power plant instrumentation and control handbook a guide to thermal power plants pdf

www.EngineeringBooksPDF.com Power Plant Instrumentation and Control Handbook A Guide to Thermal Power Plants Swapan Basu Systems & Controls Kolkata, India Ajay Kumar Debnath Systems & Controls Kolkata, India AMSTERDAM l BOSTON l HEIDELBERG l LONDON l NEW YORK SAN DIEGO l SAN FRANCISCO l SINGAPORE l SYDNEY Academic Press is an Imprint of Elsevier www.EngineeringBooksPDF.com l l OXFORD TOKYO l PARIS Academic Press is an imprint of Elsevier 32 Jamestown Road, London NW1 7BY, UK 525 B Street, Suite 1800, San Diego, CA 92101-4495, USA 225 Wyman Street, Waltham, MA 02451, USA The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK Copyright © 2015 Elsevier Ltd All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein) Notices Knowledge and best practice in this field are constantly changing As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data A cataloge record for this book is available from the Library of Congress ISBN: 978-0-12-800940-6 For information on all Academic Press publications visit our web site at http://store.elsevier.com/ www.EngineeringBooksPDF.com Dedication This book is dedicated to the promising and growing engineers working in/around or studying thermal power plant instrumentation and control systems who can render services to mankind by providing sparse, pollution-free energy for human progression www.EngineeringBooksPDF.com Foreword With the advent of technological advancement in all the fields, knowledge and know-how are now available, in bits and pieces, with just a click of the mouse, on the computer However, it can be time-consuming to find the desired information in a consolidated manner, or it may be difficult to find the exact subject information required Modern power plant engineering is a vast subject with different fields of application for all branches of technology In this book, the authors have included their experiences from a different angle focusing on instrumentation and control systems There are number of valuable books available on power plants covering different subjects, but there is a dearth of a single volumes incorporating the majority of the equipment in relation to the process The chapters of this book cover various subjects on the process and associated instrumentation with alternative arrangements (if any) The text is well demonstrated with facts and figures that make this book easy to understand In general, this book accentuates both subcritical and supercritical plants, and there are separate appendices covering supercritical plants as well the emerging demand for the higher efficiency and lower pollution aspects of subcritical plants The authors worked for decades with leading consulting firms in India and abroad and keep in touch with modern technology I truly feel that their experiences will greatly benefit both practicing engineers and students of power plant engineering I wish every success to the authors of this book S K Sen ix www.EngineeringBooksPDF.com Preface Technical books that have theoretical and practical approaches are available worldwide about several subsystems of thermal power plant instrumentation and controls This book endeavors to act as a way to balance two extreme lines of thinking, giving a comprehensive approach to plants’ measurements and controls What is here is primarily meant for professionals working with thermal power plant instrumentation and control systems Budding (fresh) engineers who start their careers in thermal power plant instrumentation and control engineering, and those practicing professionals of other disciplines, will greatly benefit from the comprehensiveness and practical approaches in this book It will be a very good reference for engineering students who are pursuing higher-level studies in various branches of engineering Highly developed and advanced mathematical deductions are passed up as much as possible; instead physical explanations have been given so that readers get a proper feel of the system so that the book could be kept within a very limited dimension The text part incorporates an abridged description on the subject being dealt with along with relevant figures and tables to visually show a clear picture of it In all cases, detailed specifications of the instruments, subsystems, and systems have been included in addition to practical control loops and logistics to enable the book to be “all-time companion” for practicing engineers Discussions about both subcritical and super-ultra supercritical power plants, as well as IGCCs, have been included in order to take a look at future trends in power plants Content keeps pace with development work in the field of electronics and control and communication engineering, with special attention to inclusion of the means and methods of system integration with fieldbus systems, OPC servers, and so on Application of artificial intelligence and fuzzy logic in power plant instrumentation have been covered in detail In an attempt to incoporate this extensive subject area into the form of a book, the authors have carried out a great deal of research over years so as to include the knowledge gained during their decades-long global experience in thermal power plant instrumentation engineering We wish to convey our sincere thanks to the companies who entrusted us to work in this specialized area of engineering The authors feel rewarded only when their research work is able to benefit future engineers who can serve the global population by providing scarce pollution-free energy for human development Swapan Basu Ajay Kumar Debnath xi www.EngineeringBooksPDF.com Acknowledgments At the outset, the authors wish to extend their gratitude to their professors of their engineering institutiondBengal Engineering College, Sibpore (now IIEST)dand their power plant and instrumentation gurus: the late Samir Kumar Shome (former DCL) and the late Makhan Lal Chakraborty (former DCL) for their great teaching in this area The authors are extremely indebted to Dr Shankar Sen (former professor at B E.College) for his encouragement during development the book While working on the book we were supported with information and suggestions of former colleagues D K Sarkar, J K Sarkar, D J Gupta, S Chakraborty, A Thakur, and Arijit Ghosh In addition, we convey sincere thanks to friends: A Bhattachariya (Kolkata), A Sarkar (Norway), A Tendulkar (Mumbai), N Kirloskar (Pune), and S Mohanty (Gurgaon) for their support and sharing of technical information We would like to thank the authors of the works mentioned throughout the book and the Internet documents that stimulated and helped us write this book The authors also like to thank the entire team of Systems & Controls Kolkata for infrastructural support The authors would like to thank the entire team at Elsevier, the publisher, who took all the pains to bring it through to publication Last but not the least, we would like to thank our children Idai(Raj), Piku(Deb), Arijita, and Arijit for their continuous inspiration and support A special thanks to our wives, Bani Basu and Syama Debnath, for managing the family show with care and for encouraging us so that we could dedicate time