Boiler -Emergency Handling

1. 1. BOILER EMERGENCIES  Drum level low  Drum level high  Any FD fan trip  Any ID fan trip  PA fan trip
 DCF trip Continued…
2. 2. BOILER EMERGENCIES  Bed temperature too high  Final Steam temperature too high  Final Steam
temperature too low  PSH O/L steam temperature high  Economizer O/L FW temperature high Continued…
3. 3. BOILER EMERGENCIES  High positive draught  High negative draught  Hot bed material leakage from PA
lines or bed ash drain  O/L steam pressure too low  Back fire in PA lines
4. 4. Drum Level Low  Check BFP discharge header pr. And start another BFP if required  Check FW control valves
position in DCS and in field  Check position of all MOVs and operate them accordingly.  Check for any abnormal
sound from furnace.
5. 5. Drum Level High  Operate IBD as per requirement.  Check FW control valves position in DCS and in field.  Close
MOVs of Feed Water station as per requirement.  Observe PSH O/L steam temperatures.  Observe Final steam
temperature and if it starts dropping, close Boiler stop valve immediately.
6. 6. Any FD fan trip  Stop coal feeding.  Reduce load on Turbine according to requirement  Observe Bed temperature 
Check for reason of tripping  If the situation diminishes further shut the Boiler stop valve.  Take compartments into
service one by one and load the turbine
7. 7. Any ID fan trip  Cut down air flow by operating FD dampers.  Slump two compartments.  Check the load on
running fan.  Reduce load on turbine according to requirement.  Check for reason of fan tripping.  Take compartments
into service one by one and load the turbine
8. 8. PA fan trip  Check that whether all DCF got tripped or not. Otherwise stop them immediately.  Reduce the load on
turbine according to requirement  See that the standby fan is started. Otherwise start it and increase the PA header pr. 
Check PA lines for jamming and clear them accordingly.  Take compartments into service one by one and load the
turbine
9. 9. DCF trip  Check PA header pr. If it is less increase it.  Increase feeding in other compartments or boiler.  Check for
reason of DCF tripping.  In case of all DCF tripping, isolate boiler depending on situation.  In case of any one DCF
 tripping, observe final steam pr. And temperature and if require isolate attemparator.  Take burner support according to
requirement.  If the problem persists for longer time and pressure drops, reduce load on turbine.
10. 10. Bed temperature too high  Cut down coal feeding to that compartment.  Increase air flow and PA header pr. 
Check for wind box damper position.  Constantly observe the wind box pr.  Charge bed material.  Check for abnormal
sound from furnace.  Stop the boiler if temperatures still not controlled, bed height decreases rapidly and abnormal
sound is observed.
11. 11. Final Steam temperature too high  Take attemparator by – pass into service.  Reduce feeding in 3rd , 4th and 5th
compartments.  Increase load on boiler.  Observe the TG inlet steam temperature.  Reduce the steam temperature in
other boiler.  Check attemparator control valve position in DCS and in field.  Ensure that none of drum safety valve has
popped.
12. 12. Final Steam temperature too low  Isolate attemparator and check for passing/opening of attemparator by – pass. 
Check drum level.  Observe constantly the TG inlet steam temperature.  Increase steam temperature in other boiler. 
Increase feeding in 3rd , 4th and 5th compartments.  Reduce load on boiler.  If the rate of drop is higher, isolate the
boiler immediately and operate start – up accordingly.
13. 13. PSH O/L steam temperature high  Increase load on boiler.  Minimize furnace draught.  Check the position of
overfeed secondary air dampers and open them.  Regulate air flow according to requirement.  Increase bed height. 
Meanwhile confirm that the temperature indication is correct.(Attemperator flow will increase)
14. 14. Economizer O/L FW temperature high  Increase load on boiler.  Reduce Economizer I/L feed water temperature. 
Minimize furnace draught.  Check the position of overfeed secondary air dampers and open them.  Regulate air flow
according to requirement.  Increase bed height.  Meanwhile confirm that the temperature indication is correct.
15. 15. High positive draught  Confirm that the draught indication is correct.  Check and control ID fan speed.  Check ID
dampers position.  Check FD dampers position.  Check for abnormal sound from furnace.
