Boiler

Instrumentation

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 Presentation outline
• Basic Process Measurement
•Level Measurement
•Flow Measurement
•Temp Measurement
•Steam Generator C&I system

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 CONTROLS &
INSTRUMENTATION
• Control & Instrumentation deals with various
measurement, indication, transmission and control
in different technical fields.
• Instrumentation is for measurement of various
parameters.
• And controlling various parameters from a remote
control room.

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 Instruments
• Instruments for measuring various physical quantities like
– Pressure
– Temperature
– Level
– Flow
– Turbovisory
• Vibration
• Speed etc.
– Analytical
• PH
• Conductivity
• Silica etc

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 Instruments
• Measuring Electrical parameters such as
– Load
– MVAR
– Frequency
– Voltage
– Current etc.
• Indicators
– Local
– Remote
• Recorders
– Single Point
– Multipoint
– Continuous
– Dotted

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 Pressure Measurement
• Manometers for low pressure.
– Water filled
– Mercury Filled
• Bellows for medium pressure
• Bourdon tube gauges for medium and high
pressure measurements

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 Pressure Measurement
• Transducers of different type for all ranges for telemetering
purpose.
– Capacitive type.
– LVDT type.
– Strain gauge type.
• Mode of connection of Transmitters
– Four Wire
– Two Wire

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• Type of Transmitter Microprocessor based 2 wire type,.
• 2. Sensor Type Capacitance/Piezo-electric
• 3. Accuracy ± 0.1% of span
• 4. Output signal range 4-20 mA DC (Analog)
• 5. Turn down ratio 30:1
• Zero and span drift ± 0.015% per deg.C at max span a and
0.11% per deg.C at min. span.

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 Level Measurement
• Floats and liquid displacers
• Head pressure measurement
• DP type
• Ultrasonic
• Direct Viewing
• Strain gauge

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 Level Measurement
• In closed pressurised vessels, Differential pressure measurement
is used to measure the level.
• One side condensate pot is used where constant level is
maintained.
• Other side is connected to the bottom of the vessel.
• Difference between these two heads gives the level.

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 Level Measurement (Closed
Vessel)

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 Level Measurement (Closed
Vessel)

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 Level Measurement (Float)

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 FLOW MEASUREMENT
• Controlling the flow rate of fluids is a key control
mechanism for any process plant. 
• There are many different types of devices available
to measure flow.

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 Flow Measurement
• HEAD TYPE
– Orifice Plate
– Rotameters
– Venturi Tubes
– Target Meters
• VELOCITY TYPE
– Magnetic
– Vortex
• DISPLACEMENT
– Turbine Meter

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 HEAD TYPE
• Head type devices measure flow by constricting a
stream and measuring the resulting pressure drop. 
• The pressure drop can then be related to a flow.

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 Orifice Plates

• An orifice plate is a very simple device installed in a

straight run of pipe. 
• The orifice plate contains a hole smaller than the
pipe diameter. 
• The flow constricts, experiences a pressure drop,
and then the differential pressure can be related to
a flow.

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 Orifice Plates

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 Rotameters
• Rather than using a constant restriction area and a variable
pressure differential, rotometers use a variable restriction
and a constant pressure differential to measure flow.
• Typically, rotometers are used to measure smaller flows and
the reading is usually done locally, although transmission of
the readings is possible.

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Rotameters
• The rotometer consists of a float that moves vertically through a slightly
tapered tube. 
• As fluid enters the bottom of the rotometer, the float is forced upward
until the force is balanced by gravitational forces. 
• Most rotometers are made of glass with markings on the outside so that
flow readings can be taken visually. 
• The advantage to rotometers is the simplicity of the device and a
constant pressure drop. 
• Also, rotometers do not require straight pipe runs for installation so they
can be installed just about anywhere.

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 Rotameters

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 Venturi Tubes
• A venturi tube also measures flow rates by constricting fluids and
measuring a differential pressure drop.
• Venturi tubes allow for flow measurement with lower head losses
than orifice plates.

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Target Meters
• A target flowmeter operates just as the name implies.
• A small "bullseye" is placed inside the pipe and is connected
to a pneumatic transmitter.
• Typical applications include flow measurement of steam and
outdoor liquids.
• In a target flowmeter, the square of the force exerted on the
target is proportional to the volume or mass flow through the
pipe.

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 Target Meters

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 Flow measurement
• Differential pressure flow meters • Orifice plate is a circular metal plate with
a center hole.
– Orifice pattern • In venture tube there is a gradual change
– Venture & nozzle pattern in the area.
– Pitot tube pattern • Nozzle is similar to a orifice but with a
curved form of approach
– Dall tube pattern
• Variable area flow meters
• Displacement and interferential
flow meters
• Electromagnetic flow meters.
• Ultrasonic Flow meters

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 Temperature Measurement
• Expansion of Solids
– Thermostats
• Expansion of Liquids
– Temperature Gauges
• Expansion of gases
– Temperature Gauges
• Thermal Electricity Thermocouples
– Type K Chromel Alumel etc.
• Change of Electric Resistance (RTD)
– Pt100
– Cu53
• Intensity of total radiation
– Optical Pyrometer
– Radiation Pyrometer

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 Temperature Measurement
• Expansion of Liquids and gases are used for local
gauges.
• Thermocouples and RTDs are used for most of the
remote temperature measurements and controls.
• RTDs are used for low temperature applications.
• Pyrometers are used for high temperature
measurements. (NON Contact type).

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 Temperature Measurement
• (a) Type of Thermocouple 16 AWG wire of
chromel-Alumel (Type K) or 24 AWG wire Pt-
Rhodium Pt (Type R); ungrounded type depending
on operating temperature range.
• (b) Type of RTD 3/4 wire - Pt RTD 100 ohm
(as per DIN-43760)

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 Temperature Measurement
• C J C Boxes
• a) Ref. temp. 60°C ± 1.3 °C for
Thermocouple
• b) Effect of ambient temp. ± 0.1% per 10°C
variation
c) Material 4 mm thick fibre glass reinforced polyster
d) Protection class of IP 55

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 Temperature Measurement
• Outlput signals: Analog : 4-20 mA DC
Binary : 2 NO + 2 NC for
high alarm
2. Zero & span Adjustment : Available
• 3. Ambient temp. : 60°C
• 4. Indication : Digital
• 5. Enclosure Type/Material : Weather &
Dust proof (IP 55) Die cast Aluminium/SS

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 SG RELATED CONTROL &
INSTRUMENTATION SYSTEM/EQUIPMENTS
• FLAME MONITORING SYSTEM
• COAL FEEDERS CONTROL AND INSTRUMENTATION
• ELECTROMATIC SAFETY VALVES
• FURNACE TEMPERATURE PROBES
• ACCOUSTIC PYROMETERS
• BOILER FLAME ANALYSING SYSTEM (IN LATEST
ADVANCE BOILER )

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 SG RELATED CONTROL &
INSTRUMENTATION SYSTEM/EQUIPMENTS
• COAL BUNKER LEVEL MONITORING SYSTEM
• ELECTRONIC REMOTE DRUM LEVEL
MONITORING SYSTEM(Hydra step)
• CONDUCTIVITY TYPE LEVEL SWITCHING
SYSTEM
• ASLD SYSTEM
• APH FIRE SENSING

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 THANK YOU

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