to the book The authors sincerely acknowledge that without all these supports it would have been impossible to publish this book xiii www.EngineeringBooksPDF.com Chapter I Introduction INTRODUCTION The authors of this book have been associated with the Instrumentation and Control System of Modern Power Plants for more than two decades while working with a leading consulting firm They are still in touch with modern technology by associating with the engineering and consultancy activities of ongoing projects We wanted to document their extended experience in the form of a reference book so that professional engineers, working engineers in power plants, and students could benefit from the knowledge gathered during their tenure There are so many valuable and good books available on a variety of subjects related to power plants about boilers, turbines, and generators and their subsystems, but it is very difficult to get a single book or single volume of a book to cater to the equipment, accessories, or items along with the instrumentation and control systems associated with them In this book, there is a very brief description of the system and equipment along with diagrams for a cursory idea about the entire plant Up-to-date piping and instrumentation diagrams (P&IDs) are included to better understand the tapping locations of measuring and control parameters of the plant Various types of instruments, along with sensors, transmitters, gauges, switches, signal conditioner/converter, etc., have been discussed in depth in dedicated chapters, whereas special types of instruments are covered in separate chapters Instrument data sheets or specification sheets are included so that beginners may receive adequate support for preparing the documents required for their daily work The control system chapters VIII, IX and X incorporate the latest control philosophy that has been adopted in several power stations This book mainly emphasizes subcritical boilers, but a separate appendix is provided on supercritical boilers because of their economic and low-pollution aspects, which create a bigger demand and need than conventional subcritical boilers It is hoped that this book may help students and/or those who perform power plant-oriented jobs FUNDAMENTAL KNOWLEDGE ABOUT BASIC PROCESS Power plant concepts are based on the Laws of Thermodynamics, which depict the relationship among heat, work, and various properties of the systems All types of energy transformations related to various systems (e.g., mechanical, electrical, chemical etc.) may fall under the study of thermodynamics and are basically founded on empirical formulae and system and/or process behavior A thermodynamic system is a region in space on control volume or mass under study toward energy transformation within a system and transfer of energy across the boundaries of the system 2.0 Ideas within and Outside the System Surrounding: Space and matter outside the thermodynamic system Universe: Thermodynamic system and surroundings put together Thermodynamic systems: a Closed: Only energy may cross the boundaries with the mass remaining within the boundary b Open: Transfer of mass takes place across the boundary c Isolated: The system is isolated from its surrounding and no transfer of mass or energy takes place across the boundary State: It is the condition detailed in such a way that one state may be differentiated from all other states Property: Any observable characteristics measurable in terms of numbers and units of measurement, including physical qualities such as pressure, temperature, flow, level, location, speed, etc The property of any system depends only on the state of the system and not on the process by which the state has been achieved a Intensive: Does not depend on the mass of the system (e.g., pressure, temperature, specific volume, and density) b Extensive: Depends on the mass of the system (i.e., volume) Power Plant Instrumentation and Control Handbook Copyright © 2015 Elsevier Ltd All rights reserved www.EngineeringBooksPDF.com POWER PLANT INSTRUMENTATION AND CONTROL HANDBOOK Specific weight: The weight density (i.e., weight per unit volume) Specific volume: Volume per unit mass Pressure: Force exerted by a system per unit area of the system Path: Thermodynamic system passes through a series of states 10 Process: Where various changes of state take place 11 Cyclic process: The process after various changes of state complete their journey at the same initial point of state 2.0.1 Zeroeth Law of Thermodynamics “If two systems are both in thermal equilibrium with a third system, they are in thermal equilibrium with each other.” Thermal equilibrium displays no change in the thermodynamic coordinates of two isolated systems brought into contact; thus, they have a common and equal thermodynamic property called temperature With the help of this law, the measurement of temperature was conceived A thermometer uses a material’s basic property, which changes with temperature 2.0.1.1 Energy “The definition in its simplest form is capacity for producing an effect.” There are a variety of classifications for energy Stored energy may be described as the energy contained within the system’s boundaries There are various forms, such as: a Potential b Kinetic c Internal Energy in transition may be described as energy that crosses the system’s boundaries There are various types, such as: a Heat energy (thermal energy) b Electrical energy c Work 2.0.1.2 Work “Work is transferred from the system during a given operation if the sole effect external to the system can be reduced to the rise of a weight.” This form of energy is transferred from one system to another system originally at different temperatures It may take place by contact and without mass flow across the boundaries of the two systems This energy flows from a higher temperature to a lower temperature and is energy in transition only and not the property The unit in the metric system is kcal and is denoted by Q 2.0.1.3 Specific Heat Specific heat is defined as the amount of heat required to raise the temperature of a substance of unit mass by one degree There are two types of specific heat: At constant pressure and denoted as Cp At constant volume and denoted as Cv Heat energy is a path function and the amount of heat transfer can be given by the following: ¼ Integration from T1 to T2 of m Cn dT; ZT2 i:e:; ðm Cn dTÞ; Q2 T1 where and are two points in the path through which change takes place in the system, m is the mass, Cn is the specific heat and maybe Cp, dT is the differential temperature, and T1 and T2 are the two temperatures at point and of the path 2.0.1.4 Perfect Gas A particular gas that obeys all laws strictly under all conditions is called a perfect gas In reality no such gas exists; however, but by applying a fair approximation some gases are considered as perfect (air and nitrogen) and obey the gas laws within the range of pressure and temperature of a normal thermodynamic application 2.0.2 Boyle’s Law and the Charles Law 2.0.2.1 Boyle’s LawdLaw I The volume of a given mass of a perfect gas varies inversely as the absolute pressure when temperature is constant 2.0.2.2 Charles LawdLaw II The volume of a given mass