16. 16. High negative draught  Confirm that the draught indication is correct.  Check and control ID fan speed.  Check
wind box dampers position.  Check ID dampers position.  Check FD dampers position.  Check APH online and by –
pass dampers position.
17. 17. Hot bed material leakage from PA lines or bed ash drain/Back fire in PA lines  Observe bed temperatures constantly
and charge bed material if required.  Cut down coal feeding to that compartment, let the bed temperature be drop down
 and close wind box damper.  Check that air damper of that line is open.  Clear that line if the leakage is from vertical
portion.  If the leakage increases further, stop the boiler.
18. 18. O/L steam pressure too low  Check bed temperatures and increase coal feeding accordingly.  Check for jamming of
coal hopper, PA lines and clear them accordingly.  Take burner support if required.  Ensure that DCF chain is
rotating(no shear pin failure).  Ensure that air flow is sufficient.  Drain bed material slowly, if bed height is more.
Continued…
19. 19. O/L steam pressure too low  Check for passing or malfunctioning of Boiler safety valves.  Check for abnormal
sound from furnace.  Check for malfunctioning of Dumping control valve and PRDS control valve.  Check and increase
the feed water temperature.  If pressure goes down further and frequency drops, reduce load on turbine.

TURBINE EMERGENCIES
20. 20. TURBINE EMERGENCIES  Turbine trip  Load throw off  UAT trip  CEP trip  Hotwell level high 
Hotwell level low  Vacuum drop Continued…
21. 21. TURBINE EMERGENCIES  Fire/smoke at turbine area  Turning gear trip  Oil temperature high  Bearing
temperature high  Bearing vibration high  Steam pressure high after first stage
22. 22. Turbine trip (sharing mode)  Safeguard the running unit (Reduce load on turbine if required and Ensure that CWP,
BFP, ACWP, CT Fan, Inst.air compressor are running)  Cut down proportionate coal feeding in boilers.  Observe boiler
drum level and take steps accordingly.  Control steam pressure by operating PRDS and dumping control valves.  Start
AOP, JOP, TTG.  Investigate the reason of tripping.  Don’t switch on PEF until unless it is reset and load
23. 23. Turbine trip (Non – sharing mode)  Safeguard the running unit (Reduce load on turbine if required and Ensure that
CWP, BFP, ACWP, CT Fan, Inst.air compressor are running)  Take grid supply after ensuring Generator breaker has
opened.  Observe boiler drum level and take steps accordingly.  Control steam pressure by operating PRDS and
dumping control valves.  Ensure that extraction MOV is closed. Continued…
24. 24. Turbine trip (Non – sharing mode)  Start AOP, JOP, TTG.  Investigate the reason of tripping.  Don’t switch on
PEF until unless it is reset and load shedding is switched – off.  Maintain hotwell level and ensure that CEP is running.
25. 25. Load throw – off  Check turbine speed, if it is at alarming level and is increasing further, trip the turbine.  Observe
drum level.  Slump compartments in boiler according to the amount of load thrown off.  Take PRDS into service if both
extractions are out of service. Continued…
26. 26. Load throw off  Regulate dumping steam according to dumping header temperature and condenser vacuum.  Check
for reason of load throw – off.  If the load throw – off occurs because of any breaker opening, check thoroughly before
closing it.
27. 27. UAT trip  Observe the hotwell level and condenser vacuum and if the power is not resumed within short time, trip
the turbine and isolate all steam inputs to condenser.  Reduce load on running turbine if required.  Observe CW and
turbine oil temperatures.  Check for reason of UAT tripping and charge all remaining feeders/MCC keeping the faulty
feeder/MCC isolated.
28. 28. CEP trip  Ensure that standby pump has taken over.  Check for reason of tripping.  Check hotwell level and if it is
low, take make – up water into hotwell.  Open hotwell re – circulation valve fully.  Check for passing of condensate
valve B or C and isolate them accordingly.  If the tripping is because of overload, check for mechanical jamming of
pump.
29. 29. Hotwell level high  Ensure that standby pump has taken over.  Check running CEP(s) load.  Close hotwell re –
circulation valve.  Check position of condensate valve B or C and operate them accordingly.
