CONTROL

AND
PROTECTION

Protection and Safety

Interlocks

Protection General understanding?

What we already know.
n

Operation of the BOILER, TURBINE, GENERATOR are closely

coupled

A trip on any one of the three has a direct impact on the

continued operation of the other two causing interruption to
power production process

Why Trip On occurrence of any unsafe or abnormal operating

condition the BOILER, TURBINE, GENERATOR are tripped
individually

Protection General understanding?

What does TRIP mean
n

Boiler trip :
q
q

Turbine trip :
q
q

Stops fuel feed to Furnace

Purpose To clear out combustibles from the Boiler and prevent any
explosive condition from persisting

Close all steam admission valves (ESV, GOV Valves)

Purpose Stop steam admission to ensure turbine coasts down and
Open all drain lines of steam admission pipes upstream / down stream
valves to prevent accumulation of water which may enter the Turbine

Generator trip :
q

Opens CB connecting Generator to Grid

n

Purpose Isolate system from faulty generator

Opens Field Circuit Breaker to cut-off excitation

Signal Voting
A

1oo1

A
A

1oo2

B
A

C
B

2oo3

2oo2

Dual Systems
1oo2 Config = Shut down

High Pressure Set Point

Process Variable

Time

Which Signal
is Correct ?

TMR Systems
2oo3 = Continue to operate

Process Variable

High Pressure Set Point

High Certainty this is
a bad signal

Time

TMR Systems
2oo3 = Shut Down

Process Variable

High Pressure Set Point

High Certainty these are
good signals

High Certainty this is

a BAD signal

Time

TURBINE TRIP CONDITIONS

q
q
q
q
q
q
q
q
q
q
q
q
q

TG BEARING OIL PRESSURE LOW

CONDENSER VACUUM LOW
CONDENSER EHWL
HP EXHAUST TEMPERATURE HIGH
3 OUT OF 4 GOVERNOR VALVES TRIPPED
2 OUT OF 2 INTERCEPT VALVES TRIPPED
EHG FAULT
THRUST WEAR HIGH
STATOR COOLANT FLOW LOW
MAIN STEAM PRESSURE LOW
MAIN STEAM TEMPERATURE LOW
MFT OPERATED
86U OPERATED

NEXT

86T TG Bearing oil pressure low

n

TG BEARING OIL PRESSURE LOW

Source :

Pressure switch (2/3)

Implication: Will result in in-sufficient lubrication in

between rotor and bearing journal leading to breaking of
oil film and resulting in metal to metal rubbing and thus
damaging the Turbine
Action: 86T
Turbine Trip Conditions

86T Condenser Vacuum Low

n

Condenser Vacuum Low

Source : Pressure Transmitter (2/3).. EHG..
Implication: Will produce undue stress on Turbine blades due to
reduction of available enthalpy (rise in exhaust conditions). Usually
a Trip is preceded by de-loading of turbine as per Turbine
manufacturer recommendation
Action: 86T

Turbine Trip Conditions

86T Condenser EHWL

n

Condenser EHWL
Source : Level switch (2/3)
Implication: Flooding of the condenser will result in
a. limited heat exchange area and hence vacuum will fall
b. excessive strain on the condenser neck hanging
from LP Turbine
c. After EHWL there is no control on the level nor can it be monitored
and hence is used as a last stage of protection
b. water may reach LP blades at a later stage

Action: 86T

Turbine Trip Conditions

86T HP Exhaust Temperature High

n

HP Exhaust Tempertaure High

Source : Thermocouple (2/3)EHG .
Implication: Deviation in available enthalpy across HP Turbine
from design value will produce stress on HP blades . This is special
protection feature for Tubines equipped with HPLP Bypass.
Action: 86T

Turbine Trip Conditions

86T 3 out of 4 Governor valves tripped

n

3 out of 4 Governor valves tripped

Source : Median Select Controller EHG .
Implication: Failure of HP Gov valves stops steam admission to HP
Turbine. Admission of steam thru single Gov valve will result in non
uniform temperature distribution within the Turbine which may result
in distortion of blades , rotor.
Action: 86T

