Instrumentation Scheme of

Thermal Power Plant

By:
Shilpa Mishra
ME, IC, Panjab

There are basically three main units of a thermal power plant:

1. Steam Generator or Boiler
2. Steam Turbine
3. Electric Generator

Basic Principle

Electricity From Coal

Objectives of Instrumentation & Control

Efficient

Operation of the plant.

Economic
Safe

Operation of the plant.

operation of the plant.

Pollution

control

This entire task is often taken up by control &

instrumentation or simply instrumentation system which
has following functions:-

a)
b)
c)
d)
e)

Measurement
Control
Operation
Monitoring
Protection

For a Plant Measurement system needs to be:

Very accurate
Reliable
Delays should be as small as possible
Should be switched on manually when a overall control
system fails.

Quantities To Be Measured:

Pressure
Temperature
Flow
Level
Expansion/ Contraction
Analysis of (1) Water (2) Steam (3) Flue Gases
And Others

Measurement Points & Variables

Variables/
Parameters
(1) Pressure

(2)Tempera
ture

Measuring Points

Types Of Sensors/
Instruments

(a) Boiler
(b) Turbine
(c) Turbine Throttle

Bourdon Tube,
Diaphragm,
Bellows

(d) Furnace

Bell Gauges

(a Steam at superheater
inlet & outlet
(b Feed Water at
economiser inlet
(c Water at condenser
inlet
(d Air Preheater
(e Flue Gases

Approx. number
in the plant

375-400

Thermocouple

RTD
Thermocouple

700-750

(3) Flow

(4) Level

(e Bearing of turbine &

generator
(f feed pump, condensate
pump
(a High Pressure Steam
(b Feed water inlet
(c Condensate
(a Boiler Drum
(b condensate tank
(c Water line

Thermocouple
RTD
Orifice, Venturi,
Flow Nozzle,etc.

75-100

Differential
pressure methods

75-100

(5) Expansion

(a Turbine Shaft
(b Turbine casing

Relative
Displacement

(6) Vibration

(a turbine & generator

shafts & bearing shells

Mass spring with

Potentiometric
Capacitive, eddy
current, piezo
electric & optical
types are used

6-8

30-50

(7) Analysis
(i) WATER

(ii) STEAM

(a feed water at econ-omiser inlet

(b Boiler inlet
(c Condenser
(d Condensate pump
discharge
(a Saturated steam
(b Main line steam
(c Super heater inlet

Conductive cell
with meter

8-12

Conductive cell
with meter
Na Analyser

4-6

Zirconia cell

2-4

CO2 analyser

2-4

1-2

(iii) FLUE
GASES

(a

O2 Economiser to air

heater
(b CO2 Air heater inlet
& outlet
(c CO stack

CO analyser

2-4

(d SO2 - Stack

SO2 analyser

1-2

N- Oxide Analysesr

1-2

(e Nitrogen Oxide- stack

(f Dust concn.- stack

Optical method

2-3

Measurement of Pressure
Pressure measuring devices are divided into two groups:
Liquid Columns
Expansion Elements
Liquid columns:
.
Low range pressure measurement
May be of U-Tube type or well-Type.

Unknown
Pressure

These are not favoured in modern power plant but are still used in older
power plants.
Expansion Elements:
Used in modern power plants.
Usually metallic & its movement indicates the pressure.
Either directly coupled with mechanical linkages or indirectly by an
electrical transducer connected to a read out device .
Main Expansion Elements are:

Diaphragms.

Bellows

Bourden tube

Diaphragms

Commonly corrugated diaphragms are used because large deflection can

be produced without nonlinearity compared with flat type.
In order to increase the deflection capabilities two or more corrugated
diaphragms are welded at the circumferences--- Capsule element.

Bellows:

Manufactured from
Brass, Brass alloys,
Stainless steel.
Used for low pressure
measurement.
For high pressure
measurement bellows
are connected with
spring.

Bourden Tube
C shaped and made into an
0
0
arc of about 270
Material from which it made
depends upon the pressure range
of the device
Bourdon tubes are also used
in forms other than C type: Spiral element: large
movement than C tube.
Helical element: produce more
or less circular movement which
is useful for driving a recorder
pen directly.

Measurement of Temperature

Temperature can be measured only by using indirect methods.

The most important parameter in thermal power plant is temperature and

its measurement plays a vital role in safe operation of the plant.
Rise of temperature in a substance is due to the resultant increase in
molecular activity of the substance on application of heat; which increases
the internal energy of the material .
The efficiency of generation also depend on the temperature measurement

T2
1
T1
T2 = Tempreture inside the condenser.
T1= Superheater temperature.