of a perfect gas varies directly as the absolute temperature, if the pressure is constant 2.0.3 General and Combined Equation From a practical point of view, neither Boyle’s Law nor the Charles Law is applicable to any thermodynamic system because volume, pressure, and temperature, etc., all vary simultaneously as an effect of others Therefore, it is necessary to obtain a general and combined equation for a given mass undergoing interacting changes in volume, pressure, and temperature: n NT=p; when T is constant ðBoyle’s LawÞ n NT; when p is constant ðCharles LawÞ: Therefore, v N T/p when both pressure and temperature vary www.EngineeringBooksPDF.com Introduction Chapter | I or n ¼ k:T=p; where k is a constant that depends on temperature scale and properties of gas, or pn ¼ mRT; where m is the mass of gas and R is a constant This depends on temperature scale and properties of gas: p ¼ absolute pressure of gas in kgf/m2, v ¼ volume of gas in m3, m ¼ mass of gas in kg, and T ¼ absolute temperature of gas in degrees K Therefore R ¼ pV/mT ¼ kgf/m2  m3/kg  K ¼ kgf.m/kg/degree K R R R R ¼ ¼ ¼ ¼ 30.26 29.27 26.50 420.6 kgf.m/kg/degree K for nitrogen kgf.m/kg/per degree K for air kgf.m/kg/degree K for oxygen kgf.m/kg/degree K for hydrogen 2.0.3.1 Universal Gas Constant After performing experiments, it was revealed that for any ideal gas, the product of its characteristic gas constant and molecular weight is a constant number and is equal to 848 Therefore, by virtue of this revelation, 848 kgf.m/kg/degree K is called the Universal Gas Constant For example: MR ¼ molecular weight in kg  R MR MR MR MR ¼ ¼ ¼ ¼ 29.00  29.27 z 848 for air 2.016  420.6 z 848.5 for hydrogen 28.016  30.26 z 847.6 for nitrogen 32  26.5 z 848 for oxygen 2.0.4 Avogadro’s Law/HypothesisdLaw III This states that the molecular weights of all the perfect gases occupy the same volume under the same conditions of pressure and temperature 2.0.5 First Law of Thermodynamics When a system undergoes a cyclic change, the algebraic sum of work transfers is proportional to the algebraic sum of heat transfers or work or heat is mutually convertible one into the other Joules’ experiments on this subject led to an interesting and important observation showing the net amount of heat in kcal to be removed from the system was directly proportional to the net amount of work done in kcal on the system It is the convention that whenever work is done by the system, the amount of work transfer is considered as ỵve, and when work is done on the system, the amount of work transfer is considered as Àve 2.0.5.1 Internal Energy There exists a property of a system called energy E, such that change in its value is the algebraic sum of the heat supplied and the work done during any change in state dE ¼ vQ À vW This is also described as corollary of the First Law of Thermodynamics Energy E may include many types of energies, such as kinetic, potential, electric, magnetic, surface tension, etc., but these values, negligible considering the thermodynamic system, are ignored and only the energy due to change in temperature is considered This type of energy is called internal energy and is denoted by U 2.0.5.2 Adiabatic Work Whenever the change of state takes place without any heat transfer, it is called an adiabatic process The equation can be written as follows: DU ¼ Wad ; Wad is the adiabatic work done It can be established that change in internal energy DU is independent of process path Thus, it is evident that adiabatic work Wad would remain the same for all adiabatic paths between the same pair of end states 2.0.6 Law of the Conservation of Energy “In an isolated system, the energy of the system remains constant.” This is known as the second corollary of the First Law of Thermodynamics 2.0.6.1 Constant Volume Process The volume of the system is constant Work done being zero, due to heat addition to the system, there would be an increase in internal energy or vice versa 2.0.6.2 Constant Pressure or Isobaric Process In this process, the system is maintained at constant pressure and any transfer of heat would result in work done by the system or on the system 2.0.6.3 Enthalpy The sum of internal energy and pressure volume product (i.e., U ỵ pV ) is known as enthalpy and is denoted by H As both U, p, and V are known as system properties, enthalpy is also a system property 2.0.6.4 Constant Temperature of the Isothermal Process The system is maintained at a constant temperature by any means and an increase in volume would result in a decrease in pressure and vice versa www.EngineeringBooksPDF.com Index Note: Page numbers followed by “f” and “t” indicate figures and tables respectively A Absolute vibration, 103 casing vibration, 324 shaft vibration measurement, 307, 308f Accelerometer, 310, 317f, 318t Accessories, 239, 427e439 AFR, 427e429 air lock relay, 429 E(I)/P converter, 430 hand wheel, 430e431 limit switches, 431 position indicator, 435 position transmitter, 435 positioner, 431e435 solenoid valve, 435e436 torque switches, 436 volume booster, 436e439 Accumulator, 728 Acid dew point corrosion, 650 Acid gas removal (AGR), 393e394 Activated carbon filter (ACF), 122, 125e126, 394e395 Active protective devices, 705 Actuator sensor interface, 492 Actuators, 387e405, 419e427 electric actuators, 425e427 electro hydraulic actuator, 425 intelligent actuator, 427 ISA guidelines, 421 piston cylinders, 421e422 pneumatic actuator selection, 421 safe failure, 422e424 sizing, 419e421 Address Resolution Protocol (ARP), 448 Admission controller, 704 Aerofoil, 259 Air and flue gas system, 193e201, 195fe196f See also Cogeneration (Co Gen); Condensate system; Extraction steam system; Feed water system (FW system); Main steam system (MS system) controls, 205e206 equipment, 201e203 mill air flow, 199f miscellaneous points, 206 objective and function, 193e194 parameter, 203e205 redundancy in measurement, 206 Air Air Air Air Air and gas services, 788 bubbler type level transmitters, 286 detraining tank, 731 filter regulator (AFR), 799 flow control, 26, 34, 39, 589, 590f See also Fuel flow control control loop description, 589e595 excess air, 589 FCEs for combustion air, 594t Air flue gas path equipment, 47e51 air heaters, 48e49 dust collector units, 49e51 FO systems, 57e58 mills/pulverizers, 54e57 stoichiometric air‒fuel ratio and excess air, 51 tangential tilt burners, 58e59 Air heater (AH), 47e49, 596 soot blowers for, 692 washing medium for, 692e693 Air line, 799 Air lock relay, 429 Air preheater (APH), 593, 759 Air pressure control, 643 Air purging, 801 Air separation unit (ASU), 392, 889e894 Air service, 802, 808 Air-cooled dump condenser, 31 TG set generators, 743 Air-side seal oil, 731 Airfoil control damper, 414e415 Alarm, 605e606 annunciator, 512e513 alarm designation methods, 513 alarm display types, 514e515 alarm sequence, 513 optional items, 513e514 specification, 515 display, 558e560, 558f All volatile treatment (AVT), 98, 349e350 American Society of Mechanical Engineers (ASME), 265 Amortisseur windings, 21e22 Amperometric DO analysis, 363 Amphoteric resin, 127 Anions, 122 exchanger resins, 128e129 regeneration, 130e131 Annunciation, 511e512 See also Intelligent control system; Sequence of event (SOE) alarm