Welcome to

Control and
Instrumentation
 Syllabus:

Control concepts, annunciation

system, CFM, CTM,
moderator instrumentation,
transmitters, COIS, PDCS,
DRS, RADAS,
Fire alarm system.
 Control concepts

Control valves,
positioners, E/A converters,
Volume boosters,
pressure regulating valves,
manifolds (3 way),
solenoid valves.
 Control valve

The purpose of valve is to vary the flow of the control agent

in response To a signal received from the controller. This is usually
accomplished by Installing an automatic valve and varying the port
area through which The control agent flows. The power to change
and maintain the port area is provided by The control valve
operator / actuator.
An operator is classified according to its input signal and is out put to
the power element. It may be mechanical, pneumatic, electric, hydraulic
or electro pneumatic. A mechanical operator of this type receives an
Input signal in the form of mechanical position(stroke) and its
mechanically Linked to the final control element.
 N N
S S

Output
.2 to 1 kg/cm2 4.5 Kg/cm2
 Pneumatic operator
Because of the great popularity of pneumatic automatic control systems
in industrial applications , the pneumatic operator is the most widely
Used in modern industry.

Output
Input Pneumatic
pressure operator stroke

The two major types of pneumatic operators used are

1. The diaphragm type and

2. The cylinder type.
 Diaphragm

the purpose of the diaphragm is to act as a pressure seal between

the Upper and lower diaphragm chambers. The conventional type
diaphragm Consists of a flat piece of flexible material of circular shape.
Its diameter Is a function of the required stem thrust. The diaphragm
often premolded In order to prevent crimping or stretching and to give
better effective Area – stroke characteristics. It is held between the case
plates by bolting.
the upper and lower cases of the diaphragm housing are of either
High tensile iron or pressed steel.
 Cylinder type operator.

Air pressure connection

Cylinder
piston

“O”ring seal

stem

Flow
The cylinder – type operator consists of a piston operating in a pressure
Tight cylinder . The piston may be made from steel or alloy steel, cast-
Iron alloy or aluminum alloy.
 Positioners.
The primary function of the positioner is to ensure that the control
valve stem position is directly proportional to the respective value
of instrument output pressure regardless of off balance forces on
the valve plug.
When a positioner is applied to a valve is no longer operated
directly by the instrument output pressure.
The positioner utilizes the instrument output pressure only as a
signal, and controls an independent pressure supply to apply whatever
pressure is required to force the valve stem to the correct position.
In short,positioner is a relay capable of applying maximum
force to position the valve stem correctly.
 The purpose of positioner

1. Up thrust control.
2. Quick operation.
 E/A converter

input output
E/A
4 to 20 mA 0 to 1 kg/cm2

An Electro pneumatic transducer, abbreviated as E/A. it receives

a milliampere DC current electrical signal and transmits a proportional
pneumatic output pressure .

It is application is in electric control loops where the final control

element, generally a control valve, is pneumatically operated.
 N N
S S

Output
.2 to 1 kg/cm2 4.5 Kg/cm2
 Principle of operation for E/A converter.
Assume that the transducer is direct acting. An increasing the DC mA
signal to the coils increase the magnetic field around the coils. This
field increases the magnetic strength in the armature and the magnetic
attraction across the air gap between the armature and the pole pieces.
The pole pieces are already polarized by the permanent magnet.
The armature polarity is as shown in fig. The magnetic attraction will
therefore be downward at the nozzle end and upward at the feed back
bellows end, resulting in a torque that rotates the armature about the
fixed torsion rod to cover the nozzle. The resulting restriction produces
an increased pressure in the nozzle, in the upper chamber of the relay,
and in the feed back bellows. The relay responds to the increase in
nozzle pressure to increase the output pressure to the control valve, the
normal output load.

The nozzle pressure is compared to the input current by the

force balance principle.
 Pressure regulating valves (PRV)

un regulated
PRV
Regulated
air pressure air pressure

The objective of a PRV is to provide a constant regulated desired

out put independent of the variations of the supply side.

Generally two types PRV’s

1. Non bleed type

2. Bleed type
 Non bleed type PRV. Schematic diagram

Adjusting screw

bonnet
spring

diaphragm Breathing hole

Regulated output

Line pressure valve

Valve spring
 Bleed type PRV

Adjusting screw

bonnet
spring

diaphragm Breathing hole

Regulated output

Line pressure valve

Valve spring
 Bleed type PRV.