30. 30. Hotwell level low  Take make – up water into hotwell.  Open hotwell re – circulation valve fully.  Check for
passing of condensate valve B or C and isolate them accordingly.
31. 31. Vacuum drop  Check gland steam pressure.  Check CW temperatures.  Check hotwell level.  Check the running
ejector.  Check for air ingress from all vacuum related lines and valves.  Cut down dumping steam.  Charge standby
ejector if the rate of drop is more.  If the rate of drop is more, reduce load on turbine.
32. 32. Fire/smoke at turbine area  Ensure that vapour extraction fan is running if the fire is because of oil leakage from any
bearing.  Use CO2 fire extinguisher in case of minor oil and electrical fires. Don’t use water or other type of fire
extinguishers.  In case of major fire, first isolate the source (trip the turbine and isolate generator from electrical circuit)
and then quench it.
33. 33. Turning gear trip  Ensure that jacking oil pressure is sufficient.  Ensure that lube oil pressure is sufficient.  Put
turbine on manual barring gear.  Check for reason of turning gear trip.
 34. 34. Oil temperature high  Ensure that the CW temperatures are not on higher side (All CT fans are running).  Stop
TOPP if it is running.  Check oil level in Main oil tank.  Provide external cooling arrangement.  Ensure that oil
temperature controller is working.  If the bearing temperatures start increasing, trip the turbine immediately and provide
external cooling arrangement for bearings.
35. 35. Bearing temperature high  Charge bleed steam.  Check oil temperature.  Check oil level in Main oil tank.  Ensure
proper oil flow to the bearing.  Check axial shift.  Provide external cooling arrangement.  Reduce load on turbine if
temperatures goes on raising.
36. 36. Bearing vibration high  Confirm that the signal is correct and is matching with Bently – Nevada vibration monitoring
system.  Confirm the same in field physically.  Ensure proper oil flow to the bearing.  Check casing temperature
difference.  Reduce load on turbine if vibration goes on raising.
37. 37. Steam pressure high after first stage  Reduce load on turbine if pressure is at alarming level.  Reduce bleed steam. 
Check control valve position and turbine speed.

BFP & Inst Air Comp

38. 38. Other emergencies  BFP trip  CWP trip  Inst. Air compressor trip
39. 39. BFP trip/Discharge header pr. low  Ensure that standby pump has taken over.  Monitor drum level (Increase
dumping CV opening, if drum level starts dropping).  Reduce load on TG.  Investigate the reason for tripping.  If both
the BFP tripped and standby has not taken over because of any common problem, trip both TG and box – up the boiler.
40. 40. CWP trip/ Discharge header pr. low  Ensure that standby pump has taken over.  Monitor condenser vacuum. 
Reduce load on TG.  Cut down dumping.  Investigate the reason for tripping.  If both the CWP tripped and standby
has not taken over because of any common problem, trip both TG and isolate all steam inputs to the condenser.
41. 41. Inst. Air compressor trip/Inst. Air pr. low  Ensure that standby compressor has taken over.  Check conservair O/L
air pr.  Monitor boiler drum level, furnace draft, CWP discharge header pr., FD control dampers position constantly. 
Ensure that running compressor is fully loaded.  Check for choking of dryer filters.  Ensure that both dryers power
supply is ON.  Check for leakages in the system.
BASIC INSTRUMENTATION

 Has a very high temperature coefficients - produce large changes in resistance in response to change in temperature.
Hence, particularly good for small span & difficult to handle large spans.
Has a Non-Linear temperature vs resistance curve.
Stability greater than 300 degrees is a problem.
Application - Temperature Control Circuits as safety device
example: on windings of transformer to detect overheating
     What are the most commonly sold types of T/C’s? (Type J and K)
   Sensor elements for industrial applications must be packaged ruggedly. RMD standard sensors are all of mineral
insulated cable design with 6 mm sheath diameter.
RTD ( Resistance Temperature Detector) sensors using platinum resistance elements provide the most stable and reliable
measurement over the range -200 to 500 C and should always be specified by choice. Sheath material is AISI 321 stainless
steel. Model 65, using platinum film type element, has its’ range reduced to meet the requirements of the international
specification IEC 751:1983 INDUSTRIAL PLATINUM RESISTANCE THERMOMETER SENSORS. ( including Amendments A1:1986
and A2:1995). Model 75, using a wire-wound element will meet IEC 751 over an extended temperature range. Grade B
tolerance class is offered as standard with Grade A as an option.