annunciator, 512e513 data sheet, 514t types, 513 Apron feeders, 136e137 Area, standard units for, 838t ASCII Encode, 461t Ash handling, 138e146 ash disposal system, 145e146 ash water system, 144e145 fly ash-handling system, 143e144 influencing factors, 140 mode of ash disposal, 140e143 Ash-handling plant (AHP), 39, 138, 510 Atomization, 224 Atomizing steam, 225f, 643 Attemperation flow control, 300 Auto manual station (A/MS), 752 Auto/manual (A/M), 726, 781 Automatic bus transfer system (ABTS), 901 Automatic generation control (AGC), 758 Automatic turbine run up system (ATRS), 476, 501, 501f, 695, 708, 709f, 767 automatic turbine testing system, 503 OLCS for, 501e503 start-up stress, 710 subgroups, 708e709, 711e713 TG system, 709 thermal stress, 710 turbine protection system, 503 warm-up process, 709e710 Automatic turbine testing (ATT), 81, 480, 695, 714f on KWU steam turbine control philosophy, 718e719 oil circuit, 715f scope, 714e718 testing process by, 696, 713e714 Automatic voltage regulator (AVR), 22e23, 699, 733e735 controller output, 735 Auxiliary cooling water system (ACW system), 117, 120, 482e483 Auxiliary load, 46 Auxiliary oil pump (AOP), 79, 213, 711 Auxiliary steam control valve (ASV), 776e777 907 www.EngineeringBooksPDF.com 908 Index Auxiliary steam system (AS system), 9, 165e169, 644e648, 797e799 See also Cogeneration (Co Gen); Condensate system; Extraction steam system; Feed water system (FW system); Main steam system (MS system) boiler and turbine, 166f controls, 170 equipment, 169e170 header, 167fe169f objective and function, 165e166 parameters and monitoring, 170 redundancy in measurement, 170 Avogadro’s Law, Axial fans, 46e47 control devices, 46e47 Axial ring shaft seal, 729 Axial shift, 304e305 B Back-pressure turbine, 28e29 Balance chamber, 111 Balance of plant (BOP), 767 BFP recirculation control, 767e770 CEP recirculation control, 770e774 control system, 767 deaerator pressure control, 775e778 ejector control, 783 GSC minimum flow control, 774e775 HPH level control, 781e783 LPH level control, 778e781 TAS control, 783 Ball valves, 406e408 Ball-and-tube mill, 601e604, 609e618, 610f, 614f Ball-tube mills, 55 Bar graph display, 562 Barring gear, 80 Base control mode, 750 Bearing block vibration, 304 Bearing vibration measurement, 304 Bellows sensor, 238e239 Belt sway switch, 138 Benson point, 880 Bicolor level gauges, 290e291 Bimetallic elements, 252 Bimetallic gauges, 255 Bipolar junction transistor (BJT), 735 Bit collision, 452f Black starting, 19e20 See also Gas turbine (GT) automatic voltage regulator, 22e23 electric drive, 23 hydraulic drive, 23 LCI, 21e22 self-contained black start, 20 VFD, 21e22 Blade pitch control, 416 Bleed steam See Extraction steam system Block vibration (BV), 304 Blow down system, 43, 298, 380e382 Blowdown valve, 11, 74 BMS/FSSS system, 495 fault classifications, 500 features, 496e497 IEC 61508 life cycle model, 498f NFPA 85 and IEC 61511, 500, 500t risk, 499e500 SIL rating discussions, 500e501 standards, 497e499 Boiler auxiliary steam (BAS), 151, 644, 783 Boiler circulating water (BCW), 44, 72 Boiler circulating water pump (BCWP), 40 Boiler circulation pump (BCP), 877 Boiler control system, 642e664, 767 air flow control, 589e595 auto control loop system legend, 586f boiler controls, 642e664 boiler OLCS, 673e693 boiler-drum control system, 622e628 coal mill controlemill air flow, 604e618 control requirements, 585e586 fuel flow control, 595e604 furnace draft control, 618e622 FW controls, 622e628 overfire air dampers, 642e664 reheat temperature control, 634e642 steam pressure control, 586e589 superheater temperature control, 628e634 Boiler drum boiler accessories, 67e68 boiler water circulation, 72e73 drum internals, 68e69 economizers, 71 reheaters, 69e71 superheaters, 69e71 Boiler feed pump (BFP), 9, 41, 67, 109e112, 622, 759, 767, 877 See also Condensate extraction pumps (CEP) associated measurements, 112 with equidirectional impellers, 111 opposite directional impellers, 111e112 recirculation control, 767e770, 768f selection criteria, 110e111 Boiler master demand signal, 753e754, 885 Boiler maximum continuous rating (BMCR), 778 Boiler tube failure and metal temperature, 60e61 See also Air flue gas path equipment major reasons for, 61e64 measurement, 64e66 Boiler-drum control system, 622 control loop description, 623e628 drum-level computation, 623 objective, 622 shrinking and swelling, 623 Boiler(s), 8e9, 39 circulation system, 226e228 clean up, 298 demand, 763e764 energy transfer, 765 feedwater system, 40 firing, follow mode, 750, 758e759 following turbine, 759 www.EngineeringBooksPDF.com forced circulation, 8e9 fuel and air/draft system, 39 furnace position, heat source, load controller, 598e599 load demand, 756 optimization package, 580e581 parallel operation, 759 steam system, 40 trip cause and effect, 445e447 tube contents, turbine balance, 763e764 water circulation, 72, 307f forced water circulation, 72e73 natural water circulation, 72 once-through boiler, 73 Bottom ash hopper (BAH), 141 Bottom ash systems (BA systems), 138, 140e143 Bourdon tube-operated sensor, 237 Bowl mill, 601 Bowl-type mill See Vertical roller mill Boyle’s law, Brayton cycle, 13e14 Brushless de-excitation system, 735 Brushless excitation system, 734e735, 734f AVR controller output, 735 thyristors gate control, 735 thyristors/semiconductor in, 735 Burner management system (BMS), 200e201, 476, 619, 676 BMS/FSSS functional configuration, 678e685 manual operation/automation, 685 flame-monitoring system, 685e686 hardware/software functions, 677 process functions, 677 Burner tilt mechanism, 636 Burner-tilting arrangement function, 641 Burners, 57 Bus transfer system (BTS), 444, 455 Butterfly valves, 406e408 Bypass damper control, 617 Bypass gas dampers, 636 Bypass valve (BPV), 29 C Cable(s), 824e828, 826t glands, 832 installation points, 829 termination points, 829 Cantilever pumps See Vertical centrifugal pump Capacitance type level transmitters, 286 Capacitive coupling, 817 Capacitive type sensors, 236 Carbon, 147 Carbon steel (CS), 63, 787 Carnot theorem, Carrier ring type orifice plates, 264, 265f Carrier Sense Multiple Access/Collision Detect (CSMA/CD), 453 Cascade drain, 781 Casing expansion (CS), 102, 305e307 Index Casing vibration, 321 Cation exchanger resins, 127e128 Cation-anion-cation stacked bed exchanger, 98 Cations, 122 Caustic corrosion, 61 Cavitation, 391e392 Centrifugal pump, 728 Ceramics, 147 Charge amplifier, 317f Charles law, Check valves See Nonreturn valve Chemical dosing system, 40, 43 Chemiluminescence type analysis system, 332e333 Chloride analyzer, 371e373, 373f, 373te374t Choked flow, 392 Circuit/noncoincidence (COC), 444 Circulating fluidized bed combustion boiler (CFBC boiler), 387 Circulating water pump (CWP), 41, 94, 759 Circulating water system (CW system), 39, 117, 482e483, 511, 877 auxiliary and associated subsystems, 122 closed-cycle type water system, 119e120 instrumentation requirements, 121e122 makeup and treatment system, 120e121 once-through circulating water system, 118e119 Clarified cooling water system (CCW system), 117, 120 Class A tripping, 898 Class B tripping, 898 Class C tripping, 898 Class C tripping, 898 Class U trip, 444 Clausius statement, Clean grounding, 