Instrumentation and Control

INSTRUMENTATION
AND
CONTROL
BY:
Ma. Concepcion Dechavez
James G. Despabiladeras
Dindo D. Dino Jr.
Albert M. Dreu
MAIN
EQUIPMENT
OVERVIEW OF TYPES,
FUNCTIONS,AND DESCRIPTION
OF MAIN EQUIPMENT
Modern large thermal power plants have
evolved as a result of years of research work,
experience, and state-of-the-art technologies;
however, the basic equipment and/or
subsystems are more or less the same, of
course, with a lot of sophistication and
technological development to increase
efficiencies.
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FIVE FUNDAMENTAL
ELEMENTS IN
THERMAL POWER
PLANT
oBoiler
oTurbine
oCondenser
oBoiler feed pump
oGenerator
BOILER
A boiler is a combination of several items that is a means
for combustion to provide energy to be transferred to
water until it becomes heated steam that is then used for
transferring the heat to the turbine. Water is used as the
working fluid to transfer the heat to a process because it
is not expensive. As a result of the tremendous volume
change after the water is converted to steam, it needs
careful handling. The main subsystems or system
auxiliaries are divided into three (3) principal categories:
fuel and air/draft system, feedwater (FW) system, and
steam system; each has various supplementary items or
equipment to make them suitable for use in large and
modern power plants.

Fuel and Air/Draft System
Includes all necessary auxiliary equipment required to make fuel
available to create the necessary heat. The equipment needed for
the fuel system depends on the type of fuel used in the system.
The amount of fuel and air required for steam generation is
automatically controlled per steam demand. Mills/pulverizes are
used for solid fuels, pumping and heating units are required for
liquid fuels, and compressor/boosters are required for gaseous
fuels, of course with a suitable type of burner and air supply
arrangements. Supplementary equipment and/or items are
comprised of the following:

o Mills/pulverizers: For solid fuels, mills and
pulverizers are supplied with the main equipment
so as to achieve higher thermal efficiencies and
for spontaneous ignition through burning of
finely powdered fuel. The type of mills and
pulverizers depends on the type of fuels.
Associated feeders and so forth are also a part of
this subsystem.
o Pumps and heating units: For liquid types of fuels,
supply pumps are needed and heating units are
also required for a viscous type of fuel such as
heavy fuel oil (HFO)/heavy sulfur heavy stock
(LSHS) and others.

o Air flow control elements: These are, for example,
forced draft (FD) air fans, primary air (PA) fans, air
dampers or registers for fuel air,
auxiliary/secondary air, overfire air, etc.
o Draft system or flue gas system: These include
induced draft (ID) air fans and various flue gas
dampers for evacuating the product of
combustion from the furnace.
o Soot blowing system: Periodic cleaning of soot
buildup, which damages boiler metals and causes
inefficient operation, on the radiant furnace
surfaces, boiler tube banks, economizers, and air
heaters is accomplished using a soot blowing
system that blows hot steam on a regular basis.

Feedwater System
o Feedwater system provides necessary piping, heat exchangers to
preheat water, a recirculation system (if so designed), and feed control
valves to control the required amount to meet the steam demand.
o There are two sources of feedwater: the major part is condensate that
is nothing but condensed steam from the condenser and many other
heat exchangers used in the processes; the minor part (3-5%) is the
continuous and/or intermittent makeup water (demineralized, DM
water) that must come from outside of the boiler.

o Chemical dosing: This is done to clean the feedwater to
avoid blowdown causing both heat and water loss
making it slightly alkaline to minimize metal loss due to
a chemical reaction.
o Boiler circulating water system: In some plants, a boiler
circulating water pump (BCWP) is deployed for better
circulation of feedwater in the boiler with its suction
connected to a steam drum and a discharge connected
to a boiler water wall header. Furnace height may be
reduced by having BCWP.
Steam System
 Steam system includes evaporation of
water up to superheating, reheating of
cold steam (for a hot reheat system),
collection and transfer of the steam
through a piping system to the turbine.
Throughout the system, excess steam
pressure is regulated and/or vented
through suitable valves automatically.
Turbine
 The turbine accepts steam from the boiler at
a high temperature and pressure, and
converts the heat energy into mechanical
energy for driving the generator.