Thermocouples must be offered for temperatures in excess of 500 C. Up to 1100 C type K should be specified. Sheath material
must be suitable for these high temperatures and Inconel is available as standard. Thermocouples meet the requirements of
IEC 584 :1995 THERMOCOUPLES, and are available to tolerance class 2 as standard. Other tolerance classes, requiring specially
selected materials, are available as specials.
For temperatures above 1100 C thermocouples , such as types R or S, are available. These are always supplied as specials as
the high temperature environment determines the many thermocouple and sheath material options that will be required.
  Question - How is the transmitter powered?
EXCERCISE: If the transmitter has a range of 0-200°C (and we know that the mA signal is linear with temperature), what must
the mA signal be?

Basics Of Instrumentation

1. 1. BASICS • What is Instrumentation? • Basic Terminologies • Process & its Control • Field Instruments & its principles •
Valves & its working
2. 2. What is Instrumentation? • Instrumentation is about measurement and control. • Instrumentation engineering is the
engineering specialization focused on the design and configuration of process systems. • Instruments are devices which
are used in measuring attributes of process systems.
3. 3. Basic Terminologies • Process: Series of continuous or regularly recurring steps or actions intended to achieve a
predetermined result, as in heat treating metal, or manufacturing acid. • Transducer(sensor): Element which converts
one form of Energy to Other form. • Primary Transducer: Transducer which converts the Process parameter to a form
readable by Secondary Transducer. Eg: Orifice plate • Secondary Transducer: Transducer or transmitter which responds
to a measured variable and converts it to a standardized transmission signal which is a function only of the
measurement. Eg: DP Transmitter
4. 4. • Signal: The signal is the event or phenomenon that conveys data from one point to another. • Loop: A Loop is a
combination of one or more interconnected instruments arranged to measure a process variable. It shall comprises the
whole chain from Primary element to Correcting Element. • Controller: A device that operates automatically by use of
some established algorithm to regulate process variable(PV) according to the set point(SV). The controller input receives
 information about the status of the process variable and then provides an appropriate output signal(MV-manipulated
variable) to the final control element(eg-valves etc.,).
5. 5. •Interlock: It refers to the set of plant conditions(eg. Level of a tank, temp of furnace, position of furnace or a valve,
flow of a fluid, etc) which are to be satisfied before operating(starting, stopping, opening ,closing ,etc)of any instrument
or equipment. ANALYSER: •Monitor pollutant gas emissions from industrial processes. •Gas analyzer is a gas comparator
providing high linearity of signal transformation function. WEIGHFEEDER: •Controller multiplies the signal from the load
cell(belt load,kg/m) with that from the speed transducer(belt speed,m/s) to get the feed rate. •The controller then
either changes the belt speed or belt load to get the set feed rate.
6. 6. CONVEYOR: Conveyors are used as components in automated distribution and warehousing. A belt conveyor consists
of two or more pulleys, with a continuous loop of material - the conveyor belt - that rotates about them. One or both of
the pulleys are powered, moving the belt and the material on the belt forward. The powered pulley is called the drive
pulley while the unpowered pulley is called the idler. BELTWEIGHER: • Material flowing over the belt may be weighed in
transit using a beltweigher.A belweigher or belt weigher is a piece of industrial control equipment used to gauge the
mass or flow rate of material travelling over a conveyor belt.
7. 7. Process & its Control • Process Parameters: – Pressure – Level – Temperature – Flow
8. 8. Pressure Measurement • PRESSURE A force applied to or distributed over a surface. The pressure (P) of a force (F)
distributed over an area(A) is defined as : P = F / A Standard Unit of Pressure is Pascal Other units of pressure are psi
kg/cm2 bar atmosphere torr 1 Pa = 1 N/m2
9. 9. Pressure Measurement • Primary Pressure Measuring Devices: – Diaphragm – Bellows – Manometer • Pressure
measurements can be divided into three different categories: – absolute pressure – gauge pressure and – differential
pressure
10. 10. GAUGE PRESSURE • Gauge pressure is the pressure relative to the local atmospheric or ambient pressure. In
measurements a gauge is used to record the pressure difference between the system and the atmospheric pressure.
