Boiler Instrumentation

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Presentation outline
Basic Process Measurement Level Measurement Flow Measurement

Temp Measurement
Steam Generator C&I system

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CONTROLS & INSTRUMENTATION

Control & Instrumentation deals with various measurement, indication, transmission and control in different technical fields. Instrumentation is for measurement of various parameters. And controlling various parameters from a remote control room.

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Instruments
Instruments for measuring various physical quantities like Pressure Temperature Level Flow Turbovisory Vibration Speed etc. Analytical PH Conductivity Silica etc

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Instruments
Measuring Electrical parameters such as
Load MVAR Frequency Voltage Current etc.

Indicators
Local Remote

Recorders
Single Point Multipoint Continuous Dotted

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Pressure Measurement
Manometers for low pressure.

Water filled Mercury Filled

Bellows for medium pressure Bourdon tube gauges for medium and high pressure measurements

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Pressure Measurement
Transducers of different type for all ranges for telemetering purpose.

Capacitive type. LVDT type. Strain gauge type.

Mode of connection of Transmitters

Four Wire Two Wire

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Type of Transmitter

Microprocessor based 2 wire type,.

2. Sensor Type Capacitance/Piezo-electric 3. Accuracy 0.1% of span 4. Output signal range 4-20 mA DC (Analog) 5. Turn down ratio 30:1 Zero and span drift 0.015% per deg.C at max span a and 0.11% per deg.C at min. span.

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Level Measurement
Floats and liquid displacers Head pressure measurement DP type Ultrasonic Direct Viewing Strain gauge

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Level Measurement
In closed pressurised vessels, Differential pressure measurement is used to measure the level. One side condensate pot is used where constant level is maintained. Other side is connected to the bottom of the vessel. Difference between these two heads gives the level.

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Level Measurement (Closed Vessel)

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Level Measurement (Closed Vessel)

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Level Measurement (Float)

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FLOW MEASUREMENT
Controlling the flow rate of fluids is a key control mechanism for any process plant. There are many different types of devices available to measure flow.

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Flow Measurement
HEAD TYPE Orifice Plate Rotameters Venturi Tubes Target Meters VELOCITY TYPE Magnetic Vortex DISPLACEMENT Turbine Meter
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HEAD TYPE
Head type devices measure flow by constricting a stream and measuring the resulting pressure drop. The pressure drop can then be related to a flow.

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Orifice Plates
An orifice plate is a very simple device installed in a straight run of pipe. The orifice plate contains a hole smaller than the pipe diameter. The flow constricts, experiences a pressure drop, and then the differential pressure can be related to a flow.

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Orifice Plates

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Rotameters
Rather than using a constant restriction area and a variable pressure differential, rotometers use a variable restriction and a constant pressure differential to measure flow. Typically, rotometers are used to measure smaller flows and the reading is usually done locally, although transmission of the readings is possible.

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Rotameters
The rotometer consists of a float that moves vertically through a slightly tapered tube. As fluid enters the bottom of the rotometer, the float is forced upward until the force is balanced by gravitational forces. Most rotometers are made of glass with markings on the outside so that flow readings can be taken visually. The advantage to rotometers is the simplicity of the device and a constant pressure drop. Also, rotometers do not require straight pipe runs for installation so they can be installed just about anywhere.

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Rotameters

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Venturi Tubes
A venturi tube also measures flow rates by constricting fluids and measuring a differential pressure drop. Venturi tubes allow for flow measurement with lower head losses than orifice plates.

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Target Meters
A target flowmeter operates just as the name implies. A small "bullseye" is placed inside the pipe and is connected to a pneumatic transmitter. Typical applications include flow measurement of steam and outdoor liquids. In a target flowmeter, the square of the force exerted on the target is proportional to the volume or mass flow through the pipe.

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Target Meters

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Flow measurement
Differential pressure flow meters Orifice pattern
Venture & nozzle pattern Pitot tube pattern Dall tube pattern
Orifice plate is a circular metal plate with a center hole. In venture tube there is a gradual change in the area. Nozzle is similar to a orifice but with a curved form of approach

Variable area flow meters Displacement and interferential flow meters Electromagnetic flow meters. Ultrasonic Flow meters

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Temperature Measurement
Expansion of Solids
Thermostats

Expansion of Liquids
Temperature Gauges

Expansion of gases
Temperature Gauges

Thermal Electricity Thermocouples

Type K Chromel Alumel etc.

Change of Electric Resistance (RTD)

Pt100 Cu53

Intensity of total radiation

Optical Pyrometer Radiation Pyrometer

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Temperature Measurement
Expansion of Liquids and gases are used for local gauges. Thermocouples and RTDs are used for most of the remote temperature measurements and controls. RTDs are used for low temperature applications. Pyrometers are used for high temperature measurements. (NON Contact type).

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Temperature Measurement
(a) Type of Thermocouple 16 AWG wire of chromel-Alumel (Type K) or 24 AWG wire PtRhodium Pt (Type R); ungrounded type depending on operating temperature range. (b) Type of RTD 3/4 wire - Pt RTD 100 ohm (as per DIN-43760)

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Temperature Measurement
C J C Boxes a) Ref. temp. 60C 1.3 C for Thermocouple b) Effect of ambient temp. 0.1% per 10C variation c) Material 4 mm thick fibre glass reinforced polyster d) Protection class of IP 55

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Temperature Measurement
Outlput signals: Analog : Binary 4-20 mA DC : 2 NO + 2 NC for high alarm 2. Zero & span Adjustment : Available 3. Ambient temp. : 60C 4. Indication : Digital 5. Enclosure Type/Material : Weather & Dust proof (IP 55) Die cast Aluminium/SS

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SG RELATED CONTROL & INSTRUMENTATION SYSTEM/EQUIPMENTS

FLAME MONITORING SYSTEM COAL FEEDERS CONTROL AND INSTRUMENTATION ELECTROMATIC SAFETY VALVES FURNACE TEMPERATURE PROBES ACCOUSTIC PYROMETERS BOILER FLAME ANALYSING SYSTEM (IN LATEST ADVANCE BOILER )

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SG RELATED CONTROL & INSTRUMENTATION SYSTEM/EQUIPMENTS COAL BUNKER LEVEL MONITORING SYSTEM ELECTRONIC REMOTE DRUM LEVEL MONITORING SYSTEM(Hydra step) CONDUCTIVITY TYPE LEVEL SWITCHING SYSTEM ASLD SYSTEM APH FIRE SENSING

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THANK YOU

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