CONTROL & INSTRUMENTATION / FB

CUSTOMER TRAINING PROGRAM

VENUE:
BHEL, HRDC, TRICHIRAPALLI 14.

TITLE: OPERATION, MAINTENANCE & CARE OF BOILERS

LECTURE ON:
OPERATION & MAINTENANCE OF CONTROL & INSTRUMENTATION

FACULTY: Mr. R.ANBARASU, DGM.-C&I/FB.

Over view
1. Control Systems & its Types
2. 3. 4. 5. Pneumatic Control Hydraulic Control Electrical Control

Furnace Safeguard Supervisory System (FSSS) Programmable logic control (PLC) Auto Control System Instrumentation Pressure Measurement Temperature Measurement Level Measurement Flow Measurement Vibration Measurement

6.

New products introduced (BHEL make-Indigenous))

EWLI-Electronic Water Level Indicator

BHELMHO Switch BHELSONIC-Sonic tube leak detection system BHELFEED-Microprocessor based Gravimetric Feeder control system BHELSCAN- Microcontroller based Flame Scanner system

7.

Trouble shooting
Problems in Safe Flame Scanner System

CONTROL SYSTEMS &

ITS TYPES

Control Systems & Its Types

PNEUMATIC CONTROLS
# Regulating Control # On/Off Control HYDRAULIC CONTROL # Regulating Control # On/Off Control ELECTRICAL CONTROL # Regulating Control # On/Off Control

Pneumatic Control

Open/Close Power Cylinder

AFR

AIR LOCK

Regulating Power Cylinder

POSITION TRANSMITTER

4-20mA

ZT

4-20mA

Positioner

E/P
I P

AIR FILTER REGULATOR

AFR

AIR SUPPLY AIR LOCK

Pneumatic Valve (Air to Close Type)

Pneumatic Valve (Air to Open Type)

I/P CONVERTER

Hydraulic Control

Electrical Control

Electrical Control Circuit (Of Soot Blower)

Motor Control (Of Soot Blower)

Motor Control Centre (MCC)

Motor Control Centre (MCC)

Electric Actuator

AUTO CONTROL SYSTEM

Autocontrol Legends / Definitions

No 1 Function SUMMING Symbol Definition The outputs Equals the Algebraic Sum of the Inputs The outputs Equals the Algebraic sum of the inputs divided by the number of inputs The outputs equals the Algebraic difference between two inputs

Averaging

/n
3 Difference

4 5

Proportional Integral

K or P

The output is directly proportional to the input The output varies in accordance with both magnitude and duration of the input.The output is proportional to the integral of the input.

Autocontrol Legends / Definitions

No Function 6 Derivative Symbol Definition The outputs is proportional to the rate of change (derivative) of the input. The outputs Equals the products of the two inputs. The outputs equals the Quotient of the two inputs The output equals the root The output equals some nonlinear function of the input.

D or d/dt

Multiplying

X . .

8 9

Dividing Root Extractor

10 Nonlinear or unspecified Function

F(x)

Autocontrol Legends / Definitions

No Function 11 Time Function Symbol F(t) Definition The outputs equals the input times some functions of time or equals some functions of time alone. The outputs is equals to that input which is the greatest of the inputs. The outputs equals to that input which is the least of the inputs. The output equals the input or the high limit value whichever is lower. The output equals the input or the low limit value whichever is higher.

12 High Selecting

> <

13 Low selecting 14 High limiting

>

15 Low limiting

<

Autocontrol Legends / Definitions

No Function 16 Reverse proportional 17 Bias Symbol Definition The outputs is reversely proportional to the input The outputs Equals the input plus (or minus) some arbitarary value. The outputs is an analog signal developed with in the generator. The output equals input which has been selected by transfer the state of the transfer is established by external means.

