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LECTURE ON:
OPERATION & MAINTENANCE OF CONTROL & INSTRUMENTATION
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.
7.
Trouble shooting
Problems in Safe Flame Scanner System
Pneumatic Control
AFR
AIR LOCK
4-20mA
ZT
4-20mA
Positioner
E/P
I P
AFR
I/P CONVERTER
Hydraulic Control
Electrical Control
Electric Actuator
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.
D or d/dt
Multiplying
X . .
8 9
F(x)
12 High Selecting
> <
>
15 Low limiting
<
-K or -P +,- or A T
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.
Digital Gates
OR GATE I/P
SIGNAL 1 2 3
OR
AND
O/P
O/P 1 O/P 2
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
G
RESET M.F.R. TO M.F.R NO BOILER TRIP
5 MIN
IGNITION TRIP VALVE CLOSED LIGHT OIL TRIP VALVE CLOSED HEAVY OIL TRIP VALVE CLOSED
NO BOILER TRIP
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.
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.
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.
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
Pressure Transmitters
Pressure Switch
TEMPERATURE MEASUREMENT
Expansion Thermometers Resistance Thermometers Thermocouples Pyrometers Thermistors
EXPANSION THERMOMETERS
Bimetallic Thermometers
THERMOCOUPLE
THERMISTOR
K TYPE
Temperature Transmitters
RTD
Temperature Indicator
PYROMETERS
Optical Pyrometer
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
PD flow meters are commonly used for fuel oil flow measurement.
Dry parts
Pulse amplifier F/I converter
Housing
Cover plate Strainer
Strainer :
PD Meter Parts
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
Pulse generator
F/I converter
4-20mA to DCS
Oval gear tooth was damaged and shaft was slightly bent due to over speeding.
Ennore
SEISMIC DEVICE
VELOCITY PICKUP
ENCLOSURE PROTECTION
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?
IP
Characteristic letters. 1st characteristic numeral. Supplementary letter. 2nd characteristic letters.
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.
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.
3.
4.
5.
7.
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.
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.
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
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..
1 2 3 4 5 7 6
10 12 12 13 14 15 16 17 18
8 9
30.15
16.0
LEFT SIDE
FRONT SIDE
LEFT SIDE
Fdr photo-1
BHELFEED
32 Bit system 16 Bit system
Gear Box
Motor
Tacho Signal
Signal Conditioner
Demand Signal from Combustion Control
KBD & Display Coal conveyed : = Weight x Belt speed = Loadcell o/p x Tacho signal Committed to making a better world
MPGFC Panel
Easy integration with existing
feeders. Suitable for VFD, ECC and DC drives
Contd..
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
FOC LBA
O/P to FSS S
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