820e821 Client server network, 540f Closed cooling water systems, 120 Closed coupled overfire air dampers (CCOFA dampers), 656 Closed loop control system (CLCS), 186, 501, 521e536, 695 display, 560 functions, 526e527 input and output types, 531 Closed transition method, 459 Closed type See Local instrument enclosure (LIE) Closed-cycle type water system, 119e120 mechanical induced-draft type cooling tower, 119e120 NDCT, 120 Closed-loop control (CLC), 673 Closed-type regenerative feedwater heaters, 116e117 Closed/pressurized vessel, 809e810 Closely coupled over fire Air (CCOFA), 196e197 CO analyzer, 344e346, 346te347t CO2 analyzer, 347 Coal crushing, 134e136 Coal hammer crusher, 135 Coal jaw crusher, 135 Coal mill controlemill air flow, 604 alarm, 605e606 interlock, 605e606 mill control, 609e618 mill temperature control, 606e609 Coal storage and feed preparation, 392 Coal-handling plant (CHP), 39, 132 accessories, 136e137 coal crushing, 134e136 coal stacker and reclaimer, 136 conveyor safety switches, 138 dust control and ventilation systems, 136 influencing factors, 132e133 instrumentation and control, 137e138 unloading, 133e134 Coal-handling plant control systems, 509e510 Coaxial cable, 565 Cocked case, 305e307 Cogeneration (Co Gen), 206, 209e211, 212f See also Auxiliary steam system (AS system); Heater drain and vent system combined cycle plants, 207e208 GT control system, 211 GT thermodynamics, 208f, 210f objective and function, 208 parameter, 211e212 plant islanding operation, 458 redundancy in GTs, 212 single-shaft CC configuration, 212e213 Cold air damper (CAD), 604 Cold PA system, 596, 613 Cold reheat (CRH), 67e68, 671, 709, 799 steam, 9, 151 Cold rolled cold annealed (CRCA), 815 Cold start, 669 Cold start-up, 710 Colorimetric type hydrazine analyzer, 366 Combined cycle plant, 14 Combined cycle power plant (CCPP), 739 Combustible analyzer, 335 Combustion air, 53 equations, 837t Combustion air/secondary air (CA/SA), 593 Combustion engineering (CE), 58 Combustion turbine See Internal combustion engine Comité for Eurpéenne de Normalisation (CEN), 326e327 Common file format (CFF), 472 Common impedance See Conductive coupling Common mode rejection (CMR), 817 Communication medium, 565e566 module, 320 stack, 471 Compel Data, 471 Compensating cable, 833, 833te834t Component object model (COM), 472e473 www.EngineeringBooksPDF.com 909 Compressor turbine See Gas generator Computational fluid dynamic (CFD), 654e656 Concentric firing system (CFS), 656 Condensate extraction pump (CEP), 41, 79, 112, 349, 736, 759, 767 with associated measurements, 112 recirculation control, 770, 771f control loop description, 772e773 control loop operation, 773e774 and GSC, 773f recirculation line, 770e772 selection criteria, 112 Condensate polishing unit, 39, 96, 349, 354e355 See also Miscellaneous turbine auxiliaries capacity, 99 ion exchangers, 98e99 presence of corrosive materials, 97e98 quality, 99 requirements, 96e97 Condensate surge tank, 35 Condensate system, 180e185, 181f See also Extraction steam system; Reheat steam system condensate level control modes, 184f controls, 187e188 equipment, 185 miscellaneous points, 188 parameter, 185e187 redundancy in measurement, 188 Condenser(s), 40e41, 742 CEP, 41 condensing system, 711 condensing zone, 117 CT, 41 CWP, 41 evacuation, 83, 695 function, 82e83 heat exchangers, 41 hotwell level control, 736e738, 737f level control system, 736e739 steam ejectors and vacuum breaker, 41 systems, 82e86 vacuum, 83 Conductive coupling, 817 Conductivity analysis system, 355e356 type level gauge, 292 transmitters, 285 Conduit(s), 832 spacing, 828e829 Constant pressure, temperature, volume process, Constant head unit (CHU), 801 Continuous blowdown valve, 11, 74 Continuous maximum rating (CMR), 632e633 Control dampers, 414e415 intelligence, 474e475 910 Index Control (Continued) mode, 756, 757f network structure, 566e569 oil, 80e81 pressure, 704 supply, 713 parameters, 34 system, 725 display, 559f, 560e561 grouping, 523e525 Control and instrumentation system (C&I system), 787, 825fe826f Control loop, 588e589, 607e608, 641, 725e726, 768e770 BFP, 768e770 interlock, 770 operation, 770 CEP, 772e773 interlock, 774 operation, 773e774 deaerator control, 775e777 interlock, 777e778 operation, 777 furnace draft control, 619e622 GSC, 774 interlock, 774f operation, 774 HPH, 781 interlock, 783 operation, 781 interlock, 648 LPH, 780 interlock, 780 operation, 780 reheat temperature control, 636e642 superheater temperature control, 630e634 Control Net, 492 Control processing services (CPS), 550 Control system security (CSS), 475te476t attack types, 475te476t types of threats, 476 Control valve, 387e388, 389te390t, 405e414, 648 BFP, 770 bonnet, 413 CEP, 774 characteristics, 393e397 end connection for, 403 face-to-face dimension, 404e405 flow application, 395t level application, 395t LPH, 781 noise, 401e403 packing, 413e414 pressure application, 396t sizing, 388e393 Controller face plate display, 556e557 Controller-tuning display, 561 Conversion tables of units, 33t Conveyor safety switches, 138 Cooling media, 743 Cooling tower (CT), 41 Coordinated control system (CCS), 699e700, 749, 767 base control mode, 750 boiler follow mode, 758e759 boiler turbine balance, 763e764 coordinated control mode, 749, 751e756, 754f DEB, 749, 762 demand from LDC, 762e763 energy balance, 763f heat release, 764e766 manual control mode, 751 operating modes in, 749e750 run back system, 759e761, 760fe761f single unit operation, 761e762 start-up control mode, 750 turbine follow mode, 758 Copper tube, 787 Coriolis flow meters, 272e274, 273f Coriolis principles, 272e274, 273f Corner firing, 52e53 Corrosion, 49, 348e349, 349f fatigue, 64 Counter-excitation, 735 Counterflow cation exchanger regeneration methods, 130 Creep, 86e87, 720 creep-rupture, 63 Critical point, Critical temperature, 743e744 Cross-axis sensitivity, 310 Cross-talk, 818e819 Curtis turbine, 76 Cycles of concentration (COC), 120 D Dall tube, 258, 266e267 Damper windings, 21e22 Data acquisition systems (DASs), 477 de Laval turbine, 75 De-excitation system, 735 DEHA, 350 De-superheaters, 722e724 De-superheating control valve, 30 Deaeration area, 114 Deaerator pressure control, 775, 776f control loop, 775e777 interlock, 777e778 operation, 777 fixed set point interlock, 778 Deaerators, 43e44, 113e117 level control system, 738e739, 738f reason for deaeration, 113 working principles, 113e114 Decarbonators, 131 Decarburization, 61 Decibels (dB), 819e820 Degassers, 131 Demilitarized zone (DMZ), 232 Demineralized water (DM water), 120, 122e132 DM plant, 482e483, 736 inlet water quality requirement, 124 necessity for, 122e124 system operation, 124e131 Density, standard units for, 839t www.EngineeringBooksPDF.com Deposition, 348e349, 349f Desuperheating zone enclosure, 117 Device description, 471 Device Net, 492 Diaphragm sealed piston, 238e239 sensor, 238 type flow switch, 278e279, 282t valves, 408e409 Diesel generating set (DG set), 20 Differential expansion (DE), 102, 297 Differential pressure (DP), 125, 229, 593, 767, 789 control, 728 Differential pressure transmitter (DPT), 36, 230, 806e807 Differential producer, 257 Differential temperature (dT), 88 Dilution air, 19 Direct control option, 772e773 Direct