1

GPPC -PIPAVAV
TRAINING REPORT

PREPARED BY:
TRANING REPORT 2

TRAINING REPORT FOR:

SHORT TERM INDUSTRIAL TRAINING AT
GPPC POWER PLANT, PIPAVAV

SUBMITTED AND PREPARED BY:

GUIDED AND TRAINED BY:

CERTIFICATE
 TRANING REPORT 3

This is to certify that Mr xxxxxxxxxxxxx completed training in

partial fulfilment of the requirements for the award of Bachelor of
Engineering in Instrumentation& Control Engineering at Government
Engineering College, Rajkot I did my training in GPPC POWER PLANT
PIPAVAV at kovaya , rajula from 01-06-14 to 30 -06-14.

The matter presented in this Report has not been submitted by me

for the award of any other degree elsewhere.

Signature & Seal of

Training Manager

INDEX
I. Introdustion………………………………………………………………………..…….7
 Fuels, chemicals and gases…………………………………….…………7
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II. Auxiliary system in plant……………….…………………………………….

……9
1) Sea water intake system…………………………………………………………..9
2) Cooling tower & CW Treatment Plant…………….………………………..10
 Types of cooling tower………………………………..……………........10
3) Water Treatment Plant……………………………………………………….….14
 Pretreatment plant………………………………………………………..14
 Process of water treatment…………………………….…………....15
 Ro-dm plant…………………………………………………………………..15
4) Turbine………………………………………………………………………………….18
 Gas turbine……………………………………………………………………18
 Steam turbine……………………………………………………………....21
5) Air compressor……………………………………………………………….....…23
6) Effluent treatment plant (ETP)…………………………………………..…..24
7) Electrical Systems……………………………………………….………….….....26

iii. Various Instrumentation Devices Used In Plant…………….…..…..…28

1. Temperature measuring instrument……………………….………..…28
 RTD………………………………………………………………….…………...28
 Thermocouple………………………………………….…….…………….30
 Temperature gauge……………………………………….……………..35
 Temperature transmitter…………………………….……………….36
 Temperature switch…………………………………….……………….37
2. Pressure measurement……………………………………….…………..….38
 Pressure Transmitters…………………………….………………....38

 Pressure switch……………………………………….……….………..40

3. Level measurement………………………………………………………………….42
 Ultrasonic level switch……………………………………………………43
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  Level Transmitter………………………………………………………….44

4. Flow measurement………………………………………………………………...45
 Flow switch ……………………………………………………………………45
 Rota meter …………………………………………………………………...47

5. DCS……………………………………………………………………………………....48

6. PLC……………………………………………………………………………….………56

iv. Conclusion…………………………………………………………………..….…..59

SAFETY INDUCTION
 TRANING REPORT 6

1. The basic and the most essential aim of GPPC POWER PLANT. Is to
provide maximum safety to their employees.
2. Whether it’s an employee or any visitor no one is allowed to enter
the plant without safety helmet and shoes.
3. A lecture on safety induction was taken by safety manager and I am
very thankful to him for providing me necessary information about
safeties in the plant.
4. During emergencies there are 2 assembly points where all the
employees and contractors including labors gather until the
emergency is over.
5. Before going for a field work in plant person related to the operation
is provided with safety shoes, earplugs ,hand gloves & safety goggles
and other trade related personal protective equipments.
6. Safety shoes & Helmet are compulsory for all employees and visitors
while moving at GPPC site.

i. INTRODUCTION:
TRANING REPORT 7

 Power Corporation GSPC Pipavav Power Company Ltd. (GPPC) is

public limited company incorporate under the Companies Act
1956. The company is jointly promoted by Gujarat State Petroleum
Corporation Ltd. (GSPC) and Gujarat Limited

 GPPC is a 2x351.43 MW Combined Cycle Power Plant Using Natural

Gas as Fuel, is located at Kovaya village, a rural area, situated in
Amreli District, Gujarat State, about 16 KM from Rajula. A district
road connecting the state highway no. SH 34 and running between
Rajula and Jafrabad is the main access road to site at present. The
nearest National Highway is NH – 8E, running East – West from
Porbandar on the coast to Rajkot. This is at a distance of about 6
km from the state highway. The site has about125 hectares of land
bank.

 The installed generation capacity of the plant is 702.86 MW can be

achieved through two units of Gas turbine with 222 MW Capacity
and a steam Turbine with 129.43WCapacity each. The gas turbine
is connected with Heat Recovery steam Generator HRSG) and the
steam turbine put together is called “Combined Cycle”. The gas
turbine is designed for firing on fuel as Natural gas .The generated
power is fed to the GETCO (Gujarat Energy Transmission Company
Limited) grid through the network system erected in the plant. For
Natural Gas there is no storage and the Gas, which is drawn
through pipe lines by GSPL (Gujarat State).
 TRANING REPORT 8

 Sea water is pumped to the plant and is utilized for cooling

Purposes and to produce portable/ service and DM water. Sodium
hypochlorite is used for treatment of water in Water Treatment
Plant and Cooling Water System. Hydrogen is used as the cooling
medium for the higher capacity gas turbine generator and is used
in cylinders. GPPC uses various chemicals for treatment of raw
water cooling water and DM water along with boiler treatment
chemicals

 FUELS, CHEMICALS AND GASES

The fuels, chemicals, gases handled in the plant for the different
processes are as follows natural gas. Natural gas is the main fuel, which
is used to run the turbine.
 TRANING REPORT 9

ii. Auxiliary systems in plant

(1) sea water intake system

(2) cooling tower& CW Treatment Plant
(3) Water Treatment (Pretreatment, DM and Service Water) Plant
(4) Electrical Systems
(5) Effluent treatment plant (ETP)
(6) Turbine
(7) Air Compressor

(1)Sea water intake system:

• Sea water requirement for the plant will be drawn from intake
point in Arabian Sea located at a distance of about 1.0-km from
project site through a pipeline.