This is called gauge pressure and can be stated by the following equation: Pg=Pa+Po where Pg= gauge pressure Po =
atmospheric pressure • If the pressure of a system is below atmospheric, it is called vacuum pressure. •When pressure
is measured by a gauge, the quantity obtained usually excludes the ambient atmospheric pressure and is therefore
called overpressure, Poverpressure = Pgauge
11. 11. ABSOLUTE PRESSURE If atmospheric pressure is included, then the resulting pressure is called absolute pressure
Pabsolute = Patmospheric + Pgauge The absolute pressure is measured relative to the absolute zero pressure - the
pressure that would occur at absolute vacuum. P=Pg+Po P=absolute pressure, Pg=gauge pressure, Po=atmospheric
pressure. DIFFERENTIAL PRESSURE Differential pressure is the difference in pressure between two points.
12. 12. ATMOSPHERIC PRESSURE •The atmospheric pressure is the pressure in the surrounding air at or "close" to the
surface of the earth. •The atmospheric pressure varies with temperature and altitude above sea level. •Atmospheric
pressure is the pressure exerted at the surface of a body by a column of air in an atmosphere. 1 atmosphere on Earth =
760 millimeters of mercury (760 Torr) and 101,325 Pascals. STANDARD ATMOSPHERIC PRESSURE : The Standard
Atmospheric Pressure (atm) is used as a reference for gas densities and volumes. The Standard Atmospheric Pressure is
defined at sea-level at 273o K (0o C) and is 1.01325 bar or 101325 Pa (absolute). The temperature of 293o K (20o C) is
also used.
13. 13. Types of Pressure Measuring Devices Manometer Bourdan Gauge
14. 14. Contd.. Strain Gage Types Capacitive Peizo Electric LVDT
15. 15. Level Measurement • Some of the most commonly used liquid-level measurement methods are: • RF capacitance •
Conductance (conductivity) • Hydrostatic head/tank gauging • Radar • Ultrasonic
16. 16. Level Measurement Level Measurement using Pressure Transmitter P = ρgh
17. 17. Open Tank Closed Tank
18. 18. RF Capacitance Conductive Type
19. 19. Hydrostatic Head
20. 20. RADAR Type Ultrasonic Type
21. 21. Flow Measurement • Principle: – Flow is measured by measuring velocity through a known area.with this indirect
method,the flow measured is the volume flow rate Q . Q = A x V Where A is the cross sectional area of the pipe V is the
fluid velocity Unit of low is m3 /hr or litres/hr
22. 22. Flow Measurements • Types: – Head Type Flowmeters – Mechanical Flowmeters – Electronic Flowmeters – Mass
Flowmeters
23. 23. Different Type of Head Type Flowmeters • Orifice Plate • Venturi • Flow Nozzle • Pitot Tube • Elbow
24. 24. Orifice • Service: Clean Liquids, Gases Steam,(no slurries or corrosive) • Scale: Square Root • Accuracy: 1% Full Scale
• Permanent Pressure Loss: High • Cost: Low Basic Equation :V=k*(h/D)0.5
25. 25. Venturi • Service: Clean Liquids, Gases Steam Slurries and Dirty Fluids • Scale: Square Root • Accuracy: 1% Full Scale
• Rangability: 3:1 • Permanent Pressure Loss: Low • Cost: High
26. 26. Variable Area Meters
27. 27. Mechanical Flowmeters
28. 28. Electronic Flowmeters
29. 29. Vortex Flowmeters
30. 30. Ultrasonic Flowmeters
31. 31. Temperature Measurement • Temperature: – Webster’s defines temperature as “the degree of hotness or coldness
measured on a definite scale. Various units of temperature are related as C = 5/9 (F – 32) F = 9/5 (C ) + 32 K = 273 + C R =
460 + F
32. 32. Temperature Measurement • Types of Temp Measurement: – RTD – Thermocouple – Thermistor – Thermopile –
Pyrometer
33. 33. 35 Steam Cold Water Hot Water Load Disturbance TT TIC I/ P Temperature terminology Temperature Control Loop •
Temperature Loop Issues: – Fluid response slowly to change in input heat – Requires advanced control strategies •
Feedforward Control
34. 34. 36 • Example: Thermistors • RTD (discussed later) • Thermistors • Semi-conductors made from specific mixtures of
pure oxides of nickel, manganese, copper, cobalt, and other metals sintered at very high temperature. • Used with
Wheatstone Bridge which amplifies small change in resistance - in a simple circuit with a battery and a micro-ammeter.