In bleed type of PRV there is no connection between the

pilot valve stem and diaphragm . The rounded end of the valve
stem acts as a second valve. With it is seat fastened at the center of
the diaphragm. If the out put pressure become high, the extra force
will lift the diaphragm from the valve stem, allowing excess
pressure to bleed into the spring chamber which is open to
atmosphere.

This kind of PRV's are normally used to get low pressure

 Three way manifold
H L

transmitter

Equalizing valve Three way manifold

HP valve LP valve

Shut off valve

flow

orifice
 Solenoid valves

+ +
48v DC 48v DC
– –

coil
plunger

disc

De- energized energized

The solenoid valves are operated by electrical solenoid coils. These valves are
normally used to control the flow of gases and liquids.

A solenoid valve is a combination of two basic functional units

a) solenoid (electromagnet) with its plunger,
b) a disc or plug which is position to stop or the flow.
 Types of solenoid valves
1. Two way
2. Three way
3. Four way

Three way sv Four way sv

Two way sv
E
E
E

IN OUT IN OUT
IN OUT

exhaust exhaust
 TRANSMITTERS

The device that measures the pressure difference and converts this
to the proportional out put, or analog signal is known as a
Transmitter.

Input Output
Differential pressure transmitter (4 to 20 mA)

INPUT AND OUT PUT RELATION OF TRANSMITTER

 SCHEMATIC OF TRANSMITTER

Range rod
Over range adjustment armature
screw
windings

Differ transformer
flexure
Force bar

Oscillator Amp

DC power
HP valve receiver supply
LP valve

Output 4 to 20mA
Diaphragm capsules Feed back motor Zero adjustment screw
 The pressure applied to opposite sides of the silicon filled diaphragm capsules
Through the high and low pressure connections.
Any difference between these pressures exerts a force on the diaphragm –capsules,
Which is rigidly connected to the force bar by the flexure. The elgiloy diaphragm
Acts as a seal and as a fulcrum for the force bar. The force bar transmits a force,
which is exactly proportional to the differential pressure on the diaphragm
capsule, through the flexure to the range rod causing the range rod to pivot about
point.
any movement of the range rod is detected by the armature of the
differential –transformer detector. If, for instance ,there is an increase an
pressure on the HP side of the diaphragm –capsule , the armature moves towards
the secondary winding (direction shown by arrow) of the detector, thus
strengthing Inductive coupling and increasing the secondary voltage. Hence the
4 –20 mA DC Output signal from the oscillator amplifier will increase. This output
signal is fed to the feedback motor, in series with the receiver. The force exerted by
The feedback motor is exactly proportional to the force applied to the range rod
By the force bar. Since the force exerted by the force bar is exactly proportional to
the differential pressure, the current in the feedback motor and to the output is
exactly proportional to the differential pressure.
In operation the movement of the range rod is continuously, adjusting the detector
to maintain a condition of force balance between the force exerted by the feed
back motor by the force bar.
 Moderator instrumentation
Moderator system maintains criticality in the reactor core, by slowing
down the high energy neutrons coming out from fission to lower energy level.

heavy water is used as a moderator, because , it has very less neutron

Absorption cross section and very good moderating properties.

The bubbler method is used to measure the moderator level in the reactor.

The Calandria (reactor) level is measured by bubbler method.

The back pressure is Created by constant flow of helium bubbling
in to Calandria is measured and Converted into level units.

Moderator level is measured by two ranges

1. Wide range
2. Narrow range
 Moderator instrumentation
OPRD
1. Wide range 5% to 105%

105% reactor

FIV FIV 0.3kg/cm2

96% of reactor

He gas
LP HP

Tk 3231

2.5kg/cm2
HP HP
LP LP HP LP
MODERATOR

transmitters
Helium gas cylinder
5% of reactor
 Moderator instrumentation
OPRD
1. Narrow range 85% to 105%

105% reactor

FIV FIV 0.3kg/cm2

96% of reactor

He gas
LP HP

Tk 3231

2.5kg/cm2

HP HP LP
HP LP LP
MODERATOR

transmitters
Helium gas cylinder
85% of reactor
 Moderator levels in Calandria (reactor)

103% F.T
100% F.T

96% F.T

94% F.T 92.5% F.T

1. 103% F.T moderator high level trip.

