop

Controller

1oo2
PRDS to LP Header Line

TT TT

LP Header Line
PRDS to LP Header Line

CEP SWBP
 Hot well Level Makeup Control Loop
Significance:-
1)used to Compensate or Nullify the Level of Hotwell tank due to steam loss (MS Line
vent,drains,Extractions.)
2)Normally it will be in Manual mode when the demand in any of the boiler will rise leads to the drop in Hot well
level continuously will bring us in condition to put in Auto mode to achieve a desired set point.
Process Sensing Elements:-Two Level transmitters are Provided in HOTWELL Tank(HWLT1601,HWLT1602)
Final Control Element:-LCV01(Low Capacity),LCV02(High Capacity)
Set Point:-(840mmwc)
Controller Direction:-Reverse (PV Increases, Controller Output Decreases)
Control valve action:-Air to close(Air fail to open)
Control Loop:- 1) It is Closed Loop feedback control scheme
Operation:-Level transmitters will send current level feedback to summing point and controller will analyse the
magnitude of error and send controlled output to low capacity bypass control valve, which will take necessary
action to control the level.
When Level will decrease at an alarming rate and low capacity valve will open ,then its 90%open feedback to the
controller will give open command to High capacity control valve to regulate the desired level.
Override control Interlocks:-
1)Instrument Air Failure& Control system fault
3)If Differential error between two transmitters is high,controller will change PID action from AUTO to MANUAL
mode.
 HOTWELL Make up Control

Controller
Condensor

1oo2

LT Hotwell LT
Tank

DM Water Discharge
 Wander Extraction Temperature Control Valve
Significance:-Extraction Temperature control is necessary to save auxiliaries from Thermal Expansion due to
overheating (GSC,Ejector).
Process Sensing Elements:-Two Temperature Transmitters (ASTT001A,ASTT001B) via Thermocouples-2
Final Control Element:-TCV-04
Set Point:-250 deg C
Controller Direction:-Direct (PV Increases, Controller Output Increases)
Valve Action:-Air to open
Control Loop:- 1) It is Closed loop feedback Process Control
Override control Interlocks:
1)Control system fault
2)Instrument Air Failure
3) Differential error between two transmitters is high,controller will put the PID from AUTO to MANUAL mode.
Wander Extraction Temp Control
1oo2

Controller TT TT

Wander Extraction to Process

SWB
CEP
P
 HP Wander Extraction Pressure Control Valve
Significance:-1)It is given to utilize Turbine Excess steam for auxillary purpose
2)It will be in line during (23-53 MW) Approx
Process Sensing Elements:-One Pressure Transmitter(PT220 Provided in HP Process line),DPT 216A(B/W
HP Extraction and wander Extraction)
Final Control Element:-PCV216A
Set Point:-11.5 KSC
Controller Direction:-Reverse (PV Increases, Controller Output Decreases to close the control valve)
Valve Action:-Air to open
Control Loop:- 1) It is Closed loop feedback Process Control
Operation:-One Pressure Transmitter at Extraction line will give Feedback to summing point(SP-PV),which
will send the error signal to controller ,controller will generate necessary controlled output for control valve to
maintain desired pressure.
Override Control:-1)When DP Across LP Extraction control valve(DPT 216A) will be more than 0.7ksc
2)when ESV closed or Turbine trip
3)When DP across HP Extraction will be less than 0.2 KSC
4)Instrument Air Fail
HP Wander Extraction Pressure Control Loop
Controller

DPT
PT

LP Header Line
Wander Extraction to Process

DPT
 LP Wander Extraction Pressure Control Valve

Significance:-1) It is given to utilize Turbine Excess steam for auxillary purpose

2) It will be in line during (53-76 MW) Approx
Process Sensing Elements:-One Pressure Transmitter(PT220 Provided in HP Extraction line),DPT 216B
(B/W LP Extraction and wander Extraction)
Final Control Element:-PCV216B
Set Point:-11.5 KSC
Controller Direction:-Reverse (PV Increases, Controller Output Decreases to close the control valve)
Valve Action:-Air to open(Air Fail to Close)
Control Loop:- 1) It is Closed loop feedback Process Control
Override Control:-
1)when ESV closed or Turbine trip
2)When DP across LP Extraction will be less than 0.2 KSC
3)Instrument Air Failure
LP Wander Extraction Control Loop
Controller

PT

LP Header Line
Wander Extraction to HP Process

DPT
 GSPC Control Loop (Supply and Dump Control Valve)

Significance:-
1)It will maintain Gland seal header pressure by sealing the glands so that air will not ingress inside the turbine
glands (LP&HP) which is quite necessary to maintain vacuum.
Process Sensing Elements:-Two pressure transmitters(PT-01,PT-02)
Final Control Element:-(PCV01,PCV02)
Set Point:-500mmwc
Controller Direction:-PCV01(Reverse),PCV02(Direct)
Valve Action:- 1)Supply Control Valve -PCV01(Air to close),(4-12 ma)(0-50% controller o/p signal)
2) Excess to Dump Control Valve -PCV02 (Air to open),(12-20 ma)(50-100% controller o/p signal)
Control Loop:-Split range closed loop control system(controller O/P range(4-12ma),(12-20ma)
Operation:-Two pressure transmitters will sense the pressure and send it to summing junction of
controller,Controller will process the controlled output and send it to PCV01 or PCV02 to open or close as per
desired set point.At a time only one control valve will be in operation.
When the Header pressure is below 500mmwc,PCV01 will Open to control the pressure,PCV02 is closed.
When Header Pressure is more than 500mmwc,PCV02 will Open to maintain the pressure.PCV01 is closed
Gland Steam Header Pressure Control Loop
1oo2