• Sea water intake system draws water from the sea and supply to
plant . Raw water is treated and supplied for plant needs.

• Raw water caters to the need of Cooling tower (CW system), CCW
system, ACW system, fire fighting system, DM Water plant, Service
water etc.
 TRANING REPORT 10

(2)COOLING TOWER

 A cooling tower is equipment used to reduce the temperature of a

water stream by extracting heat from water and emitting it to the
atmosphere. Cooling towers make use of evaporation whereby some
of the water is evaporated into a moving air stream and
subsequently discharged into the atmosphere. As a result, the
remainder of the water is cooled down significantly (Figure-1).
Cooling towers are able to lower the water temperatures more than
devices that use only air to reject heat, like the radiator in a car, and
are therefore more cost-effective and energy efficient
 TRANING REPORT 11

TYPES OF COOLING TOWER:

1. Natural draft cooling tower.

2. Mechanical draft cooling tower.

Mechanical draft cooling tower:

Mechanical draft towers have large fans to force or draw air through
circulated water. The water falls downwards over fill surfaces, which
help increase the contact time between the water and the air - this helps
maximize heat transfer between the two. Cooling rates of mechanical
draft towers depend upon various parameters such as fan diameter and
speed of operation, fills for system resistance etc.

Three types of mechanical draft towers are there:

 Forced draft cooling tower.

 Induced draft cross flow cooling tower.
 Induced draft counter flow cooling tower
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 In GPPC 700MW , the cooling tower is a multi cell (total 20cells, 18

working and 2 standby , 10 cells for each unit) induced draft
counter flow cooling towers to dissipate heat generated in the
process
 The induced draft cooling tower makes the heat exchange
between the cooling fluid and induced air through the tower. Air is
drawn from air entry level at the bottom and passes through
various heat and mass transfer surface of cooling tower. The
 TRANING REPORT 13

process of intermolecular counter flow diffusion of air and water in

the tower cause required cooling as per thermal design.
 Required air flow rate is sucked by the axial flow FRP bladed fans at
the top. Hot water is uniformly distributed from hot water channel.
The tower is mainly composed of:

 A frame work and its cladding.

 A system of fluid distribution and dispersion above the fill.
 The heat exchange grid filling
 A basin collecting the fluid and sump from which water enters in to
suction header of CW pumps.
 A fan moving the air necessary to the heat exchange.
 Drift eliminators which catch practically all the water droplets in the
air before it is rejected to the atmosphere.

COOLING TOWER PERFORMANCE:

The following parameters are measure for performance evaluation
cooling tower:

 Wet bulb temperature of air

 Dry bulb temperature of air
 Cooling tower inlet water temperature
 Cooling tower outlet water temperature
 Exhaust air temperature
 Electrical readings of pump and fan motors
 Water flow rate
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iii. Water Treatment (Pretreatment, DM and Service

Water) Plant

PRETREATEMENT PLANT

PRINCIPAL OF PRETREATMENT PROCCESS

The non ionic impurity such as turbidity, suspended solids, colloidal
particle etc., are removed in pre-treatment .The degree of Pretreatment
depends on the type and quantity of constituents.
The pre-treatment consists of the following
1.Aeration
2.Coagulation
3.Floculation
4.Sedimentation/Settling/Clarification
5.Sludge Removal
6.Chlorination
7.Measorement of Flow
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Sea water inlet Cascade Aerator(common for DM+CW1/2)>Stilling Chambers>Hypo

Chlorite Dosing >Parsh all Flume> Lime dosing(CW SYSTEM Only)>FeCl3 dosing
>Flash Mixer>Inlet Chamber>Polyelectrolyte dosing at HRSCC>Centre of Clarifier
Mechanism zone for Clarifier Hypochlorite Dosing >DMF-Filtered water for DM
process. Clarified Water>Clarified water to other utility.

RODM Plant
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Reverse Osmosis:

“When two solutions of different

concentrations are separated by semi-
permeable membrane, the solvent
molecules diffuse from the lowered
concentrated solution to higher
concentrated solution through membrane
spontaneously until the concentrations of
both the solutions become equal. Such
spontaneous diffusion of solvent through the membrane is known as
osmosis.”

When external pressure is applied on the high concentration

solution, osmosis stops. This pressure is known as osmotic pressure.
Thus osmotic pressure may be defined as “the external pressure which
must be applied to a solution in order to prevent flow of solvent into the
solution through the semi-permeable membrane”.
 TRANING REPORT 17

Reverse Osmosis (RO) is a physical process that uses the osmosis

phenomenon, i.e., the osmotic pressure difference between the
saltwater and the pure water to remove salts from water. In this
process, a pressure greater than the osmotic pressure is applied on salt
water (feed water) to reverse the flow, which results in pure water
(freshwater) passing through the synthetic membrane pores separated
from the salt.