current excitation system, 107 Direct energy balance (DEB), 749 Direct level gauges, 289e292 See also Indirect type level gauges bicolor level gauges, 290e291 displacer type gauge, 292 float and magnet type gauge, 292 pulley type gauge, 291 and rotary shaft type gauge, 291 type gauge, 291 sight level gauge glass, 289e290 Direct mechanical type low vacuum trip, 716 over speed trip, 715e716 thrust-bearing/axial shift high trip, 717 Dirty air service, 803 Discharge coefficient, 260, 261t, 265t Displacer type gauge, 292 type level switch, 287 transmitters, 284 Display(s), 555, 556f See also Intelligent control system; Logs alarm, 558e560, 558f browser bar details, 557f control system, 559f, 560e561 controller face plate, 556e557 controller-tuning, 561 mimic/P&ID, 555e556, 558f miscellaneous, 561e562 module, 320 quantities, 555t trend, 557e558, 558f X-Y plot, 560 Dissimilar metal welds, 63 Dissolved oxygen, 775 Dissolved salts, 98 Distance, standard units for, 838t Distributed component object model (DCOM), 472e473 Distributed control system (DCS), 30, 137, 149, 299, 516, 781, 815e816, 878 Index See also Intelligent control system; Management information system (MIS); Programmable logic control (PLC) communication medium, 565e566 components, 523f configuration, 521e536, 569e572 and communication, 564 control algorithms, 519e521 network structure, 566e569 diagnostics, 516e518 functional structure, 566f integration, 519, 567f PID controller, 518fe519f redundancy, 518e519 safety aspects, 519 security, 518 access category, 517t access rights and functions, 517t standalone controller unit, 536e540 standard library functions, 521, 522te523t Distribution Network Protocol version (DNP3), 507e508 DO analyzer, 362e364, 364te365t Domain name server (DNS), 256 Domain name system, 448 Doppler frequency shift method, 271e272 Dosing control system, 298, 382e384 Double-flow turbines selection, 740 Downcomers, 72 Downshot firing, 52 DP type instrument installations See Flow instrument installations Draft system, 39 Drain control, 712e713 Drain neutralization system, 131 Drain valve, 11, 74 Drive interface (DI), 502 Droop, 754 Drum level computation, 623 control, 593, 613 Drum-type boilers, 72 Dry fog dust suppression system, 136 vacuum pump, 85, 94 Dry-type bottom ash system, 142e143 Dry-type fly ash handling system, 143e144 Dryness fraction of steam, Dummy line, 806 Dump condenser, 31 Dust collector units, 49e51 control and ventilation systems, 136 extraction system, 136 measuring instrument, 341te342t Dynamic modeling technology, 630 E E(I)/P converter, 430 Earthing, 820e824 Eccentricity, 101, 300 Economizers, 71 Eddy current proximity probes, 312e313, 313t sensing principle, 311 Effluent treatment plant (ET plant), 510 Eight-corner method, 657 Ejector control, 783 Elastic deformation pressure elements, 35e36, 229 Elecrical installation of instruments, 815e816, 829e833 cables, 824e828 installation points, 829 termination points, 829 circuit classifications, 816e817 compensating cable/extension wire, 834t copper cable, 830t grounding/earthing, 820e824 instruments, 824e828 LAN cable, 831t segregation requirements, 828e829 separation requirements, 828e829 signal interferences, 817e820 signal noise, 817e820 wiring practices, 824e828 Electrical actuators, 425e427 data and tables, 65t earthing, 821e822 eye, 614e615 low vacuum trip, 716e717 power distribution, 460e461 remote trip solenoid and testing, 717 over speed trip, 716 thrust-bearing/axial shift high trip, 717 Electro hydraulic actuator, 425 Electro hydraulic governor (EHG), 80, 501, 696, 703f, 901 control philosophy, 697e702 controller outputs selection, 702 duty assigning, 697 functional description, 703e704 hydraulic signals selection, 702e703 operational mode of, 704e705 task of, 696e697 Electro-hydraulic control system (EHC system), 80e81, 699, 754e755 Electromagnetic safety valve, 74 spectrum, 230 Electromagnetic coupling See Radiative coupling Electromagnetic interference (EMI), 312 Electromagnetic safety valve, 11 Electromagnetism, standard units for, 839t Electromotive force (EMF), 36, 104, 734 Electronic device description, 466 Electronic Industries Alliance, 448e450 Electronic over speed detection system (EODS), 303e304 Electrostatic precipitator (ESP), 47, 50e51, 138, 654e656 Emergency oil pump (EOP), 213, 711 Emergency reclaim hopper, 136 www.EngineeringBooksPDF.com 911 Emergency stop valve (ESV), 696 testing, 718 Energy, 2e3 balance signal, 762 balance system, 765e766 standard units for, 839t Enlargement tank, 107 Enthalpy, restriction, 672 Entrained hydrogen, 730e731 Entropy, 5e7 Environment, 443 protection, 790 EP See Electrostatic precipitator (ESP) Equidirectional impellers, 111 Equipment cooling water system (ECW system), 511 Ergonomic control room design, 149e151 Ethernet, 451e455, 454t, 492 Evacuation systems, 82e86 function, 82e83 methods, 83e86 Excess air, 51 Excitation current, 104 system, 41 Exciter, 41e42, 104 Executable program, 472e473 Expansion measurement, 102 Expert system, 474 Extension wire, 833te834t Extraction, 81e82 Extraction steam system, 162e164, 163f See also Feed water system (FW system); Heater drain system controls, 165 equipment, 164 parameter monitoring, 164e165 Extractive multi-analysis system, 336e337 F Fan jet See Turbofan Fans, 45e47 Fast Fourier transform (FFT), 299 Fatigue, 63, 720 Fault tolerance, 473e474 Fault Tolerant Ethernet (FTE), 232e240 Feed control valve, 880 Feed water system (FW system), 9, 150, 170, 172fe173f, 298, 587, 767e768 See also Main steam system (MS system) controls, 179 controls, 622e628 equipment, 177 feed control station design, 176f miscellaneous points, 180 motor-operated BFP, 174f objective and function, 171e177 parameter, 177e179, 178t recirculation flow control, 300 redundancy in measurement, 179e180 turbine-operated BFPs, 175f Feeder speed controller, 598 912 Index Feeder speed controller (Continued) flow, 623 heater, 115 system, 39e40, 42e43 Fiber optics, 565e566 and networks, 229 Field coil excitation, 744 flushing system, 104, 108 transmitter grounding, 822 winding, 103e104 Field device tool, 466 Fieldbus Data Link Layer (FDL), 463 Fieldbus requirements, 461e462 File Transfer Protocol (FTP), 249 Filter requirement, 729 Final control element (FCE), 387, 401, 414e419, 586 control valve sizing, 388e393 dampers, 414e419 materials of construction and associated tables, 398e399 nominal pipe size and pressure rating, 405 seat leakage classification, 397 valves and actuators, 387e405 Final superheater (FSH), 67 Fire detection and protection system, 511 Fire retardant fluid (FRF), 713 Fire tubes, Fireside corrosion fatigue, 62 Firewalls, 231e232, 231t, 475 functionality, 232 HW vs SW, 231t Firing systems, 8, 52 See also Steam generator (SG) combustion air, 53 corner firing, 52e53 fixed-type firing, 52 mills/pulverizers, 54e57 start-up procedure, 53e54 First law of thermodynamics, See also Second law of thermodynamics; Zeroeth law of thermodynamics adiabatic work, internal energy, First-stage attemperator outlet temperature control loop, 631e632 Five-valve manifolds, 790 Fixed programmed time-based operation, 675, 689 Fixed-type firing, 52 Flame-monitoring system, 685e686 Flange dimensions, 1e4 Flashing liquid, 393 Float