• Stability - • Linearity - • Slope of Output - Temperature Measurement Technology Change in RESISTANCE with
response to change in TEMPERATURE Moderate Poor (Logarithmic) Negative
35. 35. 37 Temperature Sensors RTDs • What is an RTD ? – RResistance TTemperature DDetector Platinum resistance
changes with temperature Rosemount’s Series 78, 88 Rosemount’s Series 68, 58 Series 65 Two common types of RTD
elements: Wire-wound sensing element Thin-film sensing element » Operation depends on inherent characteristic of
metal (Platinum usually): electrical resistance to current flow changes when a metal undergoes a change in
temperature. » If we can measure the resistance in the metal, we know the temperature!
36. 36. 38 Temperature Sensors RTDs • How does a RTD works? – Resistance changes are Repeatable – The resistance
changes of the platinum wiring can be approximated by an ideal curve -- the IEC 751 0 50 100 150 200 250 300 350 -400
-200 0 200 400 600 800 Resistance(Ohms) Temperature (o C) o C Ohms 0 100.00 10 103.90 20 107.79 30 111.67
International Resistance vs. Temperature Chart: IEC 751 IEC 751 IEC 751 Constants are :- A = 0.0039083, B = - 5.775 x 10
-7 , If t>=0°C, C=0, If t<0, C = - 4.183 x 10 -12 Example: RT = R0 [1 + At + Bt2 + C(t-100)t3 ] = 103.90
37. 37. 39 ProcessProcess TemperatureTemperature Hot junction – Two dissimilar metals joined at a “Hot” junction Cold
junction + - MV – The wires are connected to an instrument (voltmeter) that measures the potential created by the
temperature difference between the two ends. DT “40 millivolts!,” Tommy Seebeck yelled in a heated debate. The
junction of two dissimilar metals creates a small voltage output proportional to temperature! What is a Thermocouple ?
Temperature Sensors Thermocouples
38. 38. 40 • How does a Thermocouple work ? – The measured voltage is proportional to the temperaturetemperature
differencedifference between the hot and cold junction! (T2 - T1) =∆T. + - MVHeat Hot junction Cold junction o C
Millivolts 0 0.000 10 0.591 20 1.192 30 1.801 Thermoelectric Voltage vs. Temperature Chart: TYPE E THERMOCOUPLE ∆T
-20 0 20 40 60 80 -500 0 500 1000 Voltage(mV) Temperature (o C) IEC 584 MeasurementMeasurement JunctionJunction
TT22 ReferenceReference JunctionJunction TT11 Temperature Sensors Thermocouples
39. 39. 41 Type J – Iron / Constantan • White, Red • 0 to 760 °C • Least Expensive Types of Thermocouple Type K – Chromel
/ Alumel » Yellow, Red » 0 to 1150 °C » Most Linear Type T – Copper / Constantan » Blue, Red » -180 to 371 °C » Highly
resistant to corrosion from moisture + - + - + - Temperature Sensors Thermocouples
40. 40. 42 • Better Accuracy & Repeatability – RTD signal less susceptible to noise – Better linearity – RTD can be “matched”
to transmitter (Interchangeability error eliminated) – CJC error inherent with T/C’s; RTD’s lead wire resistance errors can
be eliminated Why choose RTD over Thermocouple ? Better Stability – T/C drift is erratic and unpredictable; RTD’s drift
predictably – T/C’s cannot be re-calibrated Greater Flexibility – Special extension wires not needed – Don’t need to be
careful with cold junctions Temperature Sensors Comparison
41. 41. 43 • Applications for Higher Temperatures • Above 1100°F • Lower Element Cost • Cost is the same when
considering temperature point performance requirements • Faster response time • Insignificant compared to response
time for T-Well and process • Perceived as more rugged • Rosemount construction techniques produce extremely
rugged RTD Why choose thermocouple over RTD ? Temperature Sensors Comparison
42. 42. 44 RANGE OFFER -200 to 500º C RTD 500 to 1100º C Thermocouple Type K >1100º C Special Thermocouple R, S or B
Temperature SensorsTemperature Sensors ComparisonComparison