Turbine Trip Conditions

86T 2 out of 2 Intercept valves closed

n

2 out of 2 Intercept valves closed

Source : Median Select Controller EHG .
Implication: Failure of IP Intercept valves stops steam
admission to IP & LP Turbine. This will disturb the HP IP
work ratio.
Action: 86T

Turbine Trip Conditions

86T EHG FAULT

n

EHG Fault
Source : Speed sensed thru eddy current probeEHG .
Implication: Failure of governing system as basic input on the basis
of which governing occurs is not available
EHG fault signifies either channel failure or speed sensor failure
Action: 86T

Turbine Trip Conditions

86T Thrust Wear High

n

Thrust Wear High

Source : Eddy Current ProbeTSE .
Implication: Indicates axial shift of rotor with respect to stator in the
axial direction and may result in fixed and moving blades fouling .
The reference point of rotor located with the stator will shift as a
result of wear on the thrust pads / collar.
Action: 86T

Turbine Trip Conditions

86T Stator Coolant Flow Low

n

Stator Coolant Flow Low

Source : Flow switch (2/3) + timer.
Implication: Will result in heating up of the hollow conductors in
generator as little or no cooling medium is present and lead to
insulation failure. This has been purposely introduced under Turbine
protection rather than generator protection due to implications in
house load operation.
Action: 86T

Turbine Trip Conditions

86T Main Steam Pressure Low

n

Main Steam Pressure Low

Source : Pressure transmitter (2/3) .EHG.
Implication: Will produce undue stress on Turbine blades due to
reduction of available enthalpy (reduction in input conditions).
Usually a Trip is preceded by an de-loading of turbine as per
Turbine manufacturer recommendation.
Action: 86T

Turbine Trip Conditions

86T Main Steam Temperature Low

n

Main Steam Temperature Low

Source : Temperature transmitter (2/3) .DCS.
Implication: Will produce undue stress on Turbine
blades due to reduction of available enthalpy (reduction
in input conditions).

Action: 86T

86T Main Steam Temperature Low Logic

Turbine Trip Conditions

Effects on Turbine Trip

n
n
n
n

n
n

Runback of Turbine via EHG

Generator/Electrical Protection operates
Preferential Tripping of MILLS
Quick Opening of HP Bypass valve if Load>
22 %
De-aerator and Heaters NRV closes
Turbine and Heater drain valves open

Turbine Trip Conditions

Boiler

Protection

and Safety Interlocks

Situations Causing Explosive conditions?

Numerous situations can arise in connection with the operation of a
boiler furnace that will produce explosive conditions.
q

Interruption of Fuel or air supply or ignition energy to the burners.

Fuel Leakage into an idle furnace and the ignition of the

accumulation

Repeated Unsuccessful attempts to light up without appropriate

purging

The Accumulation of an explosive mixture of fuel and air as a

result of a complete furnace flameout

Requirement
Multiple burner boilers require two independent
control systems.
q

One to control steam production i.e. Boiler

Control System and

One to control the fuel burning equipment i.e.

Burner Management System

BMS - What are the basic Functions?

The BMS shall be designed to perform the following functions:
n

Prevent firing unless a satisfactory furnace purge has first been completed.

Prohibit start-up of the equipment unless certain permissive interlocks have first
been completed.

Monitor and control the correct component sequencing during start-up and shutdown of the equipment.

Provide component condition feedback to the operator and, if so equipped, to

the plant control systems and/or data loggers.

Provide automatic supervision when the equipment is in service and provide

means to make a Master Fuel Trip (MFT) should certain unacceptable firing
conditions occur.

Execute a MFT upon certain adverse unit operating conditions.

How do we categorize the different

controls
A Boiler Control System shall have the following
applications
n
n
n

Combustion control
Excess air control
Steam drum level control

A Burner Management System shall have the

following applications
n
n
n
n

Boiler purge control

Fuel safety control
Pre-light up control
Individual burner control

Boiler Purge Control

Why: For removing all combustibles from the boiler furnace and replacing them
with air to prevent any explosive mixture from remaining in the furnace prior to
light up.
When: After a Master Fuel Trip has occurred
How:
A.