A concentrated salt solution is retained for disposal. The RO process is

effective for removing total dissolved solids (TDS) concentrations of up
to 45,000 mg/lit, which can be applied to desalinate both brackish water
and seawater. Reverse osmosis needs energy to operate the pumps that
raise the pressure applied to feed water
TRANING REPORT 18

Chemical dosings

Anti chemicaldosings
Reverse osmosis unit
Degasified blowers

PSF
UNIT MCF
PT-DM-Filter Unit
water tank

High pressure pump

Filter water Xper pump Cartridge filter

Concentrated water
Permeate water

Schematic diagram of R.O plant (process)

iv. TURBINE
 Gus turbine
 TRANING REPORT 19

• Heavy-duty industrial type Gas Turbine is of GE make, Frame PG 9351

(FA), 50 Hz, with Natural gas as main fuel. GT is provided with Hybrid
dry type, low NOX burners (DLN2 + Combustion system). Air intake is
provided with an evaporative cooling system. Initial starting of the gas
turbine is by a static frequency converter.
• In the three-stage turbine section, energy from hot pressurized gas
produced by the compressor and combustion section is converted to
mechanical energy. The turbine rotor is cooled by air extracted from
compressor stage. This air is also used to cool the turbine first and
second stage buckets plus the rotor wheels and spacers.

COMBUSTION CHAMBER
 TRANING REPORT 20

• The combustion system uses a reverse flow, multi-chamber (can

annular) design in which combustion chambers are arranged around
the periphery of the compressor discharge casing.
• Each chamber contains fuel nozzles and a combustion liner. Specific
chambers also contain spark plugs and flame detectors.
• Transition pieces connect the combustion liners to the turbine
nozzles.
• The DLN 2+ combustor is of single stage, multi-mode combustor
capable of operation with either gas or liquid fuel.
• Fuel is injected initially through diffusion burners up to 50% load
operation and later through premix burners throughout full load
operation.
• Minimum NOx emissions are achieved in this condition.
• The control system continuously monitors for presence or absence of
flame using flame detectors installed in several combustors.
• For controlling NOx emission, water is injected to combustors
through injection nozzles.
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TRANING REPORT 22

 STEAM TURBINE
 A steam turbine is a thermo-mechanical device that extracts
thermal energy from pressurized steam, and converts it into rotary
motion.
 Steam is vaporized water. It is a transparent gas. At standard
temperature and pressure, pure steam (unmixed with air, but in
equilibrium with liquid water) occupies about 1,600 times the
volume of an equal mass of liquid water.

 Saturated steam is steam at equilibrium with liquid water at the

same pressure and temperature.
 Superheated steam is steam at a temperature higher than its
boiling point at a given pressure
 IN GPPC POWER PLANTTWO UNIT OF STEAM TURBINE OUTPUT
129.5MW ,15.7KV.
TRANING REPORT 23
TRANING REPORT 24

v. air compressor
 As name suggest air compressor which function is compressed air.
In atmosphere suck the air & compress at 1 Pascal to 14 PASCAL.
After the compress air goes at combustion chamber.
 TRANING REPORT 25

vi. EFFLUENT TREATMENT PLANT

Following effluents will be collected /treated in the Effluent treatment

plant:
a) HRSG Blow down.
b) HRSG Area Floor Wash waste.
c) Service water waste from GTG area.
d) Service water waste from STG area.
e) Transformer Yard oily waste (Burnt Oil).
f) N-Pit waste from DM Plant.
g) GT wash water.

 The wash water wastes from GTG & STG area, HRSG Area waste
shall be collected in a common collection pit and pumped to a
Lamella Clarifier to remove the free oil and Suspended solids and
finally clear water is collected at CMB.
 The Sludge form lamella clarifier to be collected in a pit and
pumped to PT Plant for dewatering.HSG blow down with quenched
water shall be transferred to N-Pit for further treatment (if
required) and finally the same along with Regeneration waste from
neutralization pit (N-pit) in DM Plant shall be pumped to guard
pond Oily waste from Transformer yard pit (Burnt Oil Collection
pit) shall be pumped to Oil Water Separator(OWS) for oil
separation and the clear water shall be collected in Guard Pond.
 Final Effluent Transfer pump shall be provided in the Guard pond
to transfer the treated water from Guard Pond for final disposal at
terminal point.
 However, one tap off for horticulture shall be provided. One
number pH indicator and One number Flow Indicator is connected
TRANING REPORT 26

in pump discharge to check the pH, and flow of dischargeable

water.
 In case the water is not suitable for discharge, the same shall be
recalculated in to the Guard Pond. pH shall be monitored at LCP.
TRANING REPORT 27

vii. ELECTRICAL SYSTEM

• Power is generated at 15.75 kV and 19 kV from the Gas turbine

generator (GTG) and Steam turbine generator (STG) respectively.
Connections are made through phase isolated bus ducts from the
generator terminals to the LV side of the generator transformer
which step up the voltage to 220 kV.

• Generator circuit breakers are provided in the run of the bus ducts
to isolate the generators in case of faults. Synchronizing of the
generators is done at 15.75kv level across the generator circuit
breakers.
• The 220kv side of each generator transformer is connected to the
220kv switchyard. From the 220kv switchyard, connection is made
to GSEB grid through 6 nos. of 220kv lines, connecting to Gujarat
power grid.
• GTG is provided with one Unit Auxiliary Transformer, connected by
a tap off from the main bus duct on the 15.75 kV side.
• STG is provided with one Unit Auxiliary Transformer, connected by
a tap off from the main bus duct on the 15.75 kV/ 13.2 kV side.
 TRANING REPORT 28

• The transformers are of 15.75kV /6.9kV and 15.75kV or 13.2 kV/6.9

kV voltage ratio and cater to auxiliary power requirement of the
plant.
• Each UAT is sized to cater entire auxiliary power requirement of
the total plant.
• Service Transformers of adequate size and numbers are provided
to step down 6.6 kV to 430 V to cater entire LT auxiliary loads such
as motors of less than 200 kW and other LT loads.

