ROBOTICS AND AUTOMATION ASSIGNMENT ON SENSORS USED IN THERMAL POWER PLANTS

SUBMITTED BY, SHREE RAAM.R 10BEC0454 G2

INTRODUCTION:
A thermal power station is a power plant in which the prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated; this is known as a Rankine cycle. The greatest variation in the design of thermal power stations is due to the different fossil fuel resources generally used to heat the water. Some prefer to use the term energy centre because such facilities convert forms of heat energy into electrical energy. Certain thermal power plants also are designed to produce heat energy for industrial purposes of district heating, or desalination of water, in addition to generating electrical power. Globally, fossil fueled thermal power plants produce a large part of man-made CO2 emissions to the atmosphere, and efforts to reduce these are many, varied and widespread.

BLOCK DIAGRAM OF THERMAL POWER PLANT:

From the diagram it is clear that there are many parameters to monitor, they are as follows

QUANTITIES TO BE MEASURED:
* Pressure * Temperature * Flow * Level

TEMPERATURE SENSORS:
Temperature sensors are used in the following areas * Stem at superheater inlet & outlet * Feed water at economiser inlet

* Water at condenser inlet * Air preheater * Furnace * Flue gases The temperature sensors used are RTD and Thermocouple.

RTD:

Resistance thermometers, also called resistance temperature detectors (RTDs), are sensors used to measure temperature by correlating the resistance of the RTD element with temperature. Most RTD elements consist of a length of fine coiled wire wrapped around a ceramic or glass core. The element is usually quite fragile, so it is often placed inside a sheathed probe to protect it. The RTD element is made from a pure material, platinum, nickel or copper. The material has a predictable change in resistance as the temperature changes; it is this predictable change that is used to determine temperature.

THERMOCOUPLE:
A thermocouple consists of two dissimilar conductors in contact, which produce a voltage when heated. The size of the voltage is dependent on the difference of temperature of the junction to other parts of the circuit. Thermocouples are a widely used type of temperature sensor for measurement and control and can also be used to convert a temperature gradient into electricity. Commercial thermocouples are inexpensive, interchangeable, are supplied with standard connectors, and can measure a wide range of temperatures. In contrast to most other methods of temperature measurement, thermocouples are self powered and require no external form of excitation. The main limitation with thermocouples is accuracy; system errors of less than one degree Celsius (C) can be difficult to achieve.

PRESSURE SENSORS:
Pressure sensors are used in the following areas * Boiler * Turbine * Turbine throttle

* Furnace The pressure sensors used are Bourdon Tube and Diaphragm sensors.

BOURDON TUBE:

The Bourdon pressure gauge uses the principle that a flattened tube tends to straighten or regain its circular form in cross-section when pressurized. Although this change in cross-section may be hardly noticeable, and thus involving moderate stresses within the elastic range of easily workable materials, the strain of the material of the tube is magnified by forming the tube into a C shape or even a helix, such that the entire tube tends to straighten out or uncoil, elastically, as it is pressurized. Eugene Bourdon patented his gauge in France in 1849, and it was widely adopted because of its superior sensitivity, linearity, and accuracy; Edward Ashcroft purchased Bourdon's American patent rights in 1852 and became a major manufacturer of gauges. Also in 1849, Bernard Schaeffer in Magdeburg, Germany patented a successful diaphragm pressure gauge, which, together with the Bourdon gauge, revolutionized pressure measurement in industry. But in 1875 after Bourdon's patents expired, his company Schaeffer and Budenberg also manufactured Bourdon tube gauges. In practice, a flattened thin-wall, closed-end tube is connected at the hollow end to a fixed pipe containing the fluid pressure to be measured. As the pressure increases, the closed end moves in an arc, and this motion is converted into the rotation of a (segment of a) gear by a connecting link that is usually adjustable. A small-diameter pinion gear is on the pointer shaft, so the motion is magnified further by the gear ratio. The positioning of the indicator card behind the pointer, the initial pointer shaft position, the linkage length and initial position, all provide means to calibrate the pointer to indicate the desired range of pressure for variations in the behavior of the Bourdon tube itself. Differential pressure can be measured by gauges containing two different Bourdon tubes, with connecting linkages.