-K or -P +,- or A T

18 Analog signal Generator 19 Transfer

FURNACE SAFEGUARD SUPERVISORY SYSTEM

CAUSES OF FURNACE EXPLOSIONS INCORRECT OR INADEQUATE IGNITION PROCEDURE FUEL SUPPLY WITH OUT ESTABLISHING COMBUSTION INTRODUCTION OF MAIN FUEL WITH OUT ADEQUATE IGNITION ENERGY

FUNCTIONS OF FSSS
BOILER PURGE

SECONDARY AIR DAMPER MODULATION & ON OFF CONTROL IGNITOR ON - OFF OPERATION
WARM UP FUEL ON - OFF OPERATION MILL AND FEEDER ON - OFF OPERATION FLAME SCANNING BOILER TRIP PROTECTION.

Boiler Wind box Arrangement

Digital Gates
OR GATE I/P
SIGNAL 1 2 3

ON DELAY TIMER I/P O/P

OR

O/P OFF DELAY TIMER I/P O/P

AND GATE I/P

SIGNAL 1 2 3

AND

O/P

FLIP FLOP / MEMORY

NOT GATE I/P O/P I/P 1 I/P 2
S R

O/P 1 O/P 2

Boiler Trip Protection

F.D. FAN(S) OFF F.D. FAN(S) OFF EMERGENCY TRIP 2/3 FURNACE PRESSURE HIGH 2/3 FURNACE PRESSURE LOW BOILER TRIP

TURBINE TRIPPED 2/3 DRUM LEVEL HIGH 2/3DRUM LEVEL LOW AIR FLOW < 30 FALME FAILURE TRIP LOSS OF FUEL TRIP RESET M.F.R. TO BOILER TRIP

M.F.R

FURNACE PURGE SUPERVISION

ALL IGNITION VALVES CLOSED ALL HEAVY OIL VALVES CLOSED ALL LIGHT OIL VALVES CLOSED FUEL GAS TRIP VALVES CLOSED FUEL GAS CORNER N.V. CLOSED PURGE READY PURGE START PURGING

PURGE COMPLETE AND NO BOILER TRIP

G
RESET M.F.R. TO M.F.R NO BOILER TRIP

ALL SCANNERS SHOW NO FLAME ALL AUXILIARY AIR DAMPERS MODULATING

5 MIN

IGNITION TRIP VALVE CLOSED LIGHT OIL TRIP VALVE CLOSED HEAVY OIL TRIP VALVE CLOSED

NO BOILER TRIP

PROGRAMMABLE LOGIC CONTROL

WHAT IS A PLC?
PLC is short for Programmable Logic Controller. A more common name would be industrial computer. PLC is the heart of most modern factories using automation to increase the productivity. It has a power supply, microprocessor chip, RAM, input / output and com ports. It can sense large number of inputs and control a large number of outputs all in a matter of milliseconds. It uses symbolic programming language.

Basic PLC Operation

INPUT MODULES
Input modules accept a variety of analog or digital signals from various sensors and convert them to logic signals that can be used by CPU.

OUTPUT MODULES
The output modules convert control instructions from the CPU into signals that can be used to control various field devices.

CPU
The CPU makes the decision & executes control instructions based on the program in its memory.

PROGRAMMING DEVICE
Programming device is used to install the instructions that determine what the PLC has to do in response to specific inputs.

OPERATOR MODULE
The operator interface allows the process information to be displayed and new parameters to be entered.

Processor Configuration & Hardware Requirement

The system shall have dynamic self diagnostic features and indication for each component failure. Redundant central processing units(CPU). Redundant I/O system for critical outputs and nonredundant I/O system for remaining I/Os. Engineering console with interface Operating console with interface. Communication system.

Processor Configuration & Hardware Requirement contd.

The CPU shall have capability to meet the following minimum requirement. a) Logic functions b) Timing functions c) Counter d) Any other functional capabilities to perform the system requirement. The communication between the sub-system shall be redundant and with complete error checking. In case of redundant processors, the failure of any processor or any other component shall not affect the operation and the other processor shall take over the complete operation smoothly

Processor Configuration & Hardware Requirement contd.

On-line replacement of failed processor after rectification shall be possible , without affecting the operation. Redundancy shall be provided for the complete processor system including CPU, memory, power supply, and communication sub-system. The failure of any single component shall not cause the control system to be completely inoperative and thus ensuring total system availability. The failure of a processor or any other component shall be annunciated.The minimum requirements are: Processor failure Memory failure I/O module failure Communication link failure Battery voltage level low.