Ensuring that a predetermined set of fuel and air related permissive

conditions are satisfied which shall include

All fuel valves (Shut-off valves, oil valves) closed

Either of one FD Fan & ID Fan running
All Mills and Feeders stopped and Mill discharge valves closed
All PA Fans stopped and PA to Mill inlet dampers closed
All scanners sense no flame
Air flow is not less than 25% - 35 % (multiple burner boilers) of full load air flow
4 out of 6 secondary air dampers at Purge position
No MFT conditions present
MFT relay tripped

q
q
q
q
q
q
q
q

Now the Boiler is Ready for Purge

Boiler Purge Control

B.

Initiate Boiler Purge

Dampers are initiated to move to Purge position (air flow 30 to 80 T/hr)

5 minute purge timer triggers
Boiler purge in progress is indicated
After 5 minutes has elapsed the Purge process is complete and the boiler is ready for firing
If any of the condition mentioned in A fails during purging process, purging is interrupted and
the timer resets.

q
q

Fuel Safety Control

Why: To prevent any explosive condition in the furnace
What: Withdraws fuel feed to the Furnace
When: If any of the predetermined trip conditions has occurred.
Classification
Depending on the fuels involved the fuel safety control can be
made up of the following:
q Master fuel trip
q Oil fuel trip

Master Fuel Trip

If any of the predetermined master fuel trip condition occurs a master fuel
trip is initiated. The first out cause of trip indication is displayed and
alarmed. Conditions of a master fuel trip are:
q
q
q
q
q
q
q
q
q
q

All FD Fans off

All ID Fans off
Boiler air flow low for 3 secs
Loss of all fuel
Loss of all flame
Furnace pressure very high/Low
Drum level very high/low
Critical Flameout
Delayed light-up
Re-heater protection operated

Master Fuel Trip

Some more Conditions of a master fuel trip (continued) :
Loss of HT power
q Loss of UPS power
q Loss of 220V DC power
q Condenser vacuum very low
q MFT hard relay tripped
q 2 out of 3 main processors failed
q Both emergency trip push buttons operated
Any of the above occasions will result in a MFT
q

MFT can be reset when

q
q
q

None of the above trip conditions exist

Boiler purge is complete
Reset MFT is initiated
NEXT

MFT all FD fans off

n

All FD fans Off

Source :

Breaker off signal from both fans

Implication: Will result in in-sufficient air for the

combustion process and the fuel cannot burn
Action: MFT
MFT conditions

MFT all ID fans off

n

All ID fans Off

Source : Breaker off signal from all 3 fans
Implication: Will result in an uncontrolled furnace
pressurization.
Action: MFT

MFT conditions

MFT Air flow less than 25%

n

Boiler air flow less than < 25% for 3 secs

Source : Flow transmitters at FD suction
Implication: Will result in in-sufficient air for the
combustion process and the fuel cannot burn completely
Action: MFT

MFT conditions

MFT Loss of all fuel

n

Loss of all fuel

Source : Any oil burner in operation (MFT trip resets)
and closure of all burner valves and all Mills off and no
mill in shutdown mode.
Implication: As no fuel is being fed into the furnace
generation of heat for sustenance of combustion and
subsequent production of steam cannot take place

Action: MFT
MFT conditions

MFT Loss of all flame

n

Loss of all flame

Source : Any oil burner in operation and no scanners see
flame.
Implication: Will proactively safeguard all adverse effect
due to non burning of fuel (detected from the intensity of
flame) being injected into the furnace

Action: MFT
MFT conditions

MFT Furnace pressure very high/low

n

Furnace pressure very high /low

Source : Pressure switch and transmitter.
Implication: Will result in explosion or implosion of the
furnace resulting in mechanical deformity
Action: MFT

MFT conditions

MFT Drum level very high/low

n

Drum level very high / low

Source : Hydrastep and drum level transmitter
Implication:
High: Will result in Flooding of superheaters causing
a. carryover of dissolved solids and hence deposition downstream effecting
heat transfer
b. fall of steam temperature and quenching of Turbine
Low: Will result in starvation of water in the furnace tubes which will lead to
tube metal overheating as no cooling medium is present
Action: MFT
MFT conditions

MFT Critical flameout

n

Critical Flameout
Source : Furnace flame scanners detect 2 out of 3 zones
no flame
Implication: Is a consequence of improper combustion in
pre-identified zones within the furnace resulting in flame
instability which may give rise to improper heat
distribution

Action: MFT
MFT conditions

MFT Delayed light-up

n

Delayed light up
Source : MFT reset , LDO shut off valves open and no oil
gun in operation (or in other words put into service)
within 10 mins of opening of LDO shut-off valves.
Implication: Repeated unsuccessful attempts to light up
the boiler with oil gun has resulted in accumulation of
un-burnt fuel (oil) in the furnace and hence the furnace
requires purging.