The following are the
associated subsystems:
o Turbine oil system (lubricating,
control, and power oil)
o Turning gear/barring gear
o HP/LP bypass system
o Governor and isolation valves
o Gland sealing systems

o Turbine Oil System- This subsystem is one of the
most important items; it supplies the lube oil to all
the bearings, hydraulic control oil, jacking oil, and
actuator power oil through individual oil coolers,
strainers, redundant pumps, etc.
o Turning Gear/Barring Gear- The turning gear (or
barring gear) is basically a gear arrangement
provided to rotate the turbine generator (TG) rotor
shaft at a very low speed before turbine startup and
after unit shutdown at low speed (w1% of rated
speed) by the turning the gear until the temperature
comes down sufficiently.

o HP/LP Bypass System- These subsystems are supplied to
protect the boiler reheater from a burnout when no steam is
passing through the turbine with the boiler generating steam
during start up or running or tripped condition.
o Governor and Isolation Valves- These valves are provided for
both high- and intermediatepressure turbines. Both are
hydraulically operated and are special valves with high
controllability and isolating capability, respectively.
o Gland Sealing Systems- Turbine glands are a part of the turbine
so that steam cannot escape from the higher pressure parts of
it and air cannot enter the lower parts of the turbine. This
subsystem is provided to seal the glands in such a way that
leakage of steam from the high side is controlled at a certain
pressure and extra steam from the control valve outlet is
diverted to the low-pressure (LP) side glands to arrest air
ingress by maintaining a certain pressure.
Condenser
 The function of condenser is to condense the steam coming from
the turbine exhaust. High vacuum is maintained to extract steam
and then cool it vis-à-vis condensation through exchange of heat
with the cooling water from a separate source. The following
comprise the subsystems:
1. Steam ejectors or external vacuum pumps, vacuum breaker
2. Cooling water system or cooling towers
3. Condensate extraction pumps
4. Heat exchangers (drain/gland steam cooler, LP heaters)

o Steam Ejectors or External Vacuum Pumps and Vacuum Breaker
Steam ejectors or vacuum pumps are provided for maintaining a
high vacuum at the condenser. Starting ejectors are meant for the initial
operation of the condenser to achieve the vacuum quickly whereas
running ejectors are
for regular operation. A vacuum breaker is provided for speedy breaking
of the condenser vacuum in an emergency condition in order to arrest
the turbine from overspeeding in case of problems at the generator side.
o Circulating Water Pump System or Cooling Tower
The circulating water is supplied to the condenser by external
means. The open-loop configuration allows transfer of seawater or river
water through circulating water pump (CWP) and back with a higher
temperature after the
exchange of heat. The closed-loop configuration allows for a cooling
tower (CT) where the hot return cooling water is spayed from a height to
exchange heat with the ambient air.
o Condensate Extraction Pumps
The condensate extraction pump (CEP) are
connected to the condenser hot well to take out
the condensate and deliver it to the rest of the
water circuit of the whole cycle.
o Heat Exchangers (Drain/Gland Steam Cooler, LP
Heater)
The CEP discharge line is connected to
several heat exchangers, as just stated, in a series
up to the deaerator and is popularly termed a
condensate.