POWER – EVACUATION & DISTRIBUTION

• Power is generated at 15.75 kV and 19 kV from the Gas turbine
generator (GTG) and Steam turbine generator (STG) respectively.
Connections are made through phase isolated bus ducts from the
generator terminals to the LV side of the generator transformer
which step up the voltage to 220 kV.
• Generator circuit breakers are provided in the run of the bus ducts
to isolate the generators in case of faults. Synchronizing of the
generators is done at 15.75kv level across the generator circuit
breakers.
• The 220kv side of each generator transformer is connected to the
220kv switchyard. From the 220kv switchyard, connection is made
to GSEB grid through 6 nos. of 220kv lines, connecting to Gujarat
power grid.
TRANING REPORT 29

viii. Various Instrumentation Devices Used In Plant

1. TEMPERATURE MESURING INSTRUMENT

A.RTD

 Platinum resistance thermometers (PRTs) offer excellent accuracy

over a wide temperature range (from-200 to +850 °C). Standard
Sensors are are available from many manufacturers with various
accuracy specifications and numerous packaging options to suit
most applications. Unlike thermocouples, it is not necessary to use
special cables to connect to the sensor.
 The principle of operation is to measure the resistance of a
platinum element. The most common type (PT100) has a
resistance of 100 ohms at 0 °C and 138.4 ohms at 100 °C. There are
also PT1000 sensors that have a resistance of 1000 ohms at 0 °C.
 The relationship between temperature and resistance is
approximately linear over a small temperature range: for example,
 TRANING REPORT 30

if you assume that it is linear over the 0 to 100 °C range, the error
at 50 °C is 0.4 °C

 For precision measurement, it is

necessary to laniaries the
resistance to give an accurate
temperature. The most recent
definition of the relationship
between resistance and
temperature is International

 This linearization is done automatically, in software, when using Pico

signal conditioners. The linearization equation is:
 Resistance temperature detectors (RTD) accurately sense
temperature with an excellent degree of repeatability and
interchangeability of elements. The RTD is composed of certain
metallic elements whose change in resistance is a function of
temperature. In operation, a small excitation current is passed across
the element, and the voltage, which is proportional to resistance, is
then measured and converted to units of temperature calibration.
The RTD element is manufactured by winding a wire (wire wound
elements) or plating a film (thin film elements) on a ceramic or glass
core and sealing the element within a ceramic or glass capsule.
 Since most RTDs have a low initial resistance, often 100 ohms, and
have a small change in resistance per unit of temperature range, the
resistance of the lead wire is often compensated for with a three or
four wire bridge configuration built into the measuring devices. By
selecting the proper elements and protective sheathing, RTDs can
operate in a temperature range of (-200 to 650) °C [-328 to 1202] °F.
 TRANING REPORT 31

B.THERMOCOUPLE
 In 1821, Thomas See beck discovered if metals of two different
materials were joined at both ends and one end was at a different

 Temperature than the other, a current was created. This

phenomenon is known as the See beck effect and is the basis for all
thermocouples.
 joining two dissimilar metals at one end. The joined end is referred to
as t A thermocouple is a type of temperature sensor, which is made
by he HOT JUNCTION. The other end of these dissimilar metals is
referred to as the COLD END or COLD JUNCTION. The cold junction is
actually formed at the last point of thermocouple material Positive
leg Certain combinations of metals must be used to make up the
thermocouple pairs.
 If there is a difference in temperature between the hot junction and
cold junction, a small voltage is created. This voltage is referred to as
an EMF (electro-motive force) and can be measured and in turn used
to indicate temperature. The voltage created by a thermocouple is
extremely small and is measured in terms of mill volts (one mill volt
is equal to one thousandth of a volt). In fact, the human body creates
a larger mill volt signal than a thermocouple.
 To establish a means to measure temperature with thermocouples, a
standard scale of mill volt outputs was established. This scale was
established using 32 deg. F (0°C) as the standard cold junction .
 TRANING REPORT 32

COLD JUNCTION COMPENSATION

 As we mentioned earlier, the last point of thermocouple material is
known as the cold junction. The amount of output the t/c produces is
determined by the difference between the hot junction and the cold
junction temperatures. The cold junction temperature must be
known to accurately determine the temperature.
 COLD JUNCTION COMPENSATION is usually done automatically by
the measuring instrument. The instrument measures the
temperature at the cold junction and adds it back to the equation.
 If a customer were to use the wrong T/C extension wire, the same
problem could appear. This is why we must use the correct T/C
extension wire on our assemblies.
 It is also acceptable to have a third metal in the hot junction as long
as that metal is at the same temperature as the thermocouple
material.

