Control & Instrumentation

CONTROL & INSTRUMENTATION
Instrumentation
SELECTION AND APPLICATION OF INSTRUMENTS TO

MEASURE AND CONTROL THE PROCESS TO GET THE
DESIRED OUTPUT.
CONTROL & INSTRUMENTATION 3

Function
 TO MEASURE & MONITOR
 TO CONTROL THE OUTCOME OF ANY PROCESS INLINE WITH SPECIFIC

REQUIREMENT TO ACHIEVE THE DESIRED OUTPUT
 INCREASED PRODUCTIVITY
 LESS MANPOWER
 SAFETY

NEED FOR C&I IN BOILER & POWER PLANTS
 FOR SEQUENTIAL START UP, SAFE OPERATION AND
SHUTDOWN OF THE BOILER/POWER PLANT.
 TO MONITOR AND CONTROL THE PROCESS
AUTOMATICALLY WITH MINIMUM OPERATING
PERSONNEL.

PROCESS
Any operation or sequence of operations
involving a change in the substance.
Examples:
A change of energy state - Water to Steam

A change of composition - Chemical reaction
A change of dimension - Grinding coal

TYPES OF PROCESS VARIABLE
 Pressure
 Temperature
 Flow
 Level
 Mass

PROCESS CONTROL TERMINOLOGY
 PRIMARY SENSING ELEMENT: Devices that are in direct contact

with the process for measurement.
Eg.RTD, Thermocouple
 COMPUTING DEVICE: Devices used for manipulation of the

measured input signal to give control output signal.
Eg.Controllers, DCS (Distributed
Control System)
 FINAL CONTROL ELEMENT: The last control element in the process

control loop used for regulating/controlling the process.
Eg.Control valve, Regulating Dampers (Pneumatic/ electrical
operated), Variable Speed Drives

INSTRUMENTS & CONTROL
 TYPES OF INSTRUMENTS
 TYPES OF CONTROLS

TYPE OF INSTRUMENTS
 PRESSURE INSTRUMENTS
 TEMPERATURE INSTRUMENTS
 FLOW INSTRUMENTS
 LEVEL INSTRUMENTS

TRANSDUCERS
A Transducer is a device which converts one form of
energy in to another form of energy.
 Pressure to Capacitance
 Pressure to Resistance or Mv
 Temperature to Resistance
 Temperature to Mv
Example:
 Capacitance pressure sensor module
 Piezo - resistive pressure sensor module
 RTD
 Thermocouple

PRESSURE INSTRUMENTS
 PRESSURE TRANSMITTERS
 PRESSURE GAUGES
 DRAFT GAUGES
 MANOMETERS
 DIFFERENTIAL PRESSURE GAUGES

TEMPERATURE INSTRUMENTS
 TEMPERATURE GAUGES
 RTD (RESISTANCE TEMPERATURE DETECTOR)
 THERMOCOUPLE
 PYROMETERS

FLOW INSTRUMENTS
 ORIFICE PLATE
 FLOW NOZZLE
 ROTAMETER
 PITOT TUBE
 ANNUBAR
 PD METER
 MAGNETIC FLOW METER
 MASS FLOW METER
 By Laser

LEVEL INSTRUMENTS
 RADAR TRANSMITTER
 ULTRASONIC TRANSMITTER
 CAPACITANCE TRANSMITTER
 FLOAT TYPE
 DISPLACER TYPE

CONTROLS
 TYPES OF CONTROL
 CONTROL PRINCIPLE
 CONTROL LOOPS

TYPES OF CONTROLS
 ON/OFF CONTROL
 CONTINUOUS CONTROL

ON/OFF CONTROL
DISCRETE CONTROL
 START/STOP
 OPEN/CLOSE

CONTINUOUS CONTROL
CLOSED LOOP CONTROL
 MEASURE
 COMPARE/COMPUTE
 CONTROL

CONTROL PRINCIPLE
A tank with constant inflow/outflow is in equilibrium state.
If any one of the above is varied then equilibrium will get
disturbed.