Processor Configuration & Hardware equirementcontd.

On failure of a Processor in the system, it shall be possible for the outputs to be individually freezed, opened or closed. On resumption of power supply after a failure, all outputs shall either open or close as dictated by the process. Each processor shall be provided with a separate power supply and failure of one power supply shall not affect the operation. Processor offered shall be suitable to accommodate at least 30% spare capacity.

INSTRUMENTATION
SCOPE OF INSTRUMENTATION
AUTOMATIC REGULATING CONTROL AUTOMATIC SEQUENCE CONTROL INTERLOCKING PROTECTION

PERFORMANCE CHARACTRISTICS
ACCURACY RESPONSE TIME REPEATABILITY OPERATING TEMP. RANGE

VARIABLES IN MEASUREMENTS
PRESSURE TEMPERATURE LEVEL FLOW CONDUCTIVITY VIBRATION ANALYSER DENSITY ENVIRONMENTAL POLLUTANTS

PRESSURE MEASUREMENT
SIMPLE MANOMETER INCLINED MANOMETER CYSTERN MANOMETER

BELLOW PRESSURE GAUGE DIAPHRAGM PRESSURE GAUGE

BOURDON PRESSURE GAUGE

Pressure Transmitters

PRESSURE GAUGES & TRANSMITTERS

Low pressure Diaphragm Gauge

Absolute Pressure Transmitter

Diaphragm sealed Gauge Pressure Transmitter

DIFFERENTIAL PRESSURE TRANSMITTERS

Differential Static Pressure Transmitter

Diaphragm sealed Differential Pressure Transmitter

PRESSURE SWITCHES & TRANSDUCERS

Pressure Switch

Industrial Pressure Transducer Pressure Indicator

Diaphragm Pressure Transducer

DIFFERENTIAL PRESSURE SWITCHES & TRANSDUCERS

Differential Pressure Switch

Differential Pressure Transducer

TEMPERATURE MEASUREMENT
Expansion Thermometers Resistance Thermometers Thermocouples Pyrometers Thermistors

SUPERHEATER TUBE THERMOCOUPLE

Without protection With protection

EXPANSION THERMOMETERS

Mercury In Glass Thermometer

Mercury In Steel Thermometer

Bimetallic Thermometers

Vapour Pressure Thermometers

THERMOCOUPLE

THERMISTOR

K TYPE

Temperature Transmitters

RTD

Temperature Indicator

PYROMETERS

Optical Pyrometer

Emissivity Calculator Pyrometer

TEMPERATURE MEASUREMENT IN BOILER

DRUM LEVEL MEASUREMENT IN BOILER

FLOW MEASUREMENT
Orifice Plate Flow Nozzle Venturi Tube Area Flow Meter 1.Rotameter 2.Piston Type Meter

Venturi Tube

Flow Nozzle

Orifice plate

PD FLOW METERS

PD flow meter
PD flow meter : Positive Displacement Meter Principle of measurement : Displacement of oil by

volume. Hence it is known as PD flow meter.

PD flow meters are commonly used for fuel oil flow measurement.

Principle of operation of PD flow meter :

The oval wheel meter is a volumetric meter. The measuring element consists of two meshing oval wheels, driven by the liquid. Each revolution of the oval wheel displaces a precisely known volume of liquid through the meter The number of revolutions is directly proportional to the measured volume. Transmission gearing transmits the revolution of oval wheels to a mechanical register (which counts the flow of volumetric units).

PD Meter (Oval wheel meter Parts)

Wet parts
Oval gears Gear shaft

Dry parts
Pulse amplifier F/I converter

Housing
Cover plate Strainer

Strainer :

PD Meter Parts

Protect the oval wheel meters from solid matter in oil.

Select strainers with 250 microns.

Pulse amplifier :
Generates and amplifies weak pulses proportional to the volume of oil displaced thro the flow meter.

F to I converter :
Converts the pulse generated by the pulse generator into a linear 4 20 mA current signal.