 REFERENCE TABLES
 There are printed tables that show the temperature vs. mill volt
output figures. These reference tables are all based on the cold
junction being at the freezing temperature of water (32 deg F or 0
deg C).We use these tables in our Certification Lab along with ice
baths to make our cold
 TRANING REPORT 33

THERMOCOUPLE TYPES

 BASE METAL THERMOCOUPLES

 Base metal thermocouples are known as Types E, J, K, T and N and

comprise the most commonly used category of Thermocouple. The
conductor materials in base metal thermocouples are made of
common and inexpensive metals such as Nickel, Copper and Iron.
 Type E: The Type E thermocouple has a Chromel (Nickel-10%
Chromium) positive leg and a Constantan (Nickel- 45% Copper)
negative leg. Type E has a temperature range of -330 to 1600F, has
the highest EMF Vs temperature values of all the commonly used
thermocouples, and can be used at sub-zero temperatures. Type E
thermocouples can be used in oxidizing or inert atmospheres, and
should not be used in sulfurous atmospheres, in a vacuum or in low
oxygen environments where selective oxidation will occur. The color
code for TYPE E wire is purple and red.
 Type J: The Type J thermocouple has an Iron positive leg and a
Constantan negative leg. Type J thermocouples can be used in
vacuum, oxidizing, reducing and inert atmospheres. Due to the
oxidation (rusting) problems associated with the iron leg, care must
be used when using this thermocouple type in oxidizing
environments
 above 1000F. The temperature range for Type J is 32 to 1400F and it
has a wire color code of white and red. THERMOCOUPLE THEORY
 Type K: The Type K thermocouple has a Chromel positive leg and an
Alumel (Nickel- 5% Aluminum and Silicon) negative leg. Type K is
recommended for use in oxidizing and completely inert
 TRANING REPORT 34

environments. Because it’s oxidation resistance is better than Types

E, J, and T they find widest use at temperatures above 1000F.
 Type K, like Type E should not be used in sulfurous atmospheres, in a
vacuum or in low oxygen environments where selective oxidation will
occur. The temperature range for Type K is -330 to 2300F and it’s
wire color code is yellow and red. Type N: The Type N thermocouple
has a Nicrosil (Nickel-14% Chromium- 1.5% Silicon) positive leg and a
Nisil (Nickel- 4.5% Silicon- .1% Magnesium) negative leg. Type N is
very similar to TYPE K but is less susceptible to selective oxidation
effects. Type N should not be used in a vacuum or in reducing
atmospheres in an unsheathed condition. The temperature range is
32-2300 deg F and its wire color code is orange and red.
 Type T: The Type T thermocouple has a Copper positive leg and a
Constantan negative leg. Type T thermocouples can be used in
oxidizing, reducing or inert atmospheres, except the copper leg
restricts their use in air or oxidizing environments to 700F or below.
The temperature range for Type T is -330 to 700F and it’s wire color
code is blue and red.

 NOBLE METAL THERMOCOUPLE TYPES

 Noble Metal Thermocouples are another category of thermocouples

and are made of the expensive precious metals Platinum and
Rhodium. There are three types of noble
 metal thermocouples:
 Type B (Platinum/Platinum-30% Rhodium)
 Type R (Platinum/Platinum-13% Rhodium)
 Type S (Platinum/Platinum-10% Rhodium)
 TRANING REPORT 35

 below approximately 2500F since there are other thermocouple

types more suited for the lower temperatures. Refractory metal
thermocouples and their associated refractory metal protection
tubes must not be used in the presence of oxygen at temperatures
above 500°F.
 The color code for refractory thermocouples are:
 Type G: White with blue tracer and red
 Type D: White with yellow tracer and red
 Type C: White with red tracer and red
 TRANING REPORT 36

C.

TEMPERATURE GAUGE

 The AT model thermo consists of stem, capillary and bourdon tube in

a aluminum case. These parts are connected to form a unit. The
complete measuring system is filled with an inert gas as standard or
mercury as an option under pressure. A temperature change causes
the internal pressure in the stem to change. The deflection of the
bourdon tube thus caused is transmitted to the pointer by a
movement. A bimetallic element is fitted in between the moment
and bourdon tube to compensate for fluctuations of ambient
temperature at the case.
 TRANING REPORT 37

 Petroleum Industries
 Thermal / Hydro Power Stations
 Heating and ventilation
 Food Process industries / Hygenic Applications
 Water treatment plants
 Iron and Steel Industries
 General Mechanical Engineering Industries
 Rubber Molding / Processing Plants
 Chemical process industries
 Air conditioning

D. TEMPERATURE TRANSMITER

 A temperature transmitter is an electrical instrument that interfa

temperature sensor (e.g. thermocouple, RTD, or thermistor) to a
measurement or control device (e.g. PLC, DCS, PC, loop controller,
data logger, display, recorder, etc.). Typically, temperature
transmitters isolate, amplify, filter noise, linearize, and convert the
input signal from the sensor then send (transmit) a standardized
output signal to the control device. Common electrical output signals
used in manufacturing plants are 4-20mA or 0-10V DC ranges. For
example, 4mA could represent 0°C and 20mA means 100°C. 
 TRANING REPORT 38

 Temperature Transmitter Inputs

 A thermocouple sensor is a pair of dissimilar metal wires joined at

one end. The junction produces a low level voltage proportional to
the difference in temperature between the open and closed ends. 

 An RTD or Resistance Temperature Detector is a passive circuit

element whose resistance increases with increasing temperature in a
predictable manner.

E. TEMPRATURE SWITCH
 Switches that react to different heat intensities and activate
electrical contacts when the temperature rises or drops below a
set level. Temperature switches are often used in heating and
cooling systems. 

 Temperature Switches are designed for use in arduous industrial

environment. The gas / vapourfrlled thermal system in combination
with diaphragm sealed piston actuator offers stable measurement
of temperature.
 TRANING REPORT 39

 Actuation mechanism ensures precise switching of desired set

points. Wide options of micro switches are available to handle
different electrical ratirrgs. Temperature Switches are available with
rigid stem for direct mounting or with flexible arrnoured capillary
for remote mounting. Adjustable sliding compression gland allows
easy installation and adjustment of immersion length.
 Standard applications include Heat Exchangers, Evaporators, Heat
Throwing, Pumps, Compressors, Furnace, Flowers, Air Dryers and so
on.