Action: MFT
MFT conditions

MFT Re-heater protection

n

Re-heater protection
Source : All governor valves closed, HP bypass valve < 2% open
with
a. at least one feeder running from remote
or
b. More than 8 out of 12 oil guns in operation
Implication: Damage to tubes that can result from firing in excess of
safe limit which will cause overheating of re-heater tubes due to
absence of a steam flow through it.
Action: MFT

MFT conditions

MFT Condenser Vacuum Low

n

Condenser Vacuum Very Low

Source : Pressure switch installed at condenser (500 mmHg abs)
Implication: Under turbine tripped condition and bypass in operation
steam dumping continues at condenser which can result in
pressurization. Under such poor vacuum conditions the condenser is
not capable of dissipating the heat load with existing CW flow and
with effect the temperature rises.
Action: MFT

MFT conditions

Oil Fuel Trip

If any of the predetermined oil fuel trip conditions is exceeded the oil fuel trip is initiated. The first
out cause of trip indication is displayed and alarmed. All oil fuel is removed from the boiler and all
oil burners are shutdown. Depending on other conditions a master fuel trip may be generated.
Conditions of an oil fuel trip are:
q
q
q
q
q
q
q
q

LDO trip valves close command

LDO trip valves not closed and LDOT condition is present
LDOT relay fail to trip and LDOT condition is present
LDO pressure very low for 3 secs and any LDO burner valves not closed
Atomising air pressure very low for 3 secs and any LDO burner valves not closed
LDO trip valve not open within 10 secs of LDOT reset
Any burner valve fail to close despite boiler load being > 50%
LDOT hard relay tripped

LDOT can be reset when

q
None of the above trip conditions exist
q
MFT relay is reset
q
Trip valve open is initiated
q
All LDO burner valves are closed

Mill Trip Conditions

The following conditions shall cause a Mill to trip
q
q

q
q
q
q
q
q
q

LOS or emergency stop pressed

Mill and feeder running from remote, oil flame not detected with either feeder
speed <30 % or coal flame not detected signifying low coal and no ignition
source
Feeder running from remote and coal and oil flame neither detected assuming
flame monitoring system is healthy signifying loss of coal flame without ignition
source
Loading gas pressure very low
Lub oil pressure very low signifying no lubrication to Mill gear box and bearings
Both PA fans stopped
Mill running from remote for >30 secs and PA flow below minimum
Mill running from remote for >30 secs and Secondary air flow < 45%
Seal air pressure very low
MFT or Mill hard relay

Preferential Mill Tripping

Why : To take out certain running Mills out of service as per preference in
order to reduce firing and compensate for the furnace conditions prevailing

When :
q
q
q

On Turbine trip
Load rejection >50 %
Single FD or PA fan running

How : It ensures that extreme burners shall trip

q

Under 4 mill condition

n
n
n
n

if Mill D is not in service then Mill A trips

If Mill A is not in service then Mill D trips
If both Mill A and Mill D are in service, Mill A trips if Mill D is the single Mill in the rear OR Mill D trips if
Mill A is the single Mill in the front
If Mill A and Mill D both are not in service then Mill B trips

Under 5 mill condition

n
n
n

Mill A and Mill D trips if they are both in service

Mill A and Mill B trips if Mill D is not in service
Mill B and Mill D trips if Mill A is not in service