43. 43. 45 • What is a thermowell (T-well) ? – A unit that protects a sensor from process flow, pressure, vibrations, and
corrosion – Allows for sensor removal without process shutdown – Slows response time (by 5 times) Why are there
different material types ? – To handle different corrosive environments – To handle different temperature and pressure
limits Sensor accessories Thermowells
44. 44. Control Valves • The control valve manipulates a flowing fluid, such as gas, steam, water, or chemical compounds, to
compensate for the load disturbance and keep the regulated process variable as close as possible to the desired set
point. • The control valve regulates the rate of fluid flow as the position of the valve plug or disk is changed by force
from the actuator. • Control valves are valves used within industrial plants and elsewhere to control operating
conditions such as temperature, pressure ,flow, and liquid level by fully or partially opening or closing in response to
signals received from controllers that compare a "set point" to a "process variable" whose value is provided by sensors
that monitor changes in such conditions. • The opening or closing of control valves is done by means of electrical,
hydraulic or pneumatic systems.
45. 45. CONTROL VALVES: They are basically pneumatically operated valves which require around 4 to 5 kg/cm2 of air
pressure to operate the valve. I / P Converter POSITIONER CONTROL VALVE SUPPLY AIR Pneumatic signal CURRENT
SUPPLY AIR
46. 46. Control Valve Types
47. 47. Valve Body Types • Diff. types of Valve Body: • Butterfly Valve • Globe Valve • Ball Valve • Plug type Valve • Needle
Valve
48. 48. Positioner & its accessories • Pneumatically operated valves depend on a positioner to take an input signal from a
process controller and convert it to valve travel. • A pneumatic signal (usually 3-15 psig) is supplied to the positioner.
The positioner translates this to a required valve position and supplies the valve actuator with the required air pressure
to move the valve to the correct position. • Analog I/P Positioner—This positioner performs the same function as the
one above, but uses electrical current (usually 4-20 mA) instead of air as the input signal.
49. 49. Automation (ancient Greek: = self dictated), roboticization or industrial automation or numerical control is the use of
control systems such as computers to control industrial machinery and processes, replacing human operators. The most
 commonly used automation systems are : • DCS - Distributed Control System • PLC - Programmable Logic Controller •
SCADA – Supervisory Control And Data Acquisition System
50. 50. DCS • Distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any
kind of dynamic systemdynamic system, in which the controller elements are not central in location (like the brain) but
are distributed throughout the system with each component sub-system controlled by one or more controllers. The
entire system of controllers are connected by a network for communication and monitoring. • DCS is a very broad term
used in a variety of industries, to monitor and control distributed equipment. • A DCS typically uses computers (usually
custom designed processors) as controllers and uses both proprietary interconnections and protocols for
communication. Input & output modules form component parts of the DCS. The processor receives information from
input modules and sends information to output modules. The input modules receive information from input
instruments in the process (a.k.a. field) and output modules transmit instructions to the output instruments in the field.
Computer buses or electrical buses connect the processor and modules through multiplexers/demultiplexers. Buses also
connect the distributed controllers with the central controller and finally to the Human-Machine Interface (HMI) or
control consoles.