1. PRESSURE MEASURTMENT

i. Pressure Transmitters
 TRANING REPORT 40

 A pressure transmitter senses a pressure and outputs a proportional

current signal. The working principle varies. Some are resistive, some
are capacitive, some are piezoelectric, all with an amplifier and
filtering circuit attached. You need to consult your sensor
documentation to check what’s it type and how it works.

Enhanced Rosemount 3051 Pressure Transmitter

Measurement Differential, Gage, Absolute, Level, Flow

Type

Output 4-20mA HART (Revision 5 and 7)

Safety Certified SIL 2/3 certified to IEC 61508

Reference + 0.04% of span

Accuracy

Total + 0.12% of span

Performance
 TRANING REPORT 41

Long Term + 0.125%  of URL for 5 years

Stability

Range down 150:1

ii. Pressure switches

 The pressure switch may be adjustable, by moving the contacts or

adjusting tension in a counterbalance spring. Industrial pressure
switches may have a calibrated scale and pointer to show the set
point of the switch. A pressure switch will have a differential range
around its set point in which small changes of pressure do not change
 TRANING REPORT 42

the state of the contacts. Some types allow adjustment of the

differential.
 The pressure-sensing element of a pressure switch may be arranged
to respond to the difference of two pressures. Such switches are
useful when the difference is significant, for example, to detect a
clogged filter in a water supply system. The switches must be designed
to respond only to the difference and not to false-operate for changes
in the common mode pressure.
 The contacts of the pressure switch may be rated a few tenths of an
ampere to around 15 amperes, with smaller ratings found on more
sensitive switches. Often a pressure switch will operate a relay or
other control device, but some types can directly control small electric
motors or other loads.
 Since the internal parts of the switch are exposed to the process fluid,
they must be chosen to balance strength and life expectancy against
compatibility with process fluids. For example, rubber diaphragms are
commonly used in contact with water, but would quickly degrade if
used in a system containing mineral oil.
 Switches designed for use in hazardous areas with flammable gas have
enclosure to prevent an arc at the contacts from igniting the
surrounding gas. Switch enclosures may also be required to be
weatherproof, corrosion resistant, or submersible.
 An electronic pressure switch incorporates some variety of pressure
transducer (strain gauge, capacitive element, or other) and an internal
circuit to compare the measured pressure to a set pont. Such devices
may provide improved repeatability, accuracy and precision over a
mechanical switch
TRANING REPORT 43

2. LEVEL MEASUREMENT

A. ULTRASONIC LEVEL SWITCH

 TRANING REPORT 44

 The Rosemount 3100 Series Ultrasonic Level Transmitter is

the reliable and cost-effective, non-contacting measurement solution
from Emerson. Time proven ultrasonic technology with advanced
software and state-of-the-art electronics delivers high reliability in a
wide variety of applications.

 The 3101 is the entry level model for simple level measurement.

Choose the 3102 for local control functionality with 2 integral signal
relays. For hazardous area applications, the 3105 is certified
intrinsically safe.

 Available now with an engineered polymer (glass-filled nylon) housing

for corrosive, harsh environments. It is rugged, lightweight, and
corrosive resistant.

 Continuous non-contacting level measurement with no moving parts

 Standard Integral LCD and push buttons for simple setup and on-site
programming
 2 Integral signal relays for local control for (3102 only) .Aluminum or
polymer (glass-filled nylon) housing options
 Corrosion resistant PVDF wetted material
 Volume and open channel flow calculations (3102 and 3105 only)
 Easy plant integration with 4-20mA ⁄ HART® output and Plant Web
support
 Temperature compensation with integral or optional remote
temperature sensor
 Two-wire direct current (dc) loop-powered
 Wide operating range to 36 ft. (11 m)
TRANING REPORT 45

B.  Level Transmitter
 TRANING REPORT 46

A level transmitter can be an application of a level sensor.

a Capacitive Transducer can be used, usually, as a level
translator(but it should be noted that a level translator is
actually more of an electronic circuitry term!).The principle of the level
translator is based on the changein capacitance due to the change in the
overlapping area of the dielectric i.e. ,the change in the level of the
element that’s being measured can be associated with that of the
dielectric in a suitable capacitive transducer setup.

3. Flow measurement
b. FIOW SWITCH
 TRANING REPORT 47

 SWITZER SM FLOW SWITCH specially designed for Water Flow

Detection is easy to install and simple to maintain. It has adjustable
pneumatic timer to ensure avoidance of false alarms and so is free
from fluctuations in water flow. Different saddles are available to fit
pipe sizes from 2" to 6". The instrument is suitable for horizontal or
Style GB, ABS cover to vertical water pipe and
Enclosure IP:65 sprinkler installations.
Static Pr. Rating 10 bar maximum Range settings are
Actuating Flow Rate15 to 40 LPM easily done by a screw
Line Sizes Water Pipes 2" to 6", adjustment available
  Sch.10 to 40 inside the cover.
‘One’ or ‘Two
Switching ’instrument quality
snap acting micro
  switches
each having SPCO
  contacts.
Switch Rating 15A 230V AC
Max. Time Delay 60 seconds, adjustable
Repeatability ±2% of maximum flow
Dead band Less than 8%
Via Saddle & ‘U’ Clamp
Mounting with
GENERAL
  gaskets
SPECIFICATIONS
Process Temperature 50°C maximum
Wetted Parts
Material  
Vane HDPE
Body Brass c. ROTAMETER
Seal Silicone
Gasket Neoprene
Electrical Entry 2 Nos. 3/4" ET
  PVC Cable Gland
 TRANING REPORT 48

Principle of operation

Rotameters are utilised for the flow rate measurement of most liquids
and gases with direct readout of flow rate. A special "float" is fitted
within a tapered glass tube. With the flow vertically upward through the
meter the float settles at a position where its mass is balanced by the
upward forces of the flow through the annulus between the tube and
float. The greater the flow the higher the float rises to increase the
annulus and balance. The top edge of the float is read against the scale,
giving an instantaneous reading of the flow rate. Various methods of
alarm output are available for signalling low or high flow conditions.

