Power Plant Instrumentation

Power Plant Instrumentation

Second Edition

K. Krishnaswamy
Dean, Curriculum Development and Student Affairs
Kongu Engineering College
Erode, Tamil Nadu

M. Ponni Bala
Assistant Professor
Department of Electronics and Instrumentation Engineering
Kongu Engineering College
Erode, Tamil Nadu

PHI Learning Private Limited

Delhi-110092
2013
POWER PLANT INSTRUMENTATION, Second Edition
K. Krishnaswamy and M. Ponni Bala

© 2013 by PHI Learning Private Limited, Delhi. All rights reserved. No part of this book may be
reproduced in any form, by mimeograph or any other means, without permission in writing from
the publisher.

ISBN-978-81-203-4824-0

The export rights of this book are vested solely with the publisher.

Fourth Printing (Second Edition) . . . . . . . . . August, 2013

Published by Asoke K. Ghosh, PHI Learning Private Limited, Rimjhim House, 111 Patparganj
Industrial Estate, Delhi-110092 and Printed by Mudrak, 30-A, Patparganj, Delhi-110091.
 Contents

Foreword ..................................................................................................................................... xi
Preface ....................................................................................................................................... xiii
Preface to the First Edition ......................................................................................................... xv

1. Overview of Power Generation ....................................................... 1–51

1.1 Introduction 1
1.2 Various Sources of Electrical Energy 1
1.3 Non-conventional Energy Sources 2
1.3.1 Wind Power 2
1.3.2 Solar Power 3
1.3.3 Tidal Power 4
1.3.4 Geothermal Power 4
1.3.5 Magnetohydrodynamic (MHD) Power 6
1.3.6 Fuel Cells 7
1.3.7 Biomass Power 7
1.4 Conventional Energy Sources 8
1.4.1 Hydropower 8
1.4.2 Nuclear Power 11
1.4.3 Gas Power 19
1.4.4 Steam Power (Thermal Power) 20
1.4.5 Comparison of Various Conventional Power Plants 28
1.5 Importance of Instrumentation and Control in Power Generation 30
1.5.1 Classification of Instruments in a Power Plant 30
1.5.2 Objectives of Instrumentation and Control 32
v
 vi Contents

1.6 Piping and Instrumentation Diagram (P and I Diagram) 33

1.6.1 Examples of ISA Instrumentation Diagramming Symbols 38
1.6.2 Examples of SAMA Instrumentation Diagramming Symbols 39
1.6.3 Examples of ISA and SAMA Diagramming 40
1.6.4 Piping and Instrumentation Diagramming 41
1.7 Cogeneration of Power 42
1.7.1 Back Pressure Turbine 42
1.7.2 Pass-Out Turbine 42
1.7.3 Process Heat Unit 43
1.8 Control Rooms 43
1.8.1 Thermal or Boiler Control Room 44
1.8.2 Electrical Control Room 44
1.8.3 Plan of Control Rooms 45
Worked-Out Problems 48
Exercises 50

2. Instrumentation and Control in Water Circuit ........................... 52–107

2.1 Water Circuit 52
2.2 Boiler Feed Water Circulation 52
2.2.1 Natural Circulation 53
2.2.2 Forced Circulation 53
2.2.3 Combined Circulation 54
2.3 Measurements in Water Circuit 57
2.3.1 Water Flow Measurement 57
2.3.2 Differential Pressure Transmitter (DPT) 60
2.3.3 Steam Flow Measurement 60
2.3.4 Water and Steam Pressure Measurements 62
2.3.5 Water and Steam Temperature Measurements 64
2.3.6 Drum Water Level Measurement 64
2.4 Controls in Water Circuit 69
2.4.1 Boiler Drum Level Control 70
2.4.2 Superheated Steam Temperature Control 76
2.4.3 Steam Pressure Control 85
2.5 Impurities in Water and Steam 87
2.5.1 Impurities in Raw Water 87
2.5.2 Effects of Impurities 88
2.5.3 Measurement of Impurities 89
2.5.4 Feed Water Treatment 94
Worked-Out Problems 97
Exercises 106
 Contents vii

3. Instrumentation and Control in Air-Fuel Circuit ...................... 108–160

3.1 Air-Fuel Circuit 108
3.1.1 Fuels 109
3.1.2 Combustion Air 110
3.1.3 Flue Gases 111
3.1.4 Waste Gases 112
3.2 Measurements in Air-Fuel Circuit 113
3.2.1 Measurement of Flow/Quantity 114
3.2.2 Measurement of Pressures 116
3.2.3 Measurement of Temperatures 118
3.2.4 Measurement of Level 118
3.3 Controls in Air-Fuel Circuit 120
3.3.1 Combustion Control 120
3.3.2 Furnace Draft Control 137
3.4 Analytical Measurement 141
3.4.1 Oxygen Measurement in Flue Gas 141
3.4.2 Measurement of Carbon Dioxide in Flue Gas 144
3.4.3 Combustibles Analyser (CO + H2) 145
3.4.4 Infrared Flue Gas Analysers 146
3.4.5 Smoke Detector 147
3.4.6 Dust Monitor 148
3.4.7 Closed Circuit Television (CCTV) 149
3.4.8 Fuel Analysers 150
3.4.9 Chromatography 151
3.4.10 Pollution Monitoring Instruments 153
Worked-Out Problems 154
Exercises 159