51. 51. ARCHITECTURE OF DCS Operator Workstation 1 Operator Workstation 2 Operator Workstation 3 Controller 1
Controller 2 Controller 3 Controller 4 Sensor 1 Actuator 1 Actuator 2 Sensor 3 Actuator 3 Sensor 4 Actuator 4 Database
Input Module Output Module Sensor 2 Input Module Input Module Input Module Output Module Output Module
Output Module
52. 52. HIS HIS ENG STATION FCS NIU NIU BCV MFCD RL BUS V NET ETHERNET FIELD INSTRUMENTS RIO BUS V NET FCS
MOPL JB 1 JB 2 FIELD INSTRUMENTS MAR MAR DCS : BASIC CONFIGURATION MAR V NET JB 3
53. 53. BASIC TERMINOLOGIES OF DCS HIS: Human Interface Station The HIS is mainly used for operation and monitoring-it
displays process variables,control parameters and alarms necessary for users to quickly grasp the operating status of the
plant. NIU: Node Interface Unit These are remote I/O units which all the Instruments are connected.these units in turn
are connected to FCS through RIO bus. FCS: Field Control Station It is the main control unit which controls the
plant.there can be more than one FCS which then communicate with each other and also communicate with the HIS
from where the Operator is operating. Vnet: The Vnet real time control system BUS links station such as FCS,HIS,BCV
andCGW. ETHERNET: Ethernet is used to link HIS,ENG and supervisory systems.it is also used for transferring data files to
 supervisory computers and for HIS data equalization. RL Bus: This a control system BUS(communication link) which
connects Field control units,operators stations. CGW: Communication Gateway This unit links the Vnet control system
BUS to an ETHERNET BUS BCV: Bus Converter The communication bus of one version of DCS may not communicate with
the newer versions so BUS CONVERTER is used to convert the BUS to suitable mode. In our plant our existing RL BUS is
converted to newer system bus Vnet by the Bus Converter kept in Engineering room near central control room.
54. 54. Programmable Logic Controller (PLC) •Programmable Logic Controller (PLC) is a microprocessor based system that
uses programmable memory to store instructions and implement functions such as logic, sequencing, timing, counting
and arithmetic in order to control machines and processes. •Unlike Personal Computer, PLC does not contain
peripherals, such as display or keyboard, that allow user to directly interact with PLC. In order to facilitate interaction,
separate computer is provided, normally taking form of a standard PC. Through this external computer, operator can re-
program PLC, provide set-points and view trends of process variables that are controlled and manipulated by PLC. PLC
Actuator Process Sensor External Computer
55. 55. Power Supply Communication Module Microprocessor + Memory Analogue Input (AI) Module Discrete Output (DO)
Module Discrete Input (DI) Module Analogue Output (AO) Module Analogue Sensor Discrete Sensor Analogue Actuator
Discrete Actuator Operator Workstation Programmable Logic Controller Architecture PLC
56. 56. Communication Module Microprocessor Input Module External Computer Programmable Logic Controller
Architecture PLC Output Module Actuator Process Sensor
57. 57. PLC consists of the following components: • Microprocessor – This is the brain of PLC. It reads input signals, executes
control program and communicates results (decisions) of control program as action signals to the outputs. • Memory –
It stores control program that is to be executed at a prescribed rate. • Power Supply – This component is used to
convert the mains AC voltage to the low DC voltage (e.g. from 240V AC to 5V DC). This unit powers the processor and
the circuits in the input and output modules. • Input Module – This component receives information from external
devices (sensors). It contains circuitry that provides electrical isolation and signal conditioning functionalities. Input
module can be analogue input (AI) or discrete input (DI) module. AI module receives continuously changing signal whose
amplitude is proportional to the current value of the measured process variable. DI module receives discrete/digital
(ON/OFF) information from discrete sensors, for example push button (ON if button is pressed, OFF if button is not
pressed). Note that DI is much more frequently used than AI. • Output Module – This module communicates control
 actions to external devices (actuators). It contains circuitry required to interface PLC with actuators (e.g. digital-to-
analogue converter and power amplifier). Like input module, output module can be analogue output (AO) or discrete
output (DO) module depending on the type of actuator used. • Communication Module – This component allows PLC to
communicate with external devices using sophisticated multiple-bit digital communication protocols (e.g. Ethernet).
58. 58. Programmable Logic Controller (PLC)
59. 59. PLC Programming • Ladder Diagram - most common • Structure Text Programming (ST) • Functional Block
Programming (FB) • Instruction List (IL) • Sequential Function Chart (SFC)
60. 60. • SCADA system performs the following tasks • Collection of data from field devices, which can be sensors, actuators
and controllers. • Transfer of field devices’ information via communication link to the central site (master station) •
Execution of any necessary analysis and supervisory control calculations, all of which are taking place at the master
stations. • Display process information on a number of operator screens. • Convey any required supervisory control
actions back to the field devices. Supervisory Control and Data Acquisition (SCADA)