4.DISTRIBUTED CONTROL SYSTEMS

 TRANING REPORT 49

 Generally, the concept of automatic control includes accomplishing

two major operations; the transmission of signals (information flow)
back and forth and the calculation of control actions (decision
making). Carrying out these operations in real plant requires a set of
hardware and instrumentation that serve as the platform for these
tasks. Distributed control system (DCS) is the most modern control
platform. It stands as the infrastructure not only for all advanced
control strategies but also for the lowliest control system. The idea of
control infrastructure is old. The next section discusses how the
control platform progressed through time to follow the advancement
in control algorithms and instrumentation technologies
 To fully appreciate and select the current status of affairs in industrial
practice it is of interest to understand the historical perspective on the
evolution of control systems implementation philosophy and
hardware elements. The evolution concerns the heart of any control
system which is how information flow and decision making advanced.
 Pneumatic Implementation: In the early implementation of automatic
control systems, information flow was accomplished by pneumatic
transmission, and computation was done by mechanical devices using
bellows, spring etc. The pneumatic controller has high margin for
safety since they are explosion proof. However, There are two
fundamental problems associated with pneumatic implementation:

 Transmission: the signals transmitted pneumatically (via air pressure)

are slow responding and susceptible to interference.
 Calculation: Mechanical computation devices must be relatively
simple and tend to wear out quickly.

 Electron analog implementation: Electrons are used as the medium of

transmission in his type of implementation mode. Computation
devices are still the same as before. Electrical signals to pressure
 TRANING REPORT 50

signals converter (E/P transducers) and vice verse (P/E transducers)

are used to communicate between the mechanical devices and
electron flow. The primary problems associated with electronic analog
implementation are:
 Transmission: analog signals are susceptible to contamination from
stray fields, and signal quality tends to degrade over long transmission
line.
 Calculation: the type of computations possible with electronic analog
devices is still limited.

 3. Digital Implementation: the transmission medium is still electron,

but the signals are transmitted as binary numbers. Such digital signals
are far less sensitive to noise. The computational devices are digital
computers. Digital computers are more flexible because they are
programmable. They are more versatile because there is virtually no
limitation to the complexity of the computations it can carry out.
Moreover, it is possible to carry out computation with a single
computing device, or with a network of such devices.

MAXDNA DCS
 TRANING REPORT 51

Digital Output Modules

16 discrete outputs per module unless otherwise noted
Four voltage output types:

I. 24/48 VDC
II. 120 VAC
III. 125 VDC
Two relay output types:
I. 240 VAC, 130 VDC Form A relay
II. 10 channel 240 VAC, 130 VDC Form C relay

High Level Analog Input Modules:

15 inputs per module
Three input ranges:
I. 4 to 20 mA
II. 0 to 6 VDC
III. 0 to 10 VDC

Resistance Temperature Detector (RTD) Input Module

7/8 inputs per moduleInputs isolated from each other, from ground, and
from module logicThree-wire or four-wire RTDs
Each input individually configurable
 TRANING REPORT 52

I. 10, 50, 100 Ω CU

II. 25 Ω NI
III. 10, 25, 100, 1000 Ω PT
Analog Output Modules

I. Eight-channel Current Adjusting Type (CAT)

II. 4 to 20 mA or 0 to 16 mA outputs

maxDNA Based HMI System for Main plant

Unit Operators OWS: Intel 64Core 2uo Processor, 2 GB RAM upgradable

to 4 GB, 2 x 146 GB SAS hard disk, 2x21” TFT Flat Monitor with resolution
of 1600 x 1200 non interfaced refresh rate minimum 85Hz, OEM
recommended PCI-Express Graphics card with minimum 256 MB RAM ,
USB standard keyboard and mouse, DVD R/W drive with 50 blank R/W
DVDs, Microsoft Windows XP Professional with latest service pack, Anti-
Virus, Ethernet NICs
 TRANING REPORT 53

Intel 64Core 2 Duo Processor, 2 GB RAM upgradable to 4 GB, 2 x

146 GB SAS hard disk, 2x21” TFT Flat Monitor with resolution of
1600 x 1200 non interfaced refresh rate minimum 85Hz, OEM
recommended PCI-Express Graphics card with minimum 256 MB
RAM , USB standard keyboard and mouse, DVD R/W drive with
50 blank R/W DVDs, Microsoft Windows XP Professional with
latest service pack, Anti-Virus, Ethernet NICs.

 The computer control network performs a wide variety of tasks: data

acquisition, servicing of video display units in various laboratories and
control rooms, data logging from analytical laboratories, control of
plant processes or pilot plant, etc. The computer network can be as
simple as an array of inexpensive PC's or it could be a large
commercial distributed control system (DCS).