BASIC CONTROL LOOPS
 PRESSURE CONTROL LOOP
 TEMPERATURE CONTROL LOOP
 FLOW CONTROL LOOP
 LEVEL CONTROL LOOP

PRESSURE CONTROL LOOP
I/P PIC
PT - PRESSURE TRANSMITTER
PIC - PRESSURE CONTROLLER
I/P - CURRENT TO PNEUMATIC
CONVERTOR
CV CV - CONTROL VALVE
PT
TO TANK
PUMP

TEMPERATURE CONTROL LOOP
TT - TEMPERATURE TRANSMITTER
TIC - TEMPERATURE CONTROLLER
I/P - CURRENT TO PNEUMATIC CONVERTOR
CV - CONTROL VALVE
I/P TIC
Water
TT
Steam
CV
Hot Water

FLOW CONTROL LOOP
FT - FLOW TRANSMITTER
TT - TEMPERAURE TRANSMITTER
FIC - FLOW CONTROLLER
CV - CONTROL VALVE
I/P FIC
FT TT
CV

LEVEL CONTROL LOOP
I/P LIC
LT - LEVEL TRANSMITTER
CV LIC - LEVEL CONTROLLER
I/P - CURRENT TO PNEUMATIC
CONVERTOR
CV - CONTROL VALVE
LT

LEVEL CONTROL LOOP
LIC I/P
LT CV
LT - LEVEL TRANSMITTER
LIC - LEVEL CONTROLLER
CV - CONTROL VALVE

MAJOR CLOSED LOOP CONTROLS IN BOILER
 DRUM LEVEL CONTROL
 SUPERHEATED STEAM TEMPERATURE CONTROL
 COMBUSTION CONTROL
 FURNACE DRAFT CONTROL

DRUM LEVEL CONTROL
The main objective of steam drum level control is to maintain
constant water level in the steam drum by selecting either
Single element control for boiler load less than 30%

or
Three element control for boiler load greater than 30%.
SINGLE ELEMENT CONTROL :

 DRUM LEVEL
THREE ELEMENT CONTROL:

 DRUM LEVEL
 FEED WATER FLOW
 STEAM FLOW

SINGLE ELEMENT CONTROL

THREE ELEMENT CONTROL

SUPERHEATED STEAM TEMPERATURE CONTROL
The main objective of the superheated steam temperature

control is to maintain constant superheated steam
temperature at main steam line.
Superheated steam temperature control is achieved

through cascade controller.

SUPERHEATED STEAM TEMPERATURE CONTROL

CASCADE CONTROL
The output of one controller is fed as a set point to another
controller.
Example:1
Primary Secondary
controller controller
r2 m Disturbance
FBC FBC
r1 Secondary Primary
c1 c2 Process Process

CASCADE CONTROL
The temperature of the liquid in the vessel is
controlled by regulating the steam pressure in the
jacket around the vessel.
Temperature Temperature
Example:2 transmitter Measurement
controller
IN Output
Measurement Pressure
Jacket controller
Pressure
transmitter
Valve
OUT Steam
Cascade Control Loop

COMBUSTION CONTROL
What is Combustion?
Combustion is the rapid chemical combination of oxygen with
combustible element of a fuel resulting in the release of heat
energy and light.
COMBUSTION CONTROL
The main objective of the combustion control is to ensure
proper combustion of the fuel by maintaining the air and fuel
ratio as per the design and safe operation of the boiler at any
point of time.

COMBUSTION CONTROL
 AIR FLOW CONTROL

Steam header
Fuel pressure Air
 FUEL FLOW CONTROL
Flow Pressure Flow
Transmitter Transmitter transmitter
Square root
Master
Square root extractor
pressure
extractor
controller
Ratio unit
x
(Set a/f ratio)
Set point Set point

for fuel For air
Fuel
< > Air controller
controller
Control damper
Control valve
Fuel Air

FURNACE DRAFT CONTROL
The main objective of furnace draft control is to maintain

Furnace pressure at the desired value at different boiler
loads.

