WEL-COME

INTRODUCTION
TO
INSTRUMENTATION
&
CONTROL
Of

BOILER
In Coal Based Thermal Power
Station, Electricity is generated by
moving GENERATOR with Steam
TURBINE. Steam is produced by
BOILER by using coal as fuel. For
safe & smooth operation of Boiler,
Instrumentation & Control System
is designed which is
called FSSS or BMS
“FUNACE SUPERVISORY AND SAFEGAURD
SYSTEM” (FSSS):-It is designed to control ‘Fuel
firing System’ and ‘Protection System’ of
BHEL Boiler.
BOILER:
Architecture
Instrumentation & Control of
BOILER or FSSS has following
Parts:-
PART 1: Measurement [Sensors]

PART 2: Control [Actuators]

PART 3: Automation [Control Loop]

PART 4: Protection [Logic]

PART 5: Monitoring [DCS]

PART 1: Measurement
FLAME INTENSITY:-
Oil / Coal fired inside the furnace
produces Heat. The status of heat is
measured as Flame Intensity. Intensity is
measured by a device called ‘Flame Scanner’.
Light emitted by Flame is focused at a
point by lens of sensor head. The pointed light
is transmitted through optical fiber upto an
Electronic Circuitry where light is converted
into electrical voltage and transmitted to the
display system. Cooling air is supplied to
Sensor Head for proper cooling.
PART 1: Measurement
Flame Scanner
PART 1: Measurement

OXYGEN %:-
Oil/ Coal fired inside Furnace requires
Oxygen for proper combustion.
Availability of Oxygen is measured by
zirconia oxygen analyzers which determines
oxygen concentration using the conductivity of a
zirconia ceramic cell. Zirconia ceramic cells only
allow oxygen ions to pass through at high
temperatures. With reference gas on one side
and sample gas on the other, oxygen ions move
from the side with the highest concentration of
oxygen to that with the lowest concentration. The
movement of ions generates an EMF which can
PART 1: Measurement
Oxygen Analyser
PART 1: Measurement
SUSPENDED PARTICULATE MATTERS (SPM):-
Coal dust fired inside Furnace is
converted into Ash particles after combustion.
The heavier Ash Particles settle down
but suspended Ash Particles emerge from
Chimney. The SPM fall down far away from
Chimney depending upon Chimney Height
and responsible for air pollution.
Transmissometer emits light which is
reflected by Reflectometer. The difference
due to opacity created by SPM is measured
and displayed.
PART 1: Measurement
SPM Analyser
PART 1: Measurement
SOx, NOx, CO:-
Insitu gas analyser measures gases by
‘Infrared Absorption Gas Filter Correlation’
technology.
Measuring Probe is mounted on Stack and
uses stainless steel measurement chamber
equipped with sintered diffuser filter to allow flue
gas excluding particulate into the measurement
chamber.
Infrared beam from transceiver unit passes
through the probe measurement chamber and is
reflected back to the infrared detector mounted
within the transceiver through gold coated
PART 1: Measurement
SOx, NOx, CO Analyser
PART1: Measurement

Air Pressure/ Furnace Pressure:-

ID Fans are run to create draught in
Furnace & FD Fans are run to create air
pressure in Wind Box.
Air Pressure / Furnace Pressure is measured
by Pressure Transmitter.
When voltage is applied between two
plates having dielectric material in between,
a Capa- citance is formed. The capacitance
value varies when distance between plates is
changed. Change in capacitance value is
measured by electronic circuit.
PART1: Measurement
Pressure Transmitter:
Capacitance type
PART1: Measurement
Pressure Transmitter:
Capacitance type
PART 1: Measurement
Air Flow/ Flue Gas Flow:-
When both, IDFan & FD Fan are run balanced
draught is created and air flow through Furnace is
established.
Air Flow is measured by Flow Transmitter: DP
Type