Boiler Feed Pumps
o The outlet of a deaerator is connected to the boiler feed
pump (BFP) suction and from there to the popular term of
the working fluid-feedwater-to reach the boiler proper. It
impels the FW with requisite pressure that dictates the
working or operating point of steam generation. BFPs are
always supplied in a redundant configuration to avoid
interruption of operation. Normally, one motor-driven BFP
is kept for startup and emergency situations and one or
two turbine-driven BFPs (maybe a motor as well) are kept
for operating up to a full load.
Generator and Exciter
o The following are the two auxiliaries with which the
generator is associated for efficient operation:
1. Hydrogen cooling system
2. Hydrogen and seal oil system
a. Excitation system
b. Stator cooling water system
c. Generator inerting system

Hydrogen Cooling System- Generators of modern
thermal power plants require very efficient cooling.
Hydrogen, with a thermal conductivity that is
almost seven times that of air, is generally used as
the efficient coolant in its pure form.
Hydrogen and Seal Oil System- hydrogen and air

is a very explosive mixture and hence it needs
sealing to prevent hydrogen leakage from the
generator itself. The same is done through oil
sealing applied near the bearings at a higher
pressure than that of hydrogen. It is a full-fledged
subsystem with redundant pumps, coolers, and
strainers.

Excitation System- The generator is a synchronous machine
that needs separate magnetic field excitation. The increase
or decrease in excitation current dictates the generator’s
output voltage.
Stator Cooling Water System- The generator stator
windings are supposed to carry a huge current which
means high copper loss; the resultant heat is dissipated by
flowing of ultrapure water through the specially designed
hollow stator conductor.
Generator Inerting System- It is extremely important that
the introduction and removal of hydrogen be done carefully
to and from the generator casing while commissioning and
decommissioning the system.

STEAM GENERATOR: BOILER
The term boiler can be used for subcritical steam generators; however, at
pressures above this (i.e., super- or ultracritical application), the term
boiler is not applicable because there is no boiling at all and the term
steam generator is the most appropriate. A boiler is a combination of
several items that present a means for combustion to provide heat
energy to be transferred to water until it becomes heated steam. There
lies the function of the furnace in order to burn the fuel and produce
heat. The heat as an intermediate step transferred to water to make
saturated steam at a temperature that depends on the pressure above
the boiling water and, needless to say, that the rate the steam
generation depends on the furnace temperature vis-à-vis its firing rate.

Boiler/Steam Generator Subsystems
o The boiler system is comprised of three (3) main
subsystems: fuel/air/draft, feedwater, and steam.
A brief discussion on each system can be found
in the following subsections.
1. Fuel System
2. Feedwater System
3. Steam System

COMPETITION SLIDE
LOREM IPSUM DOLOR SIT AMET, CONSECTETUER
ADIPISCING ELIT. MAECENAS PORTTITOR CONGUE
MASSA. FUSCE POSUERE, MAGNA SED PULVINAR
Section 1 Title Section 2 Title

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Maecenas porttitor congue massa. Fusce posuere, magna sed porttitor congue massa. Fusce posuere, magna sed pulvinar ultricies,
pulvinar ultricies, purus lectus malesuada libero, sit amet purus lectus malesuada libero, sit amet commodo magna eros quis
commodo magna eros quis urna. urna.
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malesuada fames ac turpis egestas. Proin pharetra nonummy fames ac turpis egestas. Proin pharetra nonummy pede.
pede. Mauris et orci. Mauris et orci.

o Fuel System- includes all necessary auxiliary
systems/ equipment required to make fuel
available for producing the necessary heat.
The equipment required in the fuel system
depends on the type of fuel used. The amount
of fuel and air needed for steam generation
are automatically controlled per steam
demand.
o Steam System- The steam system collects and
transfers the steam produced in the boiler.
Transfer takes place through a piping system
to the turbine. Throughout the system, excess
steam pressure is regulated/vented through
suitable valves automatically.
o Feedwater System

Deaerator
Modern large thermal power plants have
evolved as a result of years of research work,
experience, and state-of-the-art technologies;
however, the basic equipment and/or
subsystems are more or less the same, of
course, with a lot of sophistication and
technological development to increase
efficiencies.
Boiler Circulating Water
System
o In some plants, boiler circulating water pumps
are deployed for better circulation of
feedwater in the boiler with its suction
connected to a steam drum and a discharge
connected to the boiler water wall header. For
super-/ ultracritical SG plants, this pump is
necessary for start up and low-load
operation. In normal load operation, it is kept
“Off” using an interlocked operation.