2. 100% F.T moderator high level alarm.

3. 96% F.T normal level.

moderator

4. 94% F.T moderator low level alarm

5. 92.5% F.T moderator low level trip.

 COIS (computerized operates information system)
With a view to presenting to the operator the desired information in a compact,
over all fashion and reduce the large number of recorders, meters, and
annunciating windows use in the earlier plants.

A computer based operator information system has been introduced in nuclear

plants.
Cois is a data acquisition And display equipment for providing the operator.
With process alarm massages, status, trend curves, history display and print out
of group of process variables at control room.

The Cois consists of 10 nos. UCRTS and 2 nos. ACRTS based on 80386 mP.
And other 2 nos. DAC (data acquisition computers) 80586 mP.

Function of DAC

acquire the data from I/o system and other computers.

Pass the required data to display secti8on.

Logging history data on hard disk/ magnetic tape.

Network management of LAN
 Schematic Diagram of COIS

resistor

Analog
4 to 20 mA 1 - 2v input card ADC CPU LAN
form transmitter

DAC2 DAC1

To printers To ACRTs To UCRTs

 PDCS (programmable digital comparator system)

Normally indicating alarm meters are used in power plants control the process
set points.
Now a days PDCS is using instead of indicating alarm meters, because of the

following advantages.

$ More reliability and flexibility

$ Centralized system , hence analysis is easy.
$ Accurate reading.
$ Has administrative control over set point changes
$ A user friendly system.
 Schematic Diagram of PDCS

resistor
ADC

Dual
1 - 2v
o/p Analog
4 to 20 mA to MUX
signal digital CPU RORB
form transmitter
card

AU DU PRINTER

PDCS PC
 DRS (digital recording system)

DRS is a computerized recording system, used in the station for collection and
storage of data pertaining to a large number of analog and digital parameters
during normal operation and in a disturbed state. The stored data can be
received later for analysis of any event.
The important futures of this system is presentation of data in various display
formats. Printouts ,facilitating easy configuration of the signal by the operator.

The digital recording system is designed to meet the following objectives

1. To monitor and record the data of 96 analog points at an interval of a ONE

second. Normally and preserve the recorders for the last 120 hours as
archival data. This function is called NORMAL RECORDING.

2. To record the data of 96 analog inputs as in 1 a above at an interval of 200

milli seconds for a total period of 5 minutes whenever any disturbance accrued,
this function is called DISTURBANCE RECORDING.

3. To record the data of 8 analog inputs, different from those covered in 1&2
above at an interval of 5 milli seconds for a period of 5 seconds whenever
required . This function is called FAST RECORDING.
4. To record the status changes of 448 potential free contact inputs in time
sequence with a resolution of 2 milli seconds. This function is called
EVENT SEQUENCE RECORDING.
 Annunciation system
The primary objective of the annunciation system is to alarm information in the
most effective mode to alert the operator to system abnormality.
For this purpose, all alarms are presented through audio visual means.

A judicious bleed of dedicated hard wired window and CRT annunciation

schemes is adopted. About 400 alarms which calls for immediate operator action
and / or which are very important under all plant operating conditions are
retained as window type annunciation. The rest of all alarms (1000 nos.
approximately) are processed through COIS and displayed on CRT.
 CTM (channel temperature monitoring system)
boiler pcp

S outlet
moderator
Header
S inlet

N inlet Header
Header

TE

N outlet TE
Header
calandria
TE TE

Coolant
Channel
tube tube

Fuel bundle

feeders
 CFM (channel flow monitoring system)
boiler pcp

S outlet
moderator
Header
S inlet

N inlet Header
Header

FE

N outlet
FE
Header
calandria
FE
FE

Coolant
Channel
tube tube

Fuel bundle

feeders
 Fire alarm system
RB Location TB Location

FORWARD D1
D1 D2
D2 D3
D3 D4
D4
JB

ADIM
CPU
IDCT Location RAB Location

REVERSE
JB D8
D8 D7
D7 D6
D6 D5
D5

MONITOR

FIRE IN TB Location

DETECOR NO D3

DETECTOR TYPE ionization

 Advantages of fire alarm system

 Quick action takes if fire exists

 Fail safe, because microprocessor based
 We can see on the monitor, where fire exists
 Operator can listen the hooter sound, if fire exists
 Rugged in construction
 Circuit protection against temp, electromagnetic, radiation