FURNACE DRAFT CONTROL

I/P Converter.
1. Coil
2. Electro magnet
3. Gap for flux
4. Permanent magnet
5. Flapper ( 4 & 5 integral parts)
6. Nozzle
7. Throttle valve
8. Amplifier for throttle valve
9. Tensioning band
10.Potentio meter
11. Resister
Current (4 – 20 mA) is supplied to e-magnet (2) The magnetic flux of the e-magnet is
attracted by the permanent magnet (4) and is moving along with flapper (5) to allow the air
through the nozzle (6).
According to the intensity (as per current flow 4-20 mA) of the flux of e magnet the amount
of air is passed through nozzle (6)
The air is further throttled by the throttle valve (7) with amplification. The amplification to get
the desired pressure as per the supplied 4 – 20 mA is done by the amplifier (8)
The zero adjustment is made by changing the position of band (9)

Range adjustments is made by potentiometer (10) and the resister (11)

Control & Instrumentation

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CONTROL & INSTRUMENTATION

SELECTION AND APPLICATION OF INSTRUMENTS TO

CONTROL & INSTRUMENTATION 3

 TO MEASURE & MONITOR

 TO CONTROL THE OUTCOME OF ANY PROCESS INLINE WITH SPECIFIC

CONTROL & INSTRUMENTATION 4

 FOR SEQUENTIAL START UP, SAFE OPERATION AND

SHUTDOWN OF THE BOILER/POWER PLANT.

 TO MONITOR AND CONTROL THE PROCESS

AUTOMATICALLY WITH MINIMUM OPERATING

CONTROL & INSTRUMENTATION 5

A change of energy state - Water to Steam

CONTROL & INSTRUMENTATION 6

CONTROL & INSTRUMENTATION 8

 PRIMARY SENSING ELEMENT: Devices that are in direct contact

 COMPUTING DEVICE: Devices used for manipulation of the

 FINAL CONTROL ELEMENT: The last control element in the process

CONTROL & INSTRUMENTATION 9

CONTROL & INSTRUMENTATION 10

CONTROL & INSTRUMENTATION 11

CONTROL & INSTRUMENTATION 12

 DIFFERENTIAL PRESSURE GAUGES

CONTROL & INSTRUMENTATION 13

 RTD (RESISTANCE TEMPERATURE DETECTOR)

CONTROL & INSTRUMENTATION 14

CONTROL & INSTRUMENTATION 15

CONTROL & INSTRUMENTATION 16

CONTROL & INSTRUMENTATION 17

CONTROL & INSTRUMENTATION 18

CONTROL & INSTRUMENTATION 19

CLOSED LOOP CONTROL

CONTROL & INSTRUMENTATION 20

CONTROL & INSTRUMENTATION 21

 PRESSURE CONTROL LOOP

 TEMPERATURE CONTROL LOOP

 FLOW CONTROL LOOP

 LEVEL CONTROL LOOP

CONTROL & INSTRUMENTATION 22

CONTROL & INSTRUMENTATION 23

CONTROL & INSTRUMENTATION 24

CONTROL & INSTRUMENTATION 25

CONTROL & INSTRUMENTATION 26

CONTROL & INSTRUMENTATION 27

 DRUM LEVEL CONTROL

 SUPERHEATED STEAM TEMPERATURE CONTROL

 FURNACE DRAFT CONTROL

CONTROL & INSTRUMENTATION 28

Single element control for boiler load less than 30%

SINGLE ELEMENT CONTROL :

THREE ELEMENT CONTROL:

CONTROL & INSTRUMENTATION 29

CONTROL & INSTRUMENTATION 30

CONTROL & INSTRUMENTATION 31

The main objective of the superheated steam temperature

Superheated steam temperature control is achieved

CONTROL & INSTRUMENTATION 32

CONTROL & INSTRUMENTATION 33

CONTROL & INSTRUMENTATION 34