Description of the DCS elements

 The typical DCS system shown in Figure 3 can consists of one or more
of the following elements:
 Local Control Unit (LCU). This is denoted as local computer in Figure 3.
This unit can handle 8 to 16 individual PID loops, with 16 to 32 analog
 TRANING REPORT 54

input lines, 8 to 16 analog output signals and some a limited number

of digital inputs and outputs.
 Data Acquisition Unit. This unit may contain 2 to 16 times as many
analog input/output channels as the LCU. Digital (discrete) and analog
I/O can be handled. Typically, no control functions are available.
 Batch Sequencing Unit. Typically, this unit contains a number of
external events, timing counters, arbitrary function generators, and
internal logic.
 Local Display. This device usually provides analog display stations,
analog trend recorder, and sometime video display for readout.
 Bulk Memory Unit. This unit is used to store and recall process data.
Usually mass storage disks or magnetic tape are used.

 General Purpose Computer. This unit is programmed by a customer or

third party to perform sophisticated functions such as optimization,
advance control, expert system, etc.
 Central Operator Display. This unit typically will contain one or more
consoles for operator communication with the system, and multiple
video color graphics display units.
 Data Highway. A serial digital data transmission link connecting all
other components in the system may consist of coaxial cable. Most
commercial DCS allow for redundant data highway to reduce the risk
of data loss.
 Local area Network (LAN). Many manufacturers supply a port device
to allow connection to remote devices through a standard local area
network.
 TRANING REPORT 55

 The advantages of DCS systems

 The major advantages of functional hardware distribution are
flexibility in system design, ease of expansion, reliability, and ease of
maintenance. A big advantage compared to a single-computer system
is that the user can start out at a low level of investment. Another
obvious advantage of this type of distributed architecture is that
complete loss of the data highway will not cause complete loss of
system capability. Often local units can continue operation with no
significant loss of function over moderate or extended periods of time.
 Moreover, the DCS network allows different modes of control
implementation such as manual/auto/supervisory/computer
operation for each local control loop. In the manual mode, the
operator manipulates the final control element directly. In the auto
mode, the final control element is manipulated automatically through
a low-level controller usually a PID. The set point for this control loop
is entered by the operator. In the supervisory mode, an advanced
digital controller is placed on the top of the low-level controller
(Figure 1). The advanced controller sets the set point for the low-level
controller. The set point for the advanced controller can be set either
by the operator or a steady state optimization. In the computer mode,
 TRANING REPORT 56

the control system operates in the direct digital mode shown in Figure
1in goals of using DCS system is allowing the implementation of digital
control algorithms. The benefit of digital control application can
include:
 Digital systems are more precise.
 Digital systems are more flexible. This means that control
algorithms can be changed and control configuration can be modified
without having rewiring the system.
 Digital system cost less to install and maintain.
 Digital data in electronic files are easier to deal with. Operating results
can be printed out, displayed on color terminals, stored in highly
compressed form.

5. Programmable Logic Controllers

 TRANING REPORT 57

 Programmable logic controller (PLC) is another type of digital

technology used in process control. It is exclusively specialized for
non-continuous systems such as batch processes or that contains
equipment or control elements that operate discontinuously. It can
also be used for many instants where interlocks are required; for
example, a flow control loop cannot be actuated unless a pump has
been turned on. Similarly, during startup or shutdown of continuous
processes many elements must be correctly sequenced; that is,
upstream flows and levels must be established before downstream
pumps can be turned on.
 The PLC concept is based on designing a sequence of logical decisions
to implement the control for the above mentioned cases. Such a
system uses a special purpose computer called programmable logic
controllers because the computer is programmed to execute the
desired Boolean logic and to implement the desired sequencing. In
this case, the inputs to the computer are a set of relay contacts
representing the state of various process elements. Various operator
inputs are also provided. The outputs from the computer are a set of
relays energized (activated) by the computer that can turn a pump on
 TRANING REPORT 58

or off, activate lights on a display panel, operate solenoid valve, and so

on.
 PLCs can handle thousands of digital I/O and hundreds of analog I/O
and continuous PID control. PLC has many features besides the digital
system capabilities. However, PLC lacks the flexibility for expansion
and reconfiguration. The operator interface in PLC systems is also
limited. Moreover, programming PLC by a higher-level languages
and/or capability of implementing advanced control algorithms is also
limited.

 PLCs are not typical in a traditional process plant, but there some
operations, such as sequencing, and interlock operations, that can use
the powerful capabilities of a PLC. They are also quite frequently a
cost-effective alternative to DCSs (discussed next) where sophisticated
process control strategies are not needed. Nevertheless, PLCs and
DCSs can be combined in a hybrid system where PLC connected
through link to a controller, or connected directly to network.

S.No. Area PLC Make

1 Gas Turbine GT Mark-VI

 TRANING REPORT 59

2 Steam Turbine Max DNA

3 RO/ DM Plant ABB 800xa
4 Gas Skid System Siemens
5 Air Compressor System Allen Bradely
6 Sea Intake Plant GE Fanuc
7 PTP Plant GE Fanuc
8 HVAC System Allen Bradely
9 CEMS System GE Fanuc
10 Fire Protection System GE Fanuc
11 EDG System Allen Bradely
12 CW Treatment Plant Allen Bradely
13 ETP/ STP Plant System Allen Bradely
14 Electro Chloronation Siemens
15 Debris Filter KEYENCE
16 Ball Cleaning System KEYENCE
17 HVAC Chiller Compressor PCO-3

Conclusion
 TRANING REPORT 60

Now I have studied a lot about the measurement & control parameter
system. Different types of plc & max DNA DCS. In power plant I realise
the many types of measurement instrument which is use for better, safe
& controllable work.