When Air flows through duct, A1P1V1 at a point

is always equal to A2P2V2 at other point.
 A1P1V1=A2P2V2=K,
A=Velocity,P=Pressure,V=Volume
 At Nozzle (narrow passage) Velocity of liquid
increases consequently Pressure decreases.
 Differential Pressure due to change in velocity is
measured by DP Transmitter.
 Flow = Square root of “Differential Pressure”
PART 1: Measurement
FLOW Transmitter: DP Type
PART 1: Measurement
FLOW Transmitter: DP Type
PART 1: Measurement
FLOW Transmitter: DP Type
PART 1: Measurement
Drum Level:-
Water is filled up into Boiler Drum.
During steam generation water Level is
maintained at normal level which is
measured by level Transmitter:
When liquid level rises it exerts pressure
to the bottom due to its density. Amount of
pressure is proportional to level of liquid
column. Level in vessel is compared with
level in Reference Column. Difference
between pressure at bottom of ‘Reference
Column’ and bottom of vessel is measured.
PART 1: Measurement
LEVEL Transmitter : D.P. Type
PART 1: Measurement
Level Transmitter: DP Type
PART1: Measurement

Air/Flue Gas/Metal/Steam Temperature

During Steam generation temperature of Air/Flue
gas/Metal/Steam at various location is measured by
Thermocouples (High Temp. ) & RTDs (Low Temp.)
Thermocouple: Some materials have property of
generating voltage when junction of couple is kept in
high temperature with respect to other junction.
 Either Voltage between reference Junction and Hot
Junction is measured and corresponding temperature
is evaluated from Table or Signal Conditioning Card is
used to evaluate temperature.
 Temp. of ref junction is measured and compensated.
PART1: Measurement
TEMP. Transmitter :
Thermocouple
PART1: Measurement
TEMP. Transmitter:
Thermocouple
PART1: Measurement
TEMP. Transmitter:
Thermocouple
PART1: Measurement

Resistance Temperature Detector:

Some materials have property of linear
change in Resistance due to change in
temperature up to vide range.
 Change in resistance is measured and
corresponding temperature is evaluated.
 Platinum have 100 ohm resistance at 0 degree

cg.
 Error due to resistance of connecting wires is

eliminated by using 3 wire or 4 wire

configuration.
 Either Table is referred to evaluate temperature

corresponding to measured resistance or Signal

Conditioning card is used to evaluate
Temperature directly.
PART1: Measurement
TEMP Transmitter: RTD
PART1: Measurement
TEMP Transmitter: RTD
PART1: Measurement
TEMPERATURE
Temperature Trans: RTD
PART 2: Control
PRIMARY AIR CONTROL
Primary Air at desired temperature is
used to dry out and lift up pulverised Coal
and convey the same upto Boiler Furnace.
Primary Air Flow is controlled by Hot
PA Damper and Temperature is controlled
by Cold PA Damper.
Keeping desired PA Flow constant,
Hot PA Damper and Cold PA Damper are
adjusted to achieve desired temperature.
PART 2: Control
Pneumatic Power Cylinder
PART 2: Control
SECONDARY AIR DAMPER CONTROL:-
The air supplied for proper combustion
of Oil / Coal is called Secondary Air.
Though quantity of secondary Air is
controlled by FD fan but provision of sec
Air at desired location with desired
pressure is controlled by Sec Air Dampers.
(a) Fuel Air Dampers of only running Mills/
Oil Guns are open to the extent of Mill
loading. (b) Auxiliary Air Dampers are
open/closed to maintain Wind Box
pressure to the extent of Boiler loading.
PART 2: Control
SADC
PART 2: Control
SADC
PART 2: Control
TOTAL AIR FLOW CONTROL
Total Air Flow is controlled by
loading/unloading of F. D. Fans.
Loading/unloading of F. D. Fans is
achieved by changing angle of rotating
blades of Fans. This is called Blade Pitch
Control.
Oil operated servo valve is used to
control Blade Pitch. Demand is given
though an analogue Electrical Actuator.
PART 2: Control
Blade Pitch Control Actuator
PART 2: Control
FURNACE PRESSURE CONTROL
Furnace Pressure is controlled by loading/
unloading of I. D. Fans.
Loading/unloading of I. D. Fans is achieved by
changing speed of Drive by varying frequency.
This is called variable frequency drive control.
Wound Rotor Induction Motor is employed as
drive. Stator Winding is fed with normal AC
Supply and Rotor Winding is fed with variable
frequency AC supply.
To change speed of Motor, frequency is
varied.
PART 2: Control
Variable Frequency Drive
Control
PART 2: Control
Drum Level Control:
Drum Level is controlled by
Pneumatically Actuated Control Valves.

