Basics of Instrumentation

Interlocks,Control loops and

DCS
BASIC INSTRUMENTATION
 INSTRUMENTATION
It is defined as the art of science, it deals with
measuring, monitoring, displaying and controlling of
various process variables like pressure, temp, flow & level
and etc., with in a production or manufacturing area.

WHY INSTRUMENTATION?
To Achieve a goal of improving
 System productivity,
 Reliability,
 Accuracy,
 Stability,
 Optimization,
 Safety.
 PRESSURE
 Force acting per unit Area.
 Formulae: P=F/A.
 Units: Kg/Cm2, PSI, BAR, mmwc & Etc.,

PRESSURE SENSORS TYPES:

 Bourdon Tubes.
 Bellows.
 Capsules.
 Diaphragms.
 Diff. Pressure Type.
 TEMPERATURE
 The Degree of hotness or coldness of a body.
 Units: Celcius, Fahrenheit,Kelvin.

TEMPERATURE SENSOR TYPES:

 Resistance Temperature Detector.
 Thermocouple
 Thermostat
 RTD (Resistance Temp. Detector)
It operates on the principle that changes in
resistance with change in temperature. I.e. resistance
increases with the increase in temperature .
Types of RTD: PT- 100, PT- 500, PT -1000.
Based on Lead Configuration :
 THERMO COUPLE
It consists of two dissimilar metals wires with their
ends joined together,When heat is applied to the junction,
a voltage, in the range of milli-volts (mV), is generated.
TYPES OF THERMO COUPLE
There are Five types of themocouple
 J type
 K type
 R type
 S type
 T type
J type:
It is made up of iron - constantan where Iron wire is
positive & constantan wire is negative.
Operating range : - 40 to 750Deg C

k type:
It is made up of Chromel- Alumel where Chromel
wire is positive & Alumel wire is negative.
Operating range : - 200 to 1350 Deg C
 FLOW
 Quantity of the medium which passes a point in unit time
at a specified pressure and temp.
 Units:Tph, lph, m3/hr & Etc.,

TYPES OF FLOW METER:

 Mass flow meter.
 Magnetic flow meter.
 Vortex flow meter.
 Ultrasonic flow meter.
 Coriolis flow meter.
 Diff. Pressure type measurement.
Types of Diff. Pressure type measurement:

 Orifice Plate,
 Flow Nozzle,
 Venturi Tube,
 Elbow Taps.
Types of Diff. Pressure type measurement:
Orifice Plate: Elbow Taps:

Flow Nozzle:
Venturi Tube:
 LEVEL
 Difference between two Heights.
 Units : %, cm, Meters.

Types of Level Measurement:

 Hydrostatic Pressure type
Differential type (Closed Tank)
Diaphragm type (Open Tank)
 Float type
 Ultrasonic type
CLOSED LOOPS
 CLOSED LOOP
A control system that produces the maniplated
output value(MV) deponds upon difference between
Set Value(SP) and Present Value(PV).It is also called
as Controllers
Important Closed Loops in Cogen:
 Drum Level Control
 Combustion Control
 Main Steam Temperature Control
 Furnace Pressure Control
 Extraction Pressure Control
 Wander Extraction Control
 Gland Steam Control
 MODES OF THE CONTROLLERS

There are Three types of modes :

 MAN(Manual Mode)
 AUT(Auto Mode)
 CAS (CASCADE MODE)
 MANUAL MODE:
 In manual mode, Final control Element's Input(MV) is
directly given by the operator.

SV
Transmitter PV MV
4-20 mA Controller

I/P 4-20 mA
Convertor I/P
Pneumatic Signal
(0.2 to 1 Kg/cm2 or 3 to 15 psi)

Final Control Element

 AUTO MODE:
 In Auto mode, produces the maniplated output value(MV)
deponds upon difference between Set Value(SP) and
Present Value(PV)
SV
Transmitter PV MV
4-20 mA Controller

I/P 4-20 mA
Convertor I/P
Pneumatic Signal
(0.2 to 1 Kg/cm2 or 3 to 15 psi)

Final Control Element

CASCADE MODE (DRUM LEVEL)
 In a cascade loop the output of
the primary controller (MV1)
AUTO goes as set point of the
MV secondary controller (SV2).
1 The output of the secondary
controller (MV2) goes to
the final control element.

(MV2 CAS  For a cascade loop, the

) primary controller should
be in AUTO mode,but the
secondary controller has to
be in CAS mode.

Ctrl valve

→
↓
Final Control VFD
Elements BFP Cont..
 Drum Level:
 Maintaining liquid level in the boiler steam drum is the
highest priority because Low level cause Tube failure
and High level result in water carry over to turbine.
 So Drum level is maintained in "3 Element Strategy"

What is 3 Element?
 The term “3-element control” refers to the number of
process variables (PVs) that are measured.
1. Liquid level of the boiler drum,
2. Feedwater Flow to the boiler drum,
3. Flow of steam leaving from the boiler drum.
 3
.

2 1.
.
SWAS (STEAM & WATER ANALYSIS SYSTEM):

 To ensure water quality to boiler.

 To prevent corrosion.
 To identify impurities.
 To prevent scale deposit in boiler tubes.
 To prevent silica deposit on turbine blades.
INTERLOCKS
 INTERLOCK:
An interlock is a Preventing measure of undesired
states or process variable in a state machine or process.
Process Interlock:
Something that prevents incorrect operation or
possible damage to the process or equipment
Safety Interlock:
Something that prevents possible damage or death
to people operating that process or equipment.
 DCS
&
SIGNALS
 Basic Components of DCS
FCS (Field Control Station):
Used to control the process. All the instruments and
interlocks created by software reside in the memory of
the FCS. All the field instruments like transmitters and
control valves are wired to the FCS.
OPS (Operator Station):
Used to monitor the process and to operate various
instruments.
Communication Bus:
Used to communicate between the FCS and the OPS.
 Advantages of DCS
 Control function is distributed among multiple CPUs
(Field Control Stations). Hence failure of one FCS
does not affect the entire plant.
 Redundancy is available at various levels.
 Instruments and interlocks are created by software.
 Information regarding the process is presented to the
user in various formats.
 Field wiring is considerably less.
 Maintenance and trouble shooting becomes very
easy.
 Signal
Anything which carries information.
(OR)
Conveying information or instructions by means
of gesture, action, or sound.

Signals

Analog Digital
Signal Signal

Analog Analog Digital Digital

Input Output Input Output
 Signals Classification:
There are Two types of Signals
1. Analog Signal 2.Digital Signal
Analog Signals :
These are the signal which are ranging from
low to high 4-20 ma,0-20 ma and 1-5v.
Analog Input :
Signals which are received from field intruments
like transmitters(Flow,Pressure) and etc
Analog Output :
Command which are given in percentage from
operator station to field intruments like Control
Valve(I/P Converter) and Speed Reference.
Digital Signal:
These are the Signals which have only 0's and 1's
Digital Input :
Signals which are received from Switches like
Level Swich, Pressure Switch and running indication
of motors like ON,OFF and Trip. These are basically
24V or 110V or 230V
Digital Output :
Command which are given from Operator Station
like operating Solenoids valves,START and STOP the
motor , Local / Remote Selection (DCS)