PT PT

GSPC Header

Auxiliary Steam Supply to GSPC header

Controller

GS HDR Dum p Line

Aux Steam Header Condensor
 Full open(100%)
Full open(100%)
PCV01 PCV01
(GS Supply CV) (GS Dump CV)

CV
position CV
Position

Full Close(0%)
0%(4mA) 50%(12mA) 100%(20mA)
Controller O/P
 Minimum Recirculation Flow Control Loop
Significance:-
1)It is used to regulate the CEP minimum discharge flow.
Process Sensing Elements:-CEP Discharge Flow Transmitter(FT-206)
Final Control Element:-FCV
Set Point:-(125 TPH)
Controller Direction:-Reverse
Valve Action:-Air to Close
Control Loop:-Closed Loop Feedback Control .
Operation:-Flow Transmitter will sense the flow and send signal to Summing point it will generate an error
which will be compared with the set point in controller and controller will send its controlled output based on
magnitude of error to Flow control valve.Final Control element will open/close based on controlled signal given
by controller.
CEP Minimum recirculation control Loop

FT

Boiler GSC Ejector

Controller

CEP Hotwell
Tank
 Condensate Export Control Valve

Significance:-
1) It is used for Continuous recirculation of condensate water to CDQ Boilers-1,2,3,4 for steam generation by
taking reference of Normal Hotwell Level .
Process Sensing Elements:- Two Level Ttransmitter are Provided in HOTWELL Tank(HWLT1601,HWLT1602)
Final Control Element:-FCV01
Set Point:-840mmwc
Controller Direction:-PV increases, controller output increases(Direct)
Valve Action:-Air to open
Control Loop:-Closed Loop Feedback Control System
Override Control:-1)If Differential error between two transmitters is high,controller will put the PID from AUTO to
MANUAL mode.
2)Instrument Air Failure
 Condensate Export Control loop

GSC
Condensate Export to Boiler Ejector
O/L

Controller
CEP

1oo2

LT LT CEP
Hotwell
Tank
 Types Of Controller for Closed Loop Control System
Proportional Controller :-It only measure how much correction has to be made?
1)Its Controlled output(m) is the product of error and proportional gain
3)Its output is not a function of time Interval but of magnitude of error.
2)Its function is {m=Kp x error +bias) where Kp=1/PB,
Kp=PV% /Controller Output %
It is represented by
m=kp.e

SP e error Kp m process

PV
Sensor
3)Fast Process Need less Gain(As large change in input is required to produce small change in output)
& Slow process Need high gain (As small change in input is required to produce large change in input)
4)It will respond to minimize the magnitude of error only ,but it will not remove the OFFSET from desired SP.
5) Application:-It can be used for Discrete(ON-OFF) Level Control System for Preventing LOW LOW & HIGH HIGH
condition for Pump Start and Stop.
 Proportional Integral :- :-It is a defined as a change in PV
at a speed proportional to the magnitude of deviation.
Its Integral function will continuously Integrate the errors by taking past values into account
It measures ,How much(P) and how long (I) the correction should be applied?.
It is a function of duration of error to remove offset.
Output is a repeat of the proportional action as long as error exists by Increase/Decrease in RESET
Time(RPM) or Rate(MPR)
It is used for Fast response process variables (Pressure, level, Flow) to remove offset
It will continue to act till Error(offset) becomes zero
It is useful for only those applications where change in error is stable(with respect to time)
Its function is m=Kp.(e+1/Ti edt)

Error
SP Kp(.e+1/Ti edt) m
process

PV Sensor
 Proportional Integral Derivative(PID):-It defines Magnitude, Time Duration and
Rate function of error
P depends on the present error, I on the accumulation of past errors, and D is a
prediction of future errors, based on current rate of change

Derivative is a function of rate of change of error

It measures How Much, How Long and How fast correction to be applied.
Fast and stable response but limited to slow acting processes. Example:-Temperature Control Systems.
Its proportional action will Produce an output proportional to error, its integral action will bring down its offset to
zero and derivative action will reduce the rate of change of error to zero.
Its derivative action ceases when the error stops changing, which will not necessarily be at the setpoint, Its
integral function will cease when its constant offset becomes zero, and its proportional action will cease when
error is zero.
Its function is m=Kp(.e+1/Ti edt + Td.de/dt)
It includes Proportional Gain,Integral Time and Derivative time.
SP e error m
m=Kp(.e+1/Ti edt + Td.de/dt) process

PV Sensor
 Calibration is a set of operations ,that compares the measurement performed by an
instrument to those made by a standard instrument for detecting ,reporting and
adjusting error met in the instrument tested.

Accuracy of a measurement describes how close the measurement

approaches the true value of the process variable
Precision is the reproducibility with which repeated measurements can be
made under identical conditions

1)Milliamp Source
2)HART Communicator
3) Temperature calibrator(RTD and TC)
4) Dead Weight Tester
5) Vacuum pump
6) Hand Held Pressure Calibrator
Thank you