PD flow meter
Strainer

Oval wheel meter

Pulse generator

F/I converter

4-20mA to DCS

Problems faced in recent projects in PD Flow meter:

Kothagudam

Frequent stuck up in the meter

Jindal

F/I converter defective. Shaft coupling damaged.

Jojobera

Problem in connecting F/I converter sorted out

PD Flow Meter ..Contd..

Unchahar

Wrong pulse amplifier settings.

Vindyachal

F/I converter incorrect switch setting.

Kaperkheda

Oval gear tooth was damaged and shaft was slightly bent due to over speeding.

PD Flow Meter ..Contd..

WCPM

Problem in F-I converter rectified and reinstalled.

Ennore

Damage in strainer insert due to entry welding burs.

Recommendation for reducing/avoiding problems :

The major problem faced in the PDFM : Improper installation of the improper setting of the F/I converter. To avoid Installation problem : Brief notes with method of installation and Dos and Donts during installation. Since the O&M manual does not reach at the appropriate time. meter and

Mass Flow Meter ..Contd..

Alternate meter : Since mass flow meter is very costly when compared with the PD flow meter and the problems faced with PD flow meter are not mainly due to the defect in the equipment but are installation problems, PD flow meter itself shall be envisaged for this application with incorporating the recommended procedure.

VIBRATION MEASURING INSTRUMENTS

SEISMIC DEVICE

VELOCITY PICKUP

PIEZO ELECTRIC SENSOR

ENCLOSURE PROTECTION

Degree of Enclosure Protection for Electrical and Electronic Equipments.

Degrees of Protection FIRST NUMERAL IP X X SECOND NUMERAL X - : First Numeral stands for : Degree of protection against ingress of solid particles . -X : Second Numeral Stands for : Degrees of protection against ingress of Moisture . The above is as per IS 2147 which is now superseded by IS 13947 1.

----- why?

We have now the degrees of protection as

IP

Characteristic letters. 1st characteristic numeral. Supplementary letter. 2nd characteristic letters.

Degrees of Protection Indicated by First Numeral

1st Numeral & suffix 1.

Short description

Definition

Protection against solid objects greater than 50 mm. Protection against solid objects greater than 12.5 mm and against contact by standard test finger.

2L.

Protection against contact with live and moving parts. Test finger Not exceeding 80 mm length.

3.

Protection against solid objects greater than 2.5 mm. Protection against solid objects greater than 12.5 mm and against contact by 2.5 mm probe.

3 L.

Protection against contact with live and moving parts by a 2.5 mm diameter test probe not exceeding 100 mm in length.

Degrees of Protection Indicated by First Numeral

4. Protection against solid objects greater than 1.0mm. -

4 L.

Protection against solid objects greater than 12.5mm and against contact by 1.0mm probe. Dust protected

Protects against contact with live and moving parts by a 1.0 mm diameter test probe not exceeding 100 mm in length. Conditions: Prevents of ingress of dust in Quantities and locations that would interfere with the intended operation of the equipment .

5.

6.

Dust tight (Prevents ingress of dust).

Degrees of Protection Indicated by Second Numeral

Sec Num 1. 2. Short description Protection against dripping water Protection against dripping water When tilted up to 150. Protection with spraying water. Definition Vertically falling drops shall have no harmful effect. Conditions: Duration of test 10 min. Vertically falling drops shall have no harmful effect when the enclosure is tilted at any angle up to 150 from its normal position. Conditions: Duration of test 10 min. Water falling as a spray at angle up to 600 from the vertical shall have no harmful effect. Condition : Duration:10 Min : Delivery rate:: 10 L / min. : Water pressure: 0.8 bar. Water splashed against the enclosure from any direction shall have no harmful effect Condition of Test: Same as 3. Water projected by a nozzle against the enclosure from any direction shall have no harmful effect. Conditions: Nozzle: Internal dia: 6.3mm. : Delivery rate: 12.5 L/ min. :Water Pressure: 0.3 bar. : Minimum test Duration: 3 Min. : Distance from Nozzle to Eqpt: 3 meter.