Reverse power
Loss of excitation

Trip condn for

86G

Excitation Trip
Other Fault conditions

132KV diffl protn

Bus Zone Trip

86G

86U
Open GCB
Open FCB
GCB Not
open
LBB 2

O/S Bolt
operated

&

Condenser
vacuum
V.Low

Reheater protn

LBB 1

86T
FCB Closed

&
&

MFR
Low Forward
power

&

Governor Vv closed
Firing rate high
Bypass < 2%

GCB Not
open

&

Turbine trip condn

Boiler trip condn

Open GCB

Turbine Trip Conditions

Control & Instrumentation in

Thermal Power Plant

COAL

EXPORT OF
ASH TO
BANGLADESH

WAGON
C
H
I
M
N
E
Y

RAILWAY
TRACK

PRIMARY
CRUSHER
DRUM

COAL
STOCK

SECONDARY
CRUSHER

BUNKER

COAL &
PRIMARY
AIR

S
U
P
E
R

DRY
ASH
SILO

TO AMBUJA
FOR
PPC
CEMENT

ID
FAN

ESP

TO
DISTRIBUTION
SYSTEM

HCSS

TRANSFORMER

H
E
A
T
E
R

ISH
GOVERNER
VALVE

ELECTRICITY

FEEDER
STEAM

APH

TURBINE
COAL
MILL

PA FAN

SECONDARY
AIR

BOILER
BOTTOM
ASH
HOPPER

D/A

FEED
WATER

LPH CEP
CONDENSER

HPH
AIR
INTAKE

FD FAN

AIR PRE
HEATER
ZERO
DISCHARGE
SYSTEM

BFP

MAKE UP
WATER
SYSTEM

DM
PLANT

COOLING
TOWER

BOTTOM ASH

ELECTRICITY

CONDENSER COOLING
WATER SYSTEM

FORE BAY
RAW WATER
TREATMENT

COAL

GENERATOR
GENERATOR

INTAKE
PUMPS

CW
PUMP

RIVER
GANGES

Process schematic

Input

Input
Devices
-Transmitter

s
-

Switches

-Transducer

Control System for

Processes
- DCS

Output

- PLC

Output
Devices

- EHG

Actuators

AVR

Drives

AV6 (for Bypass)

Indicators

Controlled Parameters
Most commonly controlled parameters in
Industry are:
1.

Flow

2.

Level

3.

Temperature

4.

Pressure

5.

Speed (RPM)

6.

Position

FLOW
n

Measured with
q Orifice, Nozzle
Pressure drop measured with
q DP Transmitter
Flow K DP

DCS
Input

4 to 20 mA
signal
D
P

Actuator

Processor
FLOW

Output
Valve

4 to 20 mA
signal

LEVEL
n

Measured using
q Constant Head Unit
Pressure difference measured with
q DP Transmitter
Level Head

DCS
Input

4 to 20 mA
signal

Actuator

CHU

Processor

Valve

D
P

TANK
4 to 20 mA
signal

Output

TEMPERATURE
n

Measured by

RTD (Pt 100)

q Output Resistance (ohms)
q

At 0C value is 100 ohms

Change is 0.385 ohm / C (Linear)

TEMPERATURE
n

Measured by

Thermocouple
q Output mV
q Types: J,K,T,S.
Temperature Transmitter

Output 4 to 20 mA

Controlling Devices
n

Most common final control devices are:

1.

Pneumatic actuators modulating type

2.

Pneumatic actuators On/ Off type

3.

Motorised actuators On/ Off type

4.

Hydraulic actuators servo operated

5.

Variable frequency drives

6.

Servo motors

WHAT IS AUTOMATION?
What is in a Automation System?
Control Processor
Input to the
system

INPUT MODULES

Field Inputs (Transmitters

/ Switches / Sensor)

System
output

OUTPUT MODULES

Field Outputs (Valves /

Pumps / others)

Examples of Boiler Controls

n

Boiler Control System comprises the following functions

q

Boiler Master Pressure Control

Fuel Flow Control

Feeder Speed Control

Mill Air Flow Control and Temperature Control

Excess Air Control

Drum Level control

Furnace Draft Control

Super-heater Steam temperature Control

Various other Pressure, Temperature, Level, Flow , Position Controls

Examples of Turbine Controls

n

Turbine Control System comprises the following functions

q

Heater Level Control

Hotwell level Control (Condenser)

Lub Oil Temperature Control

BFP Scoop Position Control

De-aerator Level control

Governor Control

Control System Hardware

PLC
DCS

What is TMR architecture?

It means Triple Modular Redundant

TMR architecture integrates three isolated parallel

control systems ( as evident in diagram)

The system uses TWO-OUT-OF-THREE voting to

provide high integrity, error free uninterrupted
process operation with no single point failure

Hardware - PLC
n EFFECTIVE AND RELIABLE SYSTEM
FOR OVERALL SUPERVISION OF
BOILER SAFETY IN A POWER
PLANT.

Transferring control to Fault

Tolerant pair and running
self diagnostics

n CONTAINS SAFETY GUIDELINES

PROGRAMMED INSIDE FOR

Chassis
with
Processo
r and I/O
cards

TAKING PREVENTIVE MEASURES

IN EXTREME CASES TO TAKE THE
WHOLE SYSTEM TO STEP-BY-STEP
SHUTDOWN.

n IT FORESEES FUTURE ERROR AND

GENERATE ALARMS.

Running self
diagnostics and
monitoring

Hardware - PLC
n THE BMS IS A PLC, PROGRAMMED ACCORDING TO USER NEED.
n LIKE CONVENTIONAL PLC SYSTEMS THE BMS ALSO CONSISTS
OF THE FOLLOWING PARTS:1. MOUNTING RACK
2. POWER SUPPLY
3. MAIN PROCESSOR
4. I/O CARDS
5. SPECIAL MODULES
6. SPECIAL FUNCTIONS

FOR HOUSING THE WHOLE PLC

SYSTEM.
FOR SUPPLYING POWER TO THE
PLC SYSTEM.
THE BRAIN OF THE SYSTEM
INTERFACING UNITS BETWEEN
SYSTEM & FIELD
COMMUNICATION WITH OTHER
SYSTEMS, ETC.
HIGH SPEED COUNTER,
THERMOCOUPLE SENSORS (NOT IN BBGS)

Distributed Control System (DCS)

n

Comprises CLCS ,OLCS and DAS

q

CLCS Various closed loop controls for process

are incorporated here

OLCS Various open loop controls for

unidirectional and bidirectional drives are
incorporated here

DAS Data for indication purpose, historian,

trending, logs, SOE

DCS Hardware
Stations
Processor
modules

Application processors (File server) - AW

Control Processors - CP

Workstation Processors (Client user interface) - WP

Field Bus Modules (FBM) types

0 to 20 mA input

TC / mV input

RTD input

0 to 20 mA input / output

Contact/dc input/output main

INPUT /
OUTPUT
Interfacing
modules

DCS Architecture Bus Topology

Ethernet
IEEE
802.3

Application Processor

Control Processor
FT

FBMS
FOR CLCS/OLCS & DAS

Input &
Output

Workstation Processor

NODE
BUS
FIELD
BUS

DCS SYSTEM ARCHITECTURE - Mesh Network

AW70P

24 SFP Port Uplink Switches

WP70P
WP70P

100 MBPS
100 MBPS
100 MBPS
WP70P
1 GBPS

1 GBPS

1 GBPS

100 MBPS

UNIT-1

WP70P

UNIT-2

AWCS
Redundant
Switches

Redundant Switches

100 MBPS

100 MBPS

FCP270(F
T)
WP70P

100 MBPS
100 MBPS

FCP270(F
T)

100 MBPS
WP70P

100 MBPS

FCP270(FT
)

100 MBPS
100 MBPS
WP70P

100 MBPS

100 MBPS

FCP270(FT
)

100 MBPS

FCP270(F
T)
FCP270(FT
)

FBMs for Triconex

100 Series FBMs

FCP270(F
T)

LEGEND:
AW70P
WP70P
Engineering cum
Operator Station on
Windows XP

24 Port Fiber
Ethernet Switch

Operator Station
on Windows XP

FCP270 in Fault
Tolerant Mode

Redundant Switches

DCS Hardware (OLCS)

n
n
n
n
n
n
n

Field Input
INPUT
DCS Marshalling Rack
IA Enclosure DCS (Logic)
DCS Relay Rack
DCS Marshalling Rack
OUTPUT
MCC Module
Drive (Motor)

DCS Hardware (CLCS)

n
n
n
n
n

Field Input (Sensors)

INPUT
DCS Marshalling Rack
IA Enclosure DCS (Control loops)
DCS Marshalling Rack
OUTPUT
Final Control Element (Actuators)

DCS Software
n

The software comprises of mainly

q
q

Operating System
Application soft wares for
n
n

n
n
n

display building creating drawings and display pages

display configuration connecting inputs to show in display
page
control configurations comprises various control blocks , its
connectivity with other blocks to derive a control loop
Pre-trip and Post-trip software data logging
Historian software historical data for analysis
Event recorders Operator action, process alarms etc

IFL-1

CIN-2

OFL-10

CIN-20

TC02-S

CIN-6

INT-04

CO-1

CRT START

SS IN
REMOTE

PUMP IN
MANUAL

JOP SUC
PR LO

NO
ELEC TR8

MOD IN
SERV

STOP

STR / STP
ACJOP

CIN-17

CIN-1

LOCAL
START

SS IN
LOCAL

CIN-7
MOD IN
TEST

INT-02
ACJOP
AUT STR
CO-1
STR / STP
ACJOP
IFL-2

CIN-2

CRT STOP

SS IN
REMOTE

INT-04
STOP

CIN-18
LOCAL
STOP

OPEN LOOP CONTROL

CIN-19

OFL-11

CIN-2

TRB SPD
LT 1000

PUMP IN
AUTO

SS IN
REMOTE

TC01-S
JOP SUC
PR LO

EXAMPLE : LADDER LOGIC

START / STOP LOGIC

SAMA Functional Diagram

n

SAMA is an acronym standing for Scientific Apparatus Makers Association, referring

to a unique form of diagram used primarily in the power generation industry to
document control strategies.

Standard SAMA Symbols

PID Controller

DRUM LEVEL CONTROL

DRUM LEVEL LHS

DRUM PRESSURE

DRUM LEVEL RHS

LT

LT

LT

PT

PT

PT

LT

LT

LT

AIN

AIN

AIN

AIN

AIN

AIN

AIN

AIN

AIN

CALC

f(x)
/2

1
DENSITY
COMPENSATED
DRUM LEVEL

CALC

DRUM LEVEL CONTROL

MAIN STEAM FLOW

FT

FT

FT

AIN

AIN

AIN

MAIN STEAM
PRESSURE

BAD

MAIN STEAM TEMP

PT

PT

TT

TT

TT

AIN

AIN

AIN

AIN

AIN

T
CALC

CALC
AUXILIARY STEAM
FLOW

2
PRESSURE,TEMP COMPENSATED
TOTAL STEAM FLOW

DRUM LEVEL CONTROL

FEED WATER FLOW

FEED WATER TEMP

FT

FT

FT

TT

TT

TT

AIN

AIN

AIN

AIN

AIN

AIN

CALC

3
TEMP COMPENSATED
FEED WATER FLOW

f(x)

Drum Level

Main Steam
Flow

Feed Water
Flow

LC-1

LC-2

3E
MANSW

SP

PI

PI

TR

1E

FC

RSP

1E

TR

f(x)

+/T

PI
TR

f(x)

MANSW

+/T

MANSW

MANSW
SEL
VLV

+/T

AOUT

AOUT

AOUT

LLFCV

FLFCV-1

FLFCV-2

DRUM
LEVEL
CONTROL

Drum Level

Main Steam
Flow

Feed Water
Flow

LC-1

LC-2

3E
MANSW

SP

PI

PI

TR

1E

FC

RSP

1E

TR

f(x)

+/T

PI
TR

f(x)

MANSW

+/T

MANSW

MANSW
SEL
VLV

+/T

AOUT

AOUT

AOUT

LLFCV

FLFCV-1

FLFCV-2

DRUM
LEVEL
CONTROL

Drum Level

Main Steam
Flow

Feed Water
Flow

LC-1

LC-2

3E
MANSW

SP

PI

PI

TR

1E

FC

RSP

1E

TR

f(x)

+/T

PI
TR

f(x)

MANSW

+/T

MANSW

MANSW
SEL
VLV

+/T

AOUT

AOUT

AOUT

LLFCV

FLFCV-1

FLFCV-2

DRUM
LEVEL
CONTROL