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

FEEDER

S
U
P
E
R

DRY
ASH
SILO

TO AMBUJA
FOR
PPC
CEMENT

ID
FAN

ESP

TRANSFORMER

ISH

H
E
A
T
E
R

GOVERNER
VALVE

TURBINE

PA FAN

SECONDARY
AIR

FD FAN

BOTTOM
ASH
HOPPER

AIR PRE
HEATER
ZERO
DISCHARGE
SYSTEM

D/A

FEED
WATER

LPH

CEP
CONDENSER

BFP

MAKE UP
WATER
SYSTEM

DM
PLANT

COOLING
TOWER

BOTTOM ASH

ELECTRICITY

CONDENSER COOLING
WATER SYSTEM

FORE BAY
RAW WATER
TREATMENT

COAL

GENERATOR
GENERATOR

BOILER

HPH
AIR
INTAKE

ELECTRICITY

STEAM

APH
COAL
MILL

TO
DISTRIBUTION
SYSTEM

HCSS

INTAKE
PUMPS

CW
PUMP

RIVER
GANGES

Process schematic

Input

Input Devices
-Transmitters
- Switches
-Transducers

Control System for

Processes

Output

- DCS
- PLC
- EHG
- AVR
- AV6 (for Bypass)

Output Devices
- Actuators
- Drives
- Indicators

Controlled Parameters
Most commonly controlled parameters in
Industry are:
1. Flow
2. Level
3. Temperature
4. Pressure
5. Speed (RPM)
6. Position

FLOW
Measured with
Orifice, Nozzle
Pressure drop measured with
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

Measured using
Constant Head Unit
Pressure difference measured with
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
Measured by
RTD (Pt 100)
Output Resistance (ohms)
At 0C value is 100 ohms
Change is 0.385 ohm / C (Linear)

TEMPERATURE
Measured by
Thermocouple
Output mV
Types: J,K,T,S.
Temperature Transmitter

Output 4 to 20 mA

Controlling Devices

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

Boiler Control System comprises the following functions

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

Turbine Control System comprises the following functions
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

EFFECTIVE AND RELIABLE SYSTEM

FOR OVERALL SUPERVISION OF
BOILER SAFETY IN A POWER PLANT.

CONTAINS SAFETY GUIDELINES

PROGRAMMED INSIDE FOR

Transferring control to Fault

Tolerant pair and running self
diagnostics

TAKING PREVENTIVE MEASURES

IN EXTREME CASES TO TAKE THE

Chassis
with
Processor
and I/O
cards

WHOLE SYSTEM TO STEP-BY-STEP

SHUTDOWN.

IT FORESEES FUTURE ERROR AND

GENERATE ALARMS.

Running self diagnostics

and monitoring

Hardware - PLC
THE BMS IS A PLC, PROGRAMMED ACCORDING TO USER NEED.
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)

Comprises CLCS ,OLCS and DAS
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

Application processors (File server) - AW

Stations
Processor
modules

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

Workstation Processor

NODE BUS

FIELD BUS
FBMS
FOR CLCS/OLCS & DAS

Input & Output

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

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

AWCS
Redundant Switches

DCS Hardware (OLCS)

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

INPUT

OUTPUT

DCS Hardware (CLCS)

Field Input (Sensors)

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

INPUT

OUTPUT

DCS Software
The software comprises of mainly
Operating System
Application soft wares for
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

INT-04

CRT STOP

SS IN
REMOTE

STOP

CIN-18
LOCAL
STOP
CIN-19

OFL-11

CIN-2

TRB SPD
LT 1000

PUMP IN
AUTO

SS IN
REMOTE

TC01-S
JOP SUC
PR LO

OPEN LOOP CONTROL

EXAMPLE : LADDER LOGIC
START / STOP LOGIC

SAMA Functional Diagram

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

DRUM LEVEL CONTROL

DRUM LEVEL LHS

DRUM LEVEL RHS

DRUM PRESSURE

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 PRESSURE

MAIN STEAM FLOW

FT

FT

FT

AIN

AIN

AIN

BAD

MAIN STEAM TEMP

PT

PT

TT

TT

TT

AIN

AIN

AIN

AIN

AIN

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

1
LC-1

LC-2

3E
MANSW

PI

PI

TR

1E

FC

SP

RSP

PI
1E

TR

f(x)

TR

f(x)

+/-

+/T

MANSW

+/MANSW

MANSW
SEL
VLV

AOUT

AOUT

AOUT

LLFCV

FLFCV-1

FLFCV-2

DRUM
LEVEL
CONTROL

Drum Level

Main Steam
Flow

Feed Water
Flow

1
LC-1

LC-2

3E
MANSW

PI

PI

TR

1E

FC

SP

RSP

PI
1E

TR

f(x)

TR

f(x)

+/-

+/T

MANSW

+/MANSW

MANSW
SEL
VLV

AOUT

AOUT

AOUT

LLFCV

FLFCV-1

FLFCV-2

DRUM
LEVEL
CONTROL

Drum Level

Main Steam
Flow

Feed Water
Flow

1
LC-1

LC-2

3E
MANSW

PI

PI

TR

1E

FC

SP

RSP

PI
1E

TR

f(x)

TR

f(x)

+/-

+/T

MANSW

+/MANSW

MANSW
SEL
VLV

AOUT

AOUT

AOUT

LLFCV

FLFCV-1

FLFCV-2

DRUM
LEVEL
CONTROL