4. Power Plant Management ......................................................... 161–208

4.1 Introduction 161
4.2 Master Control 161
4.3 Combustion Process 163
4.3.1 Heat of Combustion/Calorific Value 163
4.3.2 Basic Chemical Equations of Combustion 163
4.3.3 Combustion Calculations 164
4.3.4 Molar Analysis 166
4.3.5 Theoretical or Stoichiometric Air Requirement 167
4.3.6 Excess Air Requirement 167
4.3.7 Products of Combustion 168
4.4 Boiler Efficiency 168
4.4.1 Calculation of Boiler Efficiency 168
viii Contents

4.5 Maintenance of Measuring Instruments 171

4.5.1 Types of Maintenance 172
4.5.2 Maintenance Costs 173
4.5.3 Life Cycle Costs 174
4.5.4 Maintenance Manuals 174
4.5.5 Maintenance Procedures 175
4.6 Intrinsic and Electrical Safety 176
4.6.1 Intrinsic Safety of Instruments 176
4.6.2 Electrical Safety 178
4.6.3 Explosion Hazards and Intrinsic Safety 179
4.7 Interlocks for Boiler Operation 180
4.7.1 Safety Interlocks 180
4.7.2 Start-up and Shutdown Interlocks 181
4.7.3 Sequencing of Burner and Other Operations 181
4.7.4 Programmable Logic Controllers (PLCs) 182
4.8 Computer Based Control and Data Logging Systems 184
4.8.1 Introduction 184
4.8.2 Data Logging (Data Acquisition System) 185
4.8.3 Supervisory Control and Data Acquisition System 186
4.8.4 Control System Networks 187
4.9 Distributed Control System (DCS) 192
4.9.1 Thermal Power Plant Process 193
4.9.2 Application of DCS in Power Plants 194
4.9.3 Advanced Control Algorithms 200
Worked-Out Problems 201
Exercises 207

5. Turbine—Monitoring and Control ............................................. 209–249

5.1 Introduction 209
5.1.1 Classification 209
5.1.2 Instrumentation Control Points of View 210
5.1.3 Principal Parts of Steam Turbines 212
5.2 Turbine Steam Inlet System 214
5.2.1 Inlet Valve Arrangements 214
5.2.2 Inlet Measurements 215
5.2.3 Governors 215
5.3 Turbine Measurements 216
5.3.1 Process Parameters 217
5.3.2 Mechanical Parameters 219
5.3.3 Electrical Parameters 221
5.4 Turbine Control System 233
5.4.1 Safety Control Systems 233
5.4.2 Process Control Systems 238
 Contents ix
5.5 Lubrication for Turbo-alternator 241
5.5.1 Lubrication System 242
5.5.2 Controls in Lubrication System 242
5.6 Turbo-Alternator Cooling System 244
5.6.1 Lube Oil Cooling System 244
5.6.2 Condensate Cooling System 244
5.6.3 Alternator/Generator Cooling System 244
Worked-Out Problems 246
Exercises 248

6. Nuclear Power Plant Instrumentation ...................................... 250–297

6.1 Introduction 250
6.2 Instrumentation and Control for Nuclear Power Plant 251
6.3 Important Components of I&C System 251
6.4 Evolution of I&C in NPP 252
6.5 Sensors and Measurement System 253
6.5.1 Thermometry 253
6.5.2 Neutron Flux Density Measurement [Ionization Sensors] 254
6.5.3 Non-ionization Neutron Flux Measurement 258
6.5.4 Location of Neutron Sensors 259
6.5.5 Ranges of the Neutron Flux Sensors 260
6.6 Reactor Control 261
6.6.1 Methods of Control 261
6.6.2 Control Loops 262
6.6.3 Functions of Control System 263
6.6.4 Pressurized Water Reactor (PWR) Controls 263
6.6.5 Boiler Water Reactor (BWR) Controls 266
6.6.6 Liquid Metal Cooled Reactor (LMCR) Control 268
6.6.7 Role of Reactor Controls during Start-up, Normal Operation and
Shut Down 269
6.7 Digital Architectures in Nuclear Power Plants 271
6.7.1 System-level Instrumentation and Control Architecture 271
6.7.2 Safety Related Systems 272
6.7.3 Non-safety-Related Systems 273
6.7.4 Man-Machine Interface System (MMIS) 274
6.7.5 Instrumentation and Controls Architecture Platform 274
6.8 Radiation Protection and Monitoring 275
6.8.1 Accident at Three Mile Island, USA 275
6.8.2 Disaster at Chernobyl Nuclear Power Plant, Ukraine (Then USSR) 277
6.8.3 Calamity at Fukushima, Daiichi Nuclear Power Plant, Japan 279
6.8.4 Radiation Units 280
6.8.5 Biological Effects of Radiation 281
6.8.6 Radiation Monitoring 282
 x Contents

6.9 Nuclear Reactor Safety 286

6.9.1 Reactor Protection System 286
6.9.2 Reactor Tripping 286
6.9.3 Engineered Safety Features 287
6.10 Surveillance, Diagnostics, and Prognostics 290
6.10.1 Surveillance 290
6.10.2 Diagnosis 291
6.10.3 Prognosis 291
Worked-Out Problems 292
Exercises 296

Index ................................................................................................. 299–303

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