Introduction to

Control Engineering
at Power Plants

Lesson 1

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1 - Power plant process
Schematic of a coal-fired steam power plant

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1 - Power plant process
Schematic of a combined cycle power plant

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Page 3
1 - Power plant process
Process and Instrumentation Diagram with KKS codes

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1 - Power plant process
Identification system for power plants : KKS

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1 - Power plant process
Identification system for power plants : KKS

Ex: 1 LDA04 AP001 KP01

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1 - Power plant process
Identification system for power plants : KKS

Ex: 0 BFA03.03

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Page 7
1 - Power plant process
Identification system for power plants : KKS

Ex: 1 UHA04.01

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Page 8
1 - Power plant process
Central Control Room Layout Concept Example

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Page 9
1 - Power plant process
Central System Room Layout Concept Example

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Page 10
1 - Power plant process
Examples of process engineering redundancy

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Page 11
1 - Power plant process
Power plant components (KKS codes)

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Page 12
1 - Power plant process
Power plant components (KKS codes)

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Page 13
2 - Instrumentation
Direct measuring circuits (KKS)

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 2 - Instrumentation
Various types

Level Pressure Temperature Positioner

Electro
Capacitance Ultrasonic Radar Rail Head pneumatic

Field

Vibration and
Flow Analytics Weighing Position
Expansion
Ultrasonic Magnetic Delta-P Belt Scales

Clamp On Coriolis Vortex

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Page 15
2 - Instrumentation
Field Instrument Mounting Racks

Furnace pressure
Drum level

Suction & discharge pressure

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Page 16
2 - Instrumentation
Field Instrument Mounting Racks

Furnace pressure
Drum level

Suction & discharge pressure

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Page 17
2 - Instrumentation
Field Instrument Measuring Chain

Drum level

Furnace pressure

Suction & discharge pressure

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Page 18
2 - Instrumentation
Field Instrument Hook Up

Drum level

Furnace pressure

Suction & discharge pressure

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3 - Signal Types
Digital signals

Digital signals are used to represent items that only have two states,
such as ON (binary 1) or OFF (binary 0) states.

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Page 20
3 - Signal Types
Analog signals

Analog signals have variable states in contrast to digital signals.

Input signals: Position feedback,temperature, pressure, level...etc.
Output signals: Set points (for VFDs, proportional control valves...etc.)

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Page 21
3 - Signal Types
RTD & Thermocouples

RTDs (Resistance Temperature Detector) and thermocouples are used

for temperature measurement. These signals have variable states as
analog signals.
Thermocouple RTD

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Page 22
 4 - Signal Loops
Relay & Contact Types

Relay Socket Circuit Diagrams Relay Set

Coil C/O Contact

Bracket LED

Coil NO Contact

Label NO: Normally open

NC: Normally close
C/O: Changeover

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4 - Signal Loops
DI signals

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4 - Signal Loops
DI signals

Single Contact Changeover Contact Electronic Sensor

24V

24V 24V

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4 - Signal Loops
DO signals

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 4 - Signal Loops
AI signals (Voltage)

Range Mod. Set

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 4 - Signal Loops
AI signals (Current)

Range Mod. Set

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Page 28
 4 - Signal Loops
AI signals (Resistance transducers or RTDs)

Range Mod. Set

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Page 29
 4 - Signal Loops
AI signals (Thermocouples)

Range Mod. Set

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4 - Signal Loops
AO signals (Voltage)

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4 - Signal Loops
AO signals (Current)

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4 - Signal Loops
Symbols and terms on drawings

DCS cabinet Field

Signal module Terminal Cable Device

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 4 - Signal Loops
Example drawings (Digital signals)

DI signal connection

Relay contact

DO signal connection

Relay coil

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 4 - Signal Loops
Example drawings (Analog signals)

AI signal connection (4-20mA_2wire)

24V

AI signal connection (4-20mA_4wire)

AO signal connection (4-20mA)

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5 - Cables
Power cables

Outer sheath Armour Filler Insulation Conductor

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5 - Cables
Instrumentation & Control Cables

Outer sheath Overall screen Individual screen Insulation Conductor

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5 - Cables
Communication Cables

Profibus DP Industrail Ethernet Fiber Optic

Cat6 (eight cores) cables up to 1Gbit/s Multimode fiber cable distance <3km
Cat5 (four cores) cables up to 100Mbit/s Single mode fiber cable >3km

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 Thank you

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