3.

4.

Protection against splashing water. Protection against water jet.

5.

Degrees of Protection Indicated by Second Numeral

6. Protection against heavy seas. Water from heavy seas or water projected in powerful jets shall not enter the enclosure in harmful quantities. Conditions: Nozzle: Internal dia: 12.5 mm. : Delivery rate:: 100 L /min. : Water pressure: 1 bar. : Minimum test Duration: 3 Min. : Distance from Nozzle to Eqpt: 3 meter.

7.

Protection against effects of immersion.

Ingress of water in a harmful quantities shall not be possible when the enclosure is immersed in water under : water shall be min. 150mm above surface (highest pt). The lowest portion of the eqpt shall be at least 1 m below the surface of water. Duration of the test shall be 30 Min. Water Temp. shall not differ from that of the eqpt. by more than 5 0 C.

Determination of harmful ingress of water If any water has entered, it shall not,
be sufficient to interfere with satisfactory operation of the equipment. Reach live parts or windings. Accumulate near the cable entry point or enter the cable. Where the water ingress could raise doubts on functioning of the equipment - a dielectric test at 50% of dielectric test voltage can be conducted.

NEW PRODUCTS INTRODUCED

EWLI Electronic Water Level Indicator

BHELMHO Switch

BHELMHO - Electronic Water Level Switch (Conductivity Type) Principle of Operation BHELMHO Level Switch operates on the principle of discrimination between the conductivity of water and steam. It contains an electronics cabinet, four sensing electrodes, and indicators. Figure shows a typical installation of the BHELMHO Water Level Switch.

Functional Drawings of BHELMHO

Typical BHELMHO Level Switch Installation in HP Heater A safe low excitation voltage is applied between the insulated tip and the body of the sensing electrodes. The sensor output gives a value for the conductance of the cell formed by the electrode and the body, which is compared with a reference value and the electronic circuitry discriminates between steam and water. In addition the electronics is capable of detecting the open and short fault conditions of the sensing system. .

BHELMHO Switch.Contd. By the use of the proven conductivity technique BHELMHO Level Switch can be employed wherever water level detection and monitoring is required, such as drain pots on steam lines or bled steam lines from turbines etc. The BHELMHO Level Switch with its self-checking, fault tolerant electronics with right level indication will be very efficient in level monitoring.

Areas of Application of BHELMHO in Power and Process Plants De-aerator storage level HP & LP Heater columns Main boiler Drum Level Blow down tank level Main steam header drain Hot and cold reheat drains Turbine Extraction drain Hot well alarms Generator coolant level Turbine casing drain

BHELSONIC Sonic Tube Leak Detection System

Sonic Tube Leak Detection System (STLD) by BHEL(T) known as BHELSONIC System is used in boilers to detect tube leakage in the pressure parts region..

Sonic Tube Assembly

BHELSONIC System Sensor Locations (in a Typical 210 MW boilers)

1 2 3 4 5 7 6

595 544 505 504 46.95 42.5 41.5 39.0

10 12 12 13 14 15 16 17 18

8 9

30.15

16.0

LEFT SIDE

FRONT SIDE

LEFT SIDE

BHELSONIC System Panel

BHELFEEDMicroprocessor based Gravimetric feeder control

Gravimetric Feeder Overall view

Fdr photo-1

Feeder Electronics Roadmap by BHEL

BHELFEED
32 Bit system 16 Bit system

8 Bit system Solid State Hard Wired

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Raw coal

Microprocessor based Gravimetric feeder Control system

Gear Box

Motor

Load cell Signal

Tacho Signal

Signal Conditioner
Demand Signal from Combustion Control

Speed Controller GFC Controller

Output Signal to Customer

KBD & Display Coal conveyed : = Weight x Belt speed = Loadcell o/p x Tacho signal Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

MPGFC Panel
Easy integration with existing
feeders. Suitable for VFD, ECC and DC drives

Actual feed rate signal for DCS.

TCI pulse output.