Measurement of Temperature
Expansion Thermometer
In this type of measurement two dissimilar metal tube having different
expansion coefficient are attached end to end.
For same temperature change difference in the lengths are compared and
calibrated for unknown temperature measurement.
Variation in length is slight and has to be magnified for detection.

THERMOELECTRIC THERMOMETRY

This device is based on SEEBACK and PELTIER effect. It comprises of

two junctions at different temperature. Then the emf is induced in the
circuit due to the flow of electrons. This is an important part in the plant.

The

actual value depend upon the material used and on temperature

difference between the junctions.

RESISTANCE THERMOMETRY
Suggested by Siemens in 1871- but not satisfactory used for high
temperature .
Today RTD is given by H.L.Calender in 1891
PROPERTY-The resistance of the conductor changes when its temperature
is changed.
Copper is occasionally used.
Platinum, nickel or nickel alloys are commonly used .
Tungsten is used for high temperature applications

METAL

MIN. TEMP.

MAX.TEMP.

-260 C

110 C

COPPER

0C

180 C

NICKEL

-220 C

300 C

TUNGSTEN

-200 C

1000 C

PLATINUM

MELTING
POINT

1773 C

1083 C

1435 C

0
0
0
0

3370 C

RTDs
ULTRA VIOLET SENSOR
This

device is used in furnace and it measures the intensity of

ultra violet rays there and according to the wave generated
which directly indicates the temperature in the furnace.

Measurement of Flow
A

universal flow meter for all applications in power station is not

available.
Infect there are more ways of measuring flow than measuring
pressure & temperature.
Dual function meters usually measure flow rate with linear output &
minimum error.
Vortex & Ultrasonic meters have become available in recent years
(1986) & their full potential is not still fully developed.
Two principle measurements are made by flow meters viz. quantity
of flow and rate of flow.
'Quantity of flow' is the quantity of fluid passing a given point in a
given time, i.e. gallons or pounds.
Rate of flow' is the speed of a fluid passing a given point at a given
instant and is proportional to quantity passing at a given instant, i.e.
gallons per minute or pounds per hour.

There are two groups of measuring devices:which measure flow by

transferring a measured quantity of fluid from the inlet to the
outlet.
2. INFERENTIAL, which measures the velocity of the flow and the
volume passed is inferred, it being equal to the velocity times the
cross sectional area of the flow. The inferential type is the most
widely
used.
1.

POSITIVE,

OR

VOLUMETRIC,

Analysis
pH, DO,TURBIDITY & HYDRAZINE:
Need

to be checked for acidity (pH), Dissolved oxygen(DO)

Turbidity arising out of
contamination by suspended
particles .
Hydrazine which is added from outside to the feed water
but the excess should be monitored.
Oxygen reacts with thallium to form thallium oxide which in
aqueous solution show good conductivity.

C&I DEPARTMENT OF
THERMAL PLANT

Functions
Control

and instrumentation in any process industry, can be compared

to the nerve system in the human being.
The way the nerve system controls the operation of various limbs of
human beings, C&I in the same way controls and operates various
motors, pumps, etc and thus helps us to achieve our targets.
C&I, as the name indicates, is a branch in engineering which deals
with various measurement, indication, transmission and control in
different technical field.
The main work of C&I department is to observe, control and
manipulate electrical as well as non-electrical quantities like
temperature, pressure, vibrations.

 C&I

department governs the whole functioning and operation of

power plant through the Central Control System (DDC-MIS)
Distributed Digital Control Monitoring and Information System.

Labs in Control and Instrumentation Department of

Thermal Plant
Control and Instrumentation Department has following labs:
1. Manometry Lab
2. Protection and Interlocks Lab
3. Automation Lab
4. Electronics Lab
5. Water Treatment Plant
6. Furnaces Safety Supervisory System Lab

Manometry Lab
1. TRANSMITTERS
It is used for pressure measurements of gases and liquids, its working
principle is that the input pressure is converted into electrostatic
capacitance and from there it is conditioned and amplified. It gives an
output of 4-20 ma DC. It can be mounted on a pipe or a wall. For liquid or
steam measurement transmitters is mounted below main process piping
and for gas measurement transmitter is placed above pipe.
2. MANOMETER
Its a tube which is bent, in U shape. It is filled with a liquid. This device
corresponds to a difference in pressure across the two limbs.
3. BOURDEN PRESSURE GAUGE
Its an oval section tube. Its one end is fixed. It is provided with a pointer
to indicate the pressure on a calibrated scale. It is of 2 types:
(a) Spiral type: for Low pressure measurement.
(b) Helical Type: for High pressure measurement.