Compressed plant Air is used to

actuate the valves. Valve position is
regulated by using an electro-mechanical
device called Positioner.
Rubber Diaphragm is used to create
enough force required to operate Valve.
PART 2: Control
Level Control Valve
PART 2: Control
FUEL FIRE CONTROL:-
To warm up the furnace of Boiler, LDO is fired,
there after HFO is fired to take initial Load.
For proper combustion LDO is atomised with Air
and HFO is atomised with Steam.
Following sequential control is executed when
LDO/HFO gun start command is given:-
(1) Insert Igniter Rod (2) Open Atomising Valve (3)
Spark for 10 sec (4) Open Oil valve (5) Retract
Igniter Rod.
If Flame is not proven within 15 second Oil
Valve and Atomising Valve are closed automatically.
PART 2: Control
Fuel Firing Equipment
PART 2: Control
COAL FLOW CONTROL
Coal Flow is controlled by varying speed
of Gravimetric Raw Coal Feeder.
Speed of Raw Coal Feeder is regulated
by changing DC Voltage of Clutch Coil. This
is called Dyno drive control.
Input Shaft of Dyno drive is driven at
constant speed by a Motor. By applying DC
Voltage on Coil, output shaft (Rotor) is
clutched.
Speed of output shaft depends on
PART 2: Control
Raw Coal Feeder
PART2: Control
Dynodrive Control
PART 3: Automation
PART 3: Automation
PART 3: Automation
PART 3: Automation
PART 3: Automation
PART 3: Automation
PART 3: Automation
Fuel Flow Control
PART 3: Automation
PART 4: Protection

BOILER PROTECTION DEVICES:-

1. PRESSURE SWITCH:-
When pressure is applied, the
bellow or diaphragm gets expand and
moves a lever against spring tension. The
Lever pushes a miniature switch. Make or
break of Contacts due to snap action of
switch are used for Boiler Protection.
Pressure set point can be changed
by adjusting tension of spring .
PART 4: Protection
Pressure Switch
PART 4: Protection

BOILER PROTECTION DEVICES:-

2. HYDRASTEP
Flange and Tip are insulated with
each other by porcelain insulator. Flange is
connected to ground. Voltage is applied on
Tip through stud.
When probe is submerged into water
conduction takes place. Current flowing
due to conductivity of water is measured
thus level is sensed.
PART 4: Protection
Hydrastep
PART 4: Protection
Hydrastep
PART 4: Protection
LOGIC
PERMISSIVE: AND LOGIC
AND
Input 1…………………….
Input 2…………………….
Input 3…………………….
Input 4 ……………………

Input N…………………….
…………..Output
PART 4: Protection
LOGIC
PROTECTION: OR LOGIC
OR
Input 1…………………….
Input 2…………………….
Input 3…………………….
Input 4 ……………………

Input N………………………….……………
Output
PART 4: Protection
LOGIC
BOILER PERGE PERMISSIVE:
AND
No Boiler Trip……………………….
Heavy Oil Trip Valve closed….…….
Light Oil Trip Valve closed………….
All Heavy Oil Nozzle Valve closed…
All Light Oil Nozzle Valve closed……
All Primary Air Fans off ……………
All Raw Coal Feeders off ...
………………..Output 1
PART 4: Protection
LOGIC
BOILER PERGE PERMISSIVE:
AND
Output 1 …….……………………….
All Hot Air Gates closed……….…….
All Aux. Air Dampers Modulating.…….
Total Air Flow >30%&<40%.........…
All Scanner no Flame….…..………………. PERGE
MFT Output Module not freezed….…
READY
PART 4: Protection
LOGIC
PERMIT INTERLOCK:

PURGE READY………… ………PUSH TO PERGE

PURGE START………………..…PERGING

5 Min
PERGING………………………PERGE COMPLETE
PART 4: Protection
LOGIC
INTERLOCK:
PERGE COMPLETE………….MASTER FUEL TRIP

RESET
MUL
MASTER ……..…………..Permit to open LOTV
FUEL ..….………..Permit to open HOTV
TRIP……………….Permit to Start PAF/Mills/RCF
RESET ……………..Permit to Open HPBP
… ……….Permit to Reset
Turbine
PART 4: Protection
LOGIC
BOILER PROTECTION:
OR
All I.D. Fans off ………….……….
All F.D. Fans off ………………….
Flame Failure Trip ……………….
Loss of Fuel Trip ..……………..…
Reheater Protection Trip…………
Furnace Pressure V. High…….….
Furnace Pressure V. Low….………………
Output 1
PART 4: Protection
LOGIC
BOILER PROTECTION:
OR
Output 1 …….…………….
Low Air Flow <30%…………….
Drum Level V. High (225)…….
Drum Level V. Low (-225).…
Loss of 115 V A.C. ………….…
Loss of 220 V D.C………….….
Emergency Trip ………...........………Master Fuel
Trip
MFT Network Failed……… Operated
PART 4: Protection
LOGIC
TRIP INTERLOCK:
MUL
MASTER ……….Protection to close LOTV
FUEL ……….Protection to close HOTV
TRIP………………….…Protection to trip PAFs
OPTD ……….Protection to trip Mills
……….Protection to trip RCFs
……….Protection to close HPBP
……….Protection to open SADC
………...Protection to trip Turbine
PART 4: Protection
PART 4: Protection
LOGIC
PULVERISER PERMISSIVE:
AND
SA Hdr Pr adequate (>200mmwc)…….
Bunker O/L Gate open….…….
Feeder I/L Gate open………….
Pulv. Discharge valve open……….…
Burner Isolation Gate open.……
Pulv. O/L Temp <115 cg………
Raw Coal Feeder off ………….
……………..Output A
PART 4: Protection
LOGIC
PULVERISER PERMISSIVE:
AND
Output A……………………………….
(Ignition Energy) AND OR
Boiler Load >30%..……..
Adj. RCF proven>50%..............
……… Pulv.
3/4 Oil Guns in Service……… ……Start
Permit
PART 4: Protection
LOGIC
PULVERISER PROTECTION:
OR
Master Fuel Trip Optd……….
Lub oil Pr. V. Low<0.4ksc….….
Discharge Vlv Closed.……….
SA hdr/ Pulv. DP Lo<125….…
Burner Iso gate closed.…….…
Loss of Primary Air………..….
Pulv Motor Vib>10mm/s….……………Pulveriser
Trip
Brg. Temp High>90cg…….….
PART 4: Protection
LOGIC
RCF PERMISSIVE:
AND
Ignition permit available……….…….
Master Fuel Trip Not Optd….….…….
Feeder in Remote…………..……….
Pulveriser ON…………………….…
Feeder SA Valve open………….……
Feeder O/L Gate open……..……… RCF
Pulv. Outlet Temp not Low<60……….……… Start
permit
PART 4: Protection
LOGIC
RCF PROTECTION:
OR
Pulveriser OFF………..……….
No coal Flow……………….….
Master Fuel Trip Optd……….
No Ignition Energy………….…
Feeder SA valve closed.…….…
PA Flow Low< 50 T/hr………..….
Pulv outlet temp low<60………
Mill current <20 Amp………………………..RCF Trip
PART 4: Protection
Logic
PART 5: Monitoring
REQUIREMENTS:-

 Display : For Instant value

 Trend : For tendency of rising or falling

 Record : For history of value

 Events : For analysis

PART 5: Monitoring
Display: FLAME
PART 5: Monitoring
Trend
PART 5: Monitoring
Record
PART 5: Monitoring
Event
Instrumentation & Control
System: Control Stations
Instrumentation & Control
System: DCS
Distributed Control System
 All the Control cabinets are connected

to a common data bus.

 All the Control Stations are connected

to common data bus.

 All the measured values are displayed in

all the Control Stations.

 All the Actuators and Drive Motors are

controlled from all the Control Stations.

Instrumentation & Control
System: DCS
Instrumentation & Control
System: DCS
Instrumentation & Control
System: Controls Boiler
Instrumentation & Control
System: Controls Turbine
Instrumentation & Control
System:
Controls Generator
Instrumentation & Control
System:
Controls entire Power Plant
Thank You. R.K.SAHU,
E.E.(C&I)