floating ground, 821 and magnet type gauge, 292 pulley type gauge, 291 and rotary shaft type gauge, 291 signal, 822e824 type gauge, 291 Flow elements, 231e232, 259e270 Flow gauges, 36, 280e283 Flow instrument installations, 807e808 Flow measurement, 36, 231e232, 256, 258t See also Level measurements flow switch, 277e280 flow transmitters and meters, 270e277 level excursion method, 268e270 units of measurement, 256e259 Flow meters See Flow transmitters Flow nozzle, 258, 261e262, 796 flow metering installation, 807e808 Flow switch, 231, 277e280 diaphragm type flow switch, 278e279 flapper or paddle type, 277 piston type flow switch, 279 shuttle type flow switch, 279 thermal mass flow type, 279e280 vane type flow switch, 277e278 with velocity-based actuation, 280 Flow transmitters, 232, 270e277 Coriolis flow meters, 272e274 magnetic flow meters, 270e271 mass flow meters, 274e275 swirl flow meters, 274 ultrasonic type, 271e272 vortex flow meter, 274 Flue gas, 59 recirculation damper, 675 service, 803 Flue gas denitrification plant, 51 Flue gas desulfurization (FGD), 47 plant, 51 Fly ash-handling system, 143e144 FO trip valve, 58 Force collector, 236e237 Force/weight, standard units for, 839t Forced circulation system, 8e9, 67 Forced draft (FD), 20, 39, 316, 589, 593 Forced draft fan (FDF), 756 Forced draught fan (FD fan), 45 Forced oxidation, 658e659 Forced water circulation, 72e73 Foundation Fieldbus, 467e472 Frame GTs See Heavy duty industrial GTs Free governing mode of operation (FGMO), 749 Free mineral acidity (FMA), 130 Frequency modulation (FM), 235e236 Frequency Shift Keying standard (FSK standard), 456 Frequency-influenced load demand, 754 Front firing, 52 Fuel and air/draft system, 39, 42 Fuel burners, 39 Fuel flow control, 595, 597f See also Air flow control loop, 617e618 loop description, 596e599 system, 26 for TT burner-type boilers, 599e604 Fuel input measurement, 764 Fuel NOX, 24 Fuel Oil (FO), 803 firing logic, 679 pressure control, 663e664 systems, 57e58 www.EngineeringBooksPDF.com Fuel oil recirculation valve, 679 Fuel oil trip valve, 679 Fuel oil-handling system, 511 Fuel/water ratio control, 299e300 Functional group control (FGC), 502 Functional subgroups, 695e696 Furnace draft, 619e622, 621f position, pressure, 618e619 control, 34e35 purge logic, 679 Furnace draft control, 618 control loop description, 619e622 furnace pressure, 618 near-atmospheric pressure, 618 Furnace safeguard supervision system (FSSS), 495, 593, 676 Fuzzy logic system, 474e475 G Gallons per minute (GPM), 256 Gamma ray type switch, 287 Gas analysis, 297, 330t, 331fe333f Gas analyzers gas components limit and range, 327t mercury in stack gas analyzer data sheet, 342te343t oxy-fuel, 326f for power plants, 325e340, 329t Gas chromatograph (GC), 335e336 Gas generator, 17 Gas phase oxidation/ammonia injection, 662e663 Gas recirculation, 59e60 Gas tempering, 59e60 Gas turbine (GT), 13, 206, 300, 303t closed loop cycle, 15 combustor with transition section, 19 with compressed air energy storage facility, 24 compressor section with diffuser, 18e19 control systems, 25e26, 211 double shaft, 17 effects of atmospheric condition, 26 emissions, 24e25 external combustion engine, 25 fuels, 25 influencing factors, 27 inlet sections, 18 open loop cycles heat exchangers/regenerator, 15 intercooling and reheating, 15e16 single shaft, 16 thermodynamics, 208f, 210f turbine firing temperature, 17 turbine pressure ratio, 17 turbine section, 19 Gas turbine generator (GTG), 387 Gas-damper, 635, 638e640 Gas-recycling damper, 636e638 Gas-to-gas heater, 659 Gasification, 387e388, 390t Gate valve, 409 Index Gauge glass, 810e812 General station description (GSD), 465 Generator, 41e42, 103 excitation, 107e109 field excitation, 108e109 hydrogen cooling, 105e106 system, 220e221 temperature control, 745 inerting system, 41e42 protection system, 735 rotor, 103e104 seal oil system, 106e107, 219e220, 220f temperature control, 744e745 stator, 104 and rotor cooling, 105 trip cause and effect, 899 working principles, 104e105 Generator circuit breaker (GCB), 700, 899 Generator control system, 732 AVR, 733e735 excitation control effect, 732e733 generator protection system, 735 generator voltage control, 732 instrumentation system, 735e736 rotor de-excitation system, 735 Gigabit Ethernet, 454e455 Gland exhaust fan, 92e93 packing, 92e93 seal subsystem, 695 sealing systems, 40, 81e82 system, 724e725 steam condenser, 92e93 Gland steam condenser (GSC), 767 minimum flow control, 774e775, 774f Gland steam coolers (GSC), Gland steam heater, 79 Globe control valves, 409e414 Gross calorific value (GCV), 132 Grounding, 820e824 Group display, 561e562, 561f Guided wave radar, 286 Guided wave radar level instruments (GWR level instruments), 293e295 H H2 (purity) gas analyzer, 347, 347te348t H2 detraining tank, 731 Hall probe, 302e303 Hammer-type mill See Impact mill Hand wheel, 430e431 Hardgrove Grindability Index (HGI), 132 Hardness ions, 122 Hardware functions, 677 Heat engine, exchangers, 41 convection type, 70 radiation type, 70e71 flux meter, 690f, 691 flux-based operation, 690e691 release, 764e766, 847t soaking, 88e89, 710 source, tracing, 801 transfer-based operation, 690e691 trap, 48 Heat recovery steam generator (HRSG), 13e14, 206, 210e211, 329, 354, 354t Heater drain system, 188e191, 778e780 See also Feed water system (FW system); Main steam system (MS system) controls, 193 equipment, 192 HPH drain system, 190f LPH drain system, 191f objective and function, 188 parameter, 192e193 Heaters, 9, 113e117 tube rupture, 780e781 Heavy duty industrial GTs, 14 Heavy fuel oil (HFO), 39, 51, 596, 679, 801 Heavy petroleum stock (HPS), 663 Heavy spot, 101 High concentration slurry disposal system, 139 High energy arc (HEA), 54, 165, 596 High temperature (HT), 307 creep, 62e63 graphitization, 63 oxidation, 62 High-pressure (HP), 695, 767, 897 cylinder, 78e79 High-pressure bypass (HPBP), 589, 721 High-pressure heater (HPH), 9, 79, 781e783 High-pressure turbine (HPT), 11e12, 305e307, 634e635, 709 High-voltage (HV), 685, 707, 816 Highway-addressable remote transmission (HART), 229e230, 456e459 Hogging, 86 Holding, 86 Hot air damper (HAD), 604 Hot air duct pressure controller, 593 Hot gas temperature control, 643 Hot primary air, 596 Hot reheat (HRH), 12, 709, 797e799 steam, 67e68 Hot reheat temperature, 581 Hot start, 669e670 House load operation, 448e450, 705 HP bypass (HPBP), 667e668 HP control fluid, 713 HP drain flash tanks, 188e191 HPeLP bypass system, 664e673, 666f Human body dimensional details, 149 Hydrastep, 37 Hydraulic signals selection, 702e703 Hydrazine analyzer See Residual hydrazine analysis system Hydrogen cooling system, 41, 105e106, 726 moisture in, 106 dew point, 731 www.EngineeringBooksPDF.com 913 embrittlement, 61, 349 gland seals, 729 purity, 735e736 and seal oil system, 41 system, 106 Hydrogen cyanide (HCN), 657 Hydrogen seal oil system, 726e729, 727f air removal, 729e731 hydrogen removal, 729e731 hydrogen system, 726 problems with, 731e732 I Igniters, 57 Ignition supports, 57 Immersion length, 249 Impact mill, 55 Impact probes See Multi-hole pressure probes Impulse line, 787, 799e802 length and diameter, 795, 795t Impulse turbine, 75 Impulse-reaction turbine, 76e78 In situ (modified) multi-analysis system, 337 In situ multichannel analysis system, 337 In-duct sorbent injection method, 660 Indirect control option, 773 Indirect draft, 316 Indirect type level gauges, 292e293 conductivity type level gauge, 292 pressure type level gauge, 293 Induced draft (ID), 20, 618 Induced draft fan (IDF), 756 Induced draught fan (ID fan), 45 Induced flue gas recirculation, 60 Induced-draft cooling tower, 119e120 Inductance, 237 Inductive coupling, 818 Inference engine, 474 Information system (IS), 521 functions, 527e528 grounding, 820e821 Initial priming, 94 Inlet damper control, 46e47 Inlet guide vanes (IGVs), 18e19 Inlet shoulder, 266e267 Inlet vane control, 46e47 Inputs/outputs (I/Os), 137 Inside diameter (ID), 787 Installation practices field instrument, 787 instruments elecrical installation, 815e833 mechanical installation, 799e815 ISA guideline, 787e790 pipe valve fitting material, 796e799 signal types, 789t supplies, 789t tapping point location, 788f tube/pipe support considerations, 790 Instrumentation cable, 832e833 earthing, 822e824, 823f 914 Index Instrumentation (Continued) system, 735e736 Instruments, 35e37, 824e828 elecrical installation, 815e833 mechanical installation, 799e815 Insulated gate bipolar transistor (IGBT), 418, 735 Insulation, 743 Integrated gasification combined cycle technology (IGCC technology), 387, 388f control scheme and system architecture, 391f control system, 388e393 gasification, 387e388 Intelligent actuator, 427 Intelligent control system, 443 control intelligence, 474e475 fault tolerance, 473e474 Fieldbus requirements, 461e462 firewall, 475 Foundation Fieldbus, 467e472, 468f HART Protocol, 456e459 MODBUS Protocol, 459e461 network basics, 445e456 OPC server, 472e473 PROFIBUS Application, 462e466 PROFINET, 466e467, 467t security, 476 signals and signal processing, 443e445 World FIP, 472, 472t Intelligent electronic devices (IEDs), 904 Intelligent system, 443 Interference modes, 818e819, 819t Interlock, 606 Intermediate pressure turbine (IPT), 9, 709 Intermediate-pressure check valve (IPCV), 704 Intermediate-pressure cylinder (IP cylinder), 78e79 Intermittent blowdown valve, 11, 74 Internal combustion engine, 13 Internal energy, International Organization for Standardization (ISO), 261, 445e447 International Union of Pure and Applied Chemistry (IUPAC), 256 Internet Control Message Protocol (ICMP), 448 Internet Group Management Protocol (IGMP), 448 Internet layer, 448 Internet Protocol (IP), 448 Ion exchangers, 98e99, 127 Ion-exchanger units, 126e131 ISA practices, 787 guideline, 787e790 ISA standards, 147e151 Isobaric process, Isolation/block valves, 722 ISOeOSI model, 468e469 reference protocol model, 445e447, 446f J Jacking oil, 81 Jacking oil pump (JOP), 81, 711 Jet engines, 14 Junction box (JB), 470, 832 K Katharometer, 334e335 Kelvin Planck statement, Key phasor (KP), 304, 306f Krell’s bar orifice plate, 266 KWU steam turbine control philosophy, 718e719 L Labyrinth glands, 82 Large integrated computer network, 231, 244f Large video screen, 551, 561e562 Latent heat, Law of conservation of energy, Lead cation resin, 98 Leak test valves, 224, 678 Leak-off steam, 82 Level excursion method, 268e270 Level gauge, 36e37, 232, 288e293 direct level gauges, 289e292 indirect type level gauges, 292e293 Level instrument installations, 808e813 Level measurement, 232, 283 level gauge, 288e293 level switch, 286e288 level transmitters, 283e286 magnetostrictive and guided wave radar level instruments, 293e295 Level switches, 232, 286e288 displacer type, 287 gamma ray type switch, 287 magnetic and mechanical float type, 287 RF admittance type, 288 rotating paddle type, 288 vibration or tuning fork type, 287 Level transmitters, 35, 232, 283 air bubbler type level transmitters, 286 capacitance or RF type, 286 conductivity type level transmitters, 285 displacer type level transmitters, 284 magnetostriction and guided wave radar, 286 pressure or DP type, 283e284 ultrasonic type level transmitters, 285 Light diesel oil (LDO), 58, 165, 596, 679 Light emitting diode (LED), 235 semiconductor laser vs., 229, 230t Limit pressure control, 701 Limit switches, 431 Limit value monitor (LVM), 609, 770 Linear variable differential transformer (LVDT), 299 Link Active Scheduler, 468, 471 Link layer See Network interface layer Liquid crystal display (LCD), 235, 541e542 Liquid services, 788, 803 Liquid-ring vacuum pump, 85, 94 Load commutated inverter, 21e22 Load dispatch center (LDC), 699e700, 749 www.EngineeringBooksPDF.com Load dispatch controls (LDCs), 587 Load/power controller, 701 Local Area Network (LAN), 445 cable, 831t Local instrument enclosure (LIE), 789e790 pressure transmitter/switch installation 1, 804e805 Local instrument rack (LIR), 789 pressure transmitter/switch installation 1, 804e805 Logical link control (LLC), 446 Logs, 562 See also Display(s) generation, 564 log/report types, 562f maintenance log/report, 563 on-demand log, 563e564 performance, 563 time-based log/report, 563 Long recirculation line, 663 Low vacuum trip, 716 trip system for, 716e717 Low voltage (LV), 707, 816 Low-cycle fatigue, 87, 720 Low-NOx burner (LNB), 653e654, 654f Low-NOx concentric firing system (LNCFS), 656 Low-pass filter, 619e620 Low-pressure (LP), 767, 897 cylinder, 78e79 turbine, 877 Low-pressure bypass (LPBP), 667e668, 695, 721e724 Low-pressure heater (LPH), 9, 79, 772e773, 778e781 Low-pressure turbine (LPT), 9, 709 Low-sulfur high-stock (LSHS), 596, 663 Low-temperature gas cooler, 393 Lubricating oil (LO), 79e80 temperature control, 744 M Machine health/condition monitoring system, 318e321 Machine vibration analysis system, 321 Magnetic flow meters, 270e271 Magnetomotive force (MMF), 109 Magnetostriction, 286 Magnetostrictive instruments, 293e295 Main bearing, 91 Main condensate valve, 773 Main oil pump (MOP), 79, 213, 711 Main path gas dampers, 636 Main steam flow, 623e625 pressure control, 599e601, 600f demand, 755e756 Main steam control valve (MSCV), 696 testing, 717e718 Main steam stop valve (MSSV), 10, 73, 702 Main steam system (MS system), 150e151, 152f controls, 155e156 equipment, 154 Index miscellaneous points, 156 parameters, 154e155, 155t process and piping, 151e154 redundancy in measurement, 156 Main steam temperature, 581 Maintenance log/report, 563 Man machine interface (MMI), 481, 540 See also Intelligent control system Chartless recorder Ethernet, 554f client server network, 540f CRT vs TFT LCD, 543t LVS, 551 printers, 551e553 recorders, 553e555, 553f Web connection, 554f workstation, 540e551, 542f, 547t Management information system (MIS), 511e512, 572e574, 572f See also Distributed control system (DCS) characteristics, 574 functions, 527e528 hierarchical system architecture, 571f OPTICOM and boiler optimization, 579f performance calculation and optimization, 575e583, 576f, 578f plant-level network and interface, 568f position and functionality, 573f, 574 time delay significance, 572t Manual control mode, 751 Mass, standard units for, 838t Mass flow meters, 274e275 Master A/M station, 598 pressure control, 34 steam pressure control mode, 758e759 Master fuel relay (MFR), 677 Master fuel trip (MFT), 298, 675 Material compositions, 147 Material science, 720 Maximum continuous rating (MCR), 232, 668e669, 