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Functional Features of MPGFC

Automatic calibration of Tare and Span. Automatic tracking of Loadcell signals. Auto change-over to Volumetric mode of operation in case of loadcell signal faults. Historic density calculation and record for use in volumetric mode of operation. Programming of specific feeder parameters.
Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Need for Gravimetric Feeding of Coal

Control of coal feeding by weight Data logging of actual coal consumption (no thumb rule method ). Data generated will be useful for control of coal

inventory and advance planning for procurement.

Actual feedrate signal as feedback for excess air control results in optimum combustion of fuel.
Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Advanced Features of MPGFC

Advanced 32-bit Processor . Highly integrated electronics with High resolution ADC & DAC - Improved reliability RTC for Date & Time stamp of events and data. User friendly Keyboard. Feeder status and alarm indicators

Contd..
Committed to making a better world

Bharat Heavy Electricals Limited TIRUCHIRAPALLI

Advanced Features of MPGFC Contd..

Vacuum Fluorescent Display 40 Ch x 2 line. Self test and diagnostics. Real time multimode data logging for coal consumption. Digital Totalizer for multimode mode operation.

Committed to making a better world

DESCRIPTION CONTROL ARCHITECTURE ELECTRONICS I / O MODULES BELT SLIPPAGE DETECTION TIMING FUNCTION FOR LOGIC SERVICING OF ELECTRONIC MODULES RESPONSE TIME FOR SERVICING COST OF SPARES AESTHETICS

BHELFEED 32 bit Microprocessor based Modular construction Hot Swap Possible Inbuilt with the system Implemented in software Component level possible Economical Immediate Economical Excellent - Rack mounted modules and reduced interconnections Better Diagnostics. Customized for Indian condition

IMPORTED 16 bit Microcontroller based Non modular Hot Swap Not possible Separate unit required Hardwired timers used Board level only possible Expensive More due to re-export Expensive Door mounted boards & interconnections Standard diagnostics

DIAGNOSTICS

Customer Appreciation

From

M/s APGENCO VTPS

BHELSCANMicrocontroller based Flame Scanners

Block diagram of BHELSCAN

One corner flame

FOC LBA

Head Electronic s ADC MC U

2/4 Flame Detect Logic

O/P to FSS S

Other corner processor o/p

BHELSCAN BHEL make indigenous

BHELSCAN System Electronic Module

Troubleshooting

Inadequate cooling capacity Inadequate flow of cooling water and /or sample Excessive flow of sample Leakages in cooling & sampling lines Analysers starving due to inadequate sample flow Chocking of sample lines/ filters Chiller : Leakage of refrigerant gas Fluctuations in sample flow to analysers Quality of cooling waer Ignorance in understanding System function. Lack of training steam power engg + instrumentation Lack of maintenance

Safe Scan System Trouble Shooting (Frequency detection Module )

Symptoms: Trim and frequency lamps are on together. Card is sent into oscillation,Which causes the flame relay on the lamp and meter card to change state rapidly. This causes the relay to generate a humming noise. Probable case : IC302(CD4011BD) Symptoms: Neither the frequency nor the trim lamps are ON Probable case : IC303(CD4047BD) Symptoms: Trim lamp will not change its pulsing rate even with a change in the DIP switch setting. Probable case : IC303(CD4047BD) Symptoms: Frequency lamp is always ON Probable case: C301,C304, or C306 (luf@50V)capacitors can be checked in circuit with an ohmmeter. Defective component will be shorted. Symptoms: Trim and frequency lamps alternateON and OFF at the same rate. Probable case:IC302(CD4011BD)

Safe Scan System Trouble Shooting (Lamp and Meter Module )

Symptoms: Flame lamp will not respond:TP404 reads approximately ) Vdc. Probable case:IC401(CD4011BD)normal condition with flame TP401, TP402~ 10Vdc TP403~0Vdc TP404~10VdcFlame relay is energized and flame lamp on. Symptoms: Needle on the meter is at the top of scale and the fault lamp is ON Probable case : B + fuse Symptoms: Needle remains in the middle of the scale and frequency lamp on the frequency detection card is OFFIntensity fault detection card is ON. Probable case : B- fuse