Protection and Interlocking Lab

INTERLOCKING
It is basically interconnecting two or more equipments so that if one
equipments fails other one can perform the tasks. This type of
interdependence is also created so that equipments connected together
are started and shut down in the specific sequence to avoid damage.

For protection of equipments tripping are provided for all the

equipments. Tripping can be considered as the series of instructions
connected through OR Gates.
When a fault occurs and any one of the tripping is satisfied a signal is
sent to the relay, which trips the circuit. The main equipments of this
lab
are
relay
and
circuit
breakers

1.

Some of instrument used for protection are:

RELAY
It is a protective device. It can detect wrong condition in electrical
circuits by constantly measuring the electrical quantities flowing under
normal and faulty conditions. Some of the electrical quantities are
voltage, current, phase angle and velocity.
FUSES
It is a short piece of metal inserted in the circuit, which melts when
heavy current flows through it and thus breaks the circuit. Usually
silver is used as a fuse material .
2.

MINIATURE CIRCUIT BREAKER

They are used with combination of the control circuits toa) Enable the staring of plant and distributors.
b) Protect the circuit in case of a fault.
In consists of current carrying contacts, one movable and other fixed.
When a fault occurs the contacts separate and are is stuck between
them.
3.

Automation Lab
This

lab deals in automating the existing equipment and feeding

routes.

Earlier,

the old technology dealt with only (DAS) Data Acquisition

System known as primary systems.

The

modern technology or the secondary systems are coupled with

(MIS) Management Information System.

All

the control instruments are excited by 24V supply (4-20mA)

because voltage can be mathematically handled with ease therefore all
control systems use voltage system for computation.

FURNACE SAFETY AND SUPERVISORY

SYSTEM LAB
This

lab has the responsibility of starting fire in the furnace to enable the
burning of coal..
Unburnt coal is removed using forced draft or induced draft fan.
The temperature inside the boiler is 1100 degree Celsius and its height is
18 to 40 m. It is made up of mild steel.
An ultra violet sensor is employed in furnace to measure the intensity of
ultra violet rays inside the furnace and according to it a signal in the same
order of same mV is generated which directly indicates the temperature
of the furnace.
For firing the furnace a 10 KV spark plug is operated for ten seconds over
a spray of diesel fuel and pre-heater air along each of the feeder-mills.

Electronics Lab
This lab undertakes the calibration and testing of various cards. It
houses various types of analytical instruments like oscilloscopes,
integrated circuits, cards auto analyzers etc.
Various processes undertaken in this lab are:
1. Transmitter converts mV to mA.
2. Auto analyzer purifies the sample before it is sent to electrodes

Operation and Maintenance Lab

Electrical Maintenance Division:

It is responsible for maintenance of:
1. Boiler side motors
2. Turbine side motors
3. Outside motors
4. Switchgear

Protection By switch gear

circuit.

It makes or breaks an electrical

Pollution Control systems:

1.

In order to ensure that NTPC comply with all the stipulated environment
norms, various pollution control systems / devices as discussed below have
been installed to control air and water pollution.

Electrostatic Precipitators:
The ash left behind after combustion of coal is arrested in high efficiency
Electrostatic Precipitators (ESPs) and particulate emission is controlled well
within the stipulated norms. The ash collected in the ESPs is disposed to Ash
Ponds in slurry form.

2.

Flue Gas Stacks:

Tall Flue Gas Stacks have been provided for wide dispersion of the gaseous
emissions (SOX, NOX etc) into the atmosphere.

3.

Neutralisation Pits:
Neutralisation pits have been provided in the Water Treatment Plant (WTP) for
pH correction of the effluents nbefore discharge into Effluent Treatment Plant
(ETP) for further treatment and use.

5. Cooling Towers
Cooling Towers have been provided for cooling the hot Condenser cooling
water in closed cycle Condenser Cooling Water (CCW) Systems. This helps
in reduction in thermal pollution and conservation of fresh water.
6. Ash Water Recycling System:
In the AWRS, the effluent from ash pond is circulated back to the station for
further ash sluicing to the ash pond. This helps in savings of fresh water
requirements for transportation of ash from the plant.

Liquid Waste Water/Effluents Treatment Plants & Management System:

1. The objective of industrial liquid effluent treatment plant (ETP) is

to discharge lesser and cleaner effluent from the power plants to
meet environmental regulations.
2. After primary treatment at the source of their generation, the
effluents are sent to the ETP for further treatment.
3. The scheme involves collection of various effluents and their
appropriate treatment centrally and re-circulation of the treated
effluent
for
various
plant
uses.

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