Mills and Pulverizers
o For solid fuels, mills and pulverizers are supplied with

the main equipment so as to achieve higher thermal
efficiencies through burning of finely powdered fuel.
The type of mills and pulverizers depends on the
type of fuels. Associated feeders and other things are
also a part of this subsystem.

Pumps and Heating Units
o For the liquid-type of fuels, supply pumps are
needed and additional heating units are
required for a viscous type of fuel; namely, for
HFO, LSHS, and so on.

Fans
o Air is the most desired constituent after

fuels for combustion to take place. There
are many types of fans used in modern
thermal power plants depending on type
of fuels.

o Forced Draught Fans- The air is supplied through
the forced draught fan (FD fan) and air ducts.
Before reaching the combustion chamber, air is
preheated using an air heater in order to increase
the overall efficiency of the boiler.
o Induced Draught Fans- An induced draught fan
(ID fan) is provided to maintain a negative
pressure in the furnace by sucking the products
of combustion from it with a slight positive
pressure at the discharge end vis-à-vis the
bottom of the chimney/stack.
o Primary Air Fans- The function of the primary air
fan (PA fan) is to transport the fine grains of solid
fuels in the required quantity and at the correct
temperature with the automatically controlled
dampers;
o Seal Air Fans- A seal air fan (SA Fan) is used to
provide air at slightly higher than PA pressure to
seal all the dust-laden equipment-namely, the
mills/pulverizers with associated dampers,
relevant parts of the feeders, and so on.
o Scanner Air Fans- The purpose of providing these
a scanner air fan (ScA fan) is to cool the flame
scanners heads meant for detecting the presence
and quality of the fuel flame.

Types of Fans available in
the Industry
o Axial fans or axial-flow fans
o Radial fans
o Cross-flow fans
o Mixed-flow fans

Axial Fans
The axial fans have blades that force air to flow
in line with the shaft on which the blades rotate.
The direction of air flow is along the axis of the
fan and thus they are so named.

Radial/Centrifugal Fans
The radial/centrifugal fans have an impeller as
the moving component; it is nothing but a set of
blades or ribs suitably placed around a central
shaft. They are also sometimes called a squirrel
cage or a scroll fan.

Air Flue Gas Path
Equipment
o The air and flue gas path is comprised of a
lot of equipment such as both a primary
and a final superheater (SH), a reheater
(RH), an air heater (AH), an economizers, a
selective catalytic reduction (SCR) plant, an
electrostatic precipitator (ESP); these are a
part of the dust-collector system for flue
gas, flue gas desulfurization (FGD) plant, etc.

Air Heaters
o Air heater is the last element in the flue gas path
where the residual heat contained in the gas is used
for air drying before taking part in the combustion
chamber to improve overall efficiency; this is done by
better and spontaneous burning of fuel and a lower
stack outlet temperature per local pollution-control
board’s stipulations.
Classification of Air Heaters
o Recuperative Air Heaters- These are mostly tubular-
type (maybe plate-type too) where the heat input
may be from the boiler flue gas or a separate
source.
o Regenerative Air Heaters- These are normally of
two types-rotary and stationary-with the heat
source being the boiler flue gas or a separate other
furnace, etc. The types are classified according to
whether the heating elements are rotary or
stationary.

Dust Collector Units
o This is a major part of the air and flue gas

path that does not take part in the thermal
cycle of the plant but plays a vital role as far
as pollution control is concerned. It separates
the fly ash part of the flue gas before the
chimney on way to the exhaust path.