DIAPHRAGM SENSOR:
The Diaphragm Pressure Gauge uses the elastic deformation of a diaphragm (i.e. membrane) instead of a liquid level to measure the difference between an unknown pressure and a reference pressure. A diaphragm seal is a flexible membrane that seals and isolates an enclosure. The flexible nature of this seal allows pressure effects to cross the barrier but not the material being contained. Common uses for diaphragm seals are to protect pressure sensors from the fluid whose pressure is being measured.

FLOW:
Flow sensors are used in the following areas * High pressure steam * Feed water inlet * Condensate

FLOW SENSORS:
A flow sensor is a device for sensing the rate of fluid flow. Typically a flow sensor is the sensing element used in a flow meter, or flow logger, to record the flow of fluids. As is true for all sensors, absolute accuracy of a measurement requires a functionality for calibration. There are various kinds of flow sensors and flow meters, including some that have a vane that is pushed by the fluid, and can drive a rotary potentiometer, or similar devices. Other flow sensors are based on sensors which measure the transfer of heat caused by the moving medium. This principle is common for microsensors to measure flow. Flow meters are related to devices called velocimeters that measure velocity of fluids flowing through them. Laser-based interferometry is often used for air flow measurement, but for liquids, it is often easier to measure the flow. Another approach is Doppler-based methods for flow measurement. Hall effect sensors may also be used, on a flapper valve, or vane, to sense the position of the vane, as displaced by fluid flow.

HALL EFFECT SENSOR:

A Hall effect sensor is a transducer that varies its output voltage in response to a magnetic field. Hall effect sensors are used for proximity switching, positioning, speed detection, and current sensing applications. In its simplest form, the sensor operates as an analog transducer, directly returning a voltage. With a known magnetic field, its distance from the Hall plate can be determined. Using groups of sensors, the relative position of the magnet can be deduced. Electricity carried through a conductor will produce a magnetic field that varies with current, and a Hall sensor can be used to measure the current without interrupting the circuit. Typically, the sensor is integrated with a wound core or permanent magnet that surrounds the conductor to be measured. Frequently, a Hall sensor is combined with circuitry that allows the device to act in a digital (on/off) mode, and may be called a switch in this configuration. Commonly seen in industrial applications such as the pictured pneumatic cylinder, they are also used in consumer equipment; for example some computer printers use them to detect missing paper and open covers. When high reliability is required, they are used in keyboards.

DOPPLER-BASED SENSOR:
The Doppler effect (or Doppler shift), named after the Austrian physicist Christian Doppler, who proposed it in 1842 in Prague, is the change in frequency of a wave (or other periodic event) for an observer moving relative to its source. It is commonly heard when a vehicle sounding a siren or horn approaches, passes, and recedes from an observer. The received frequency is higher (compared to the emitted frequency) during the approach, it is identical at the instant of passing by, and it is lower during the recession.

This principle is used in measuring flow velocity.

LEVEL SENSORS:
Flow sensors are used in the following areas * Boiler drum * Condensate tank * Water line Level sensors detect the level of substances that flow, including liquids, slurries, granular materials, and powders. Fluids and fluidized solids flow to become essentially level in their containers (or other physical boundaries) because of gravity whereas most bulk solids pile at an angle of repose to a peak. The substance to be measured can be inside a container or can be in its natural form (e.g., a river or a lake). The level measurement can be either continuous or point values. Continuous level sensors measure level within a specified range and determine the exact amount of substance in a certain place, while point-level sensors only indicate whether the substance is above or below the sensing point. Generally the latter detect levels that are excessively high or low. There are many physical and application variables that affect the selection of the optimal level monitoring method for industrial and commercial processes. The selection criteria include the physical: phase (liquid, solid or slurry), temperature, pressure or vacuum, chemistry, dielectric constant of medium, density (specific gravity) of medium, agitation (action), acoustical or electrical noise, vibration, mechanical shock, tank or bin size and shape. Also important are the application constraints: price, accuracy, appearance, response rate, ease of calibration or programming, physical size and mounting of the instrument, monitoring or control of continuous or discrete (point) levels.

CONCLUSION:
These are the various sensors used in thermal power plants. These sensors help in the measurement of various parameters that help increase the efficiency of electricity production in a thermal power plant. The above mentioned are only a few among the many sensors used.