Firing Systems
Type of Firing Systems
Fixed-Type Firing- This type is generally used in the
Babcock design and also has a variety of options.
1. Front or wall firing
2. Opposed firing
3. Downshot firing
Corner or Tangential Firing- Here the coal feeds into
the furnace at its four (4) corners. This produces a
cyclonic effect in the furnace ensuring proper mixing of
air and fuel that is essential for proper combustion.
Selection of Equipment
o Fuel flow control is an important and vital part of the combustion
control system, The selection of mills/pulverizers also plays an
important role in a modern thermal power plant. While selecting
the type of equipment, the following criteria should be taken into
consideration:
1. Cost of equipment
2. Type of fuel that uses different qualities of coallignite, etc.
3. Efficiency
4. Capacity and space requirements
5. Advantages and disadvantages such as power
consumption, noise, and vibration, sealing arrangements,
capabilities of separating and taking out harmful materials (e.g.,
magnetic components), and so on.

Function and Control
 A milling/pulverizing plant with associated
auxiliaries is installed to perform
multifarious activities. Some of the
auxiliaries are the mill/pulverizer feeders,
PA fans, SA fans, ScA fans, fuel burners,
and igniters.
o Mills/Pulverizers- The mills/pulverizers duty is to convert raw
feed into fine dust particles.
o Feeders- The feeders that have variable speeds are provided
to feed the raw fuel.
o Primary Air- Transportation of PF up to the burners; the
quantity varies because the boiler load varies. Drying of raw
feed for conversion into fine particles in an effective manner;
hot PA is used for the required function. PF and PA mixture as
produced at the outlet of a classifier that provides the initial
oxygen for combustion.
o Burners- The burners provide the arrangement for further
mixing of the PF and the primary air mixture with the
secondary air in order to have the desired quantity as needed
for a perfect or a near-perfect condition of combustion and
delivery of the whole mixture to the furnace.
o Igniters- Igniters are required to light the first flame
in the furnace with the help of oil and gas as
available.
o Seal Air Fans- Seal air (SA) fans are used for the
purpose of sealing the fuel dust and primary air
mixture so that it does not come out of the
milling/pulverizing plant.
o Scanner Air Fans- Scanner air (ScA) fans are not
actually part of process of this type of plant.
o Ignition Supports- Ignition supports are not only
required to light the initial flame in the furnace but
also to provide the oil support needed to help ignite
oil or gas as and when necessary.
Summary of Coal Mill
Controls
 To control the quality of coal being sent to the burners located
on the furnace walls. The word quality here means the
temperature and fineness of the PF. The set temperature
values are dependent on the percentage of volatile matter
that exists in the main fuel. The controlled temperature is
important for many reasons such as stability of ignition, better
grindability of solid fuels, better floating ability of suspended
PF particles, etc. However, a temperature more than -65 to 70
is not recommended for various reasons.
 The mills/pulverizers responses according to the boiler load
control include both the PA flow control and the feeder speed
control, having the main drive of mills/pulverizers run at a
fixed speed.
TURBINE TYPES

GENERATOR
The generator in a thermal power plant is a very significant

subsystem driven by the steam turbine and is necessarily
synchronous or, in other words, an alternator as it is
popularly called. It is one of the most important types of
electrical equipment and is categorized as the rotating
machine that is used for converting mechanical energy into
electrical energy or electricity when operated as a generator
and vice versa when operated as a motor.

Basic Generator Details
o Rotor (Field)- This part of the machine is rotates freely
(driven by a prime mover) and produces the magnetic field
either by a permanent magnet or by a direct current
flowing through a coil fixed onto it; this is called field
winding
o Stator (Armature)- A stator, as is evident from the very
name, is the static or fixed part of the machine that is
mounted around the rotor. The stator is also made of a
ferromagnetic material wrapped in a set of coils within the
slots distributed throughout the circumference. Stator
windings are connected to a threephase AC voltage system.
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INSTRUMENTATION

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Hydrogen and Seal Oil System- hydrogen and air

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Section 1 Title Section 2 Title

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o For solid fuels, mills and pulverizers are supplied with

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o Air is the most desired constituent after

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o This is a major part of the air and flue gas

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The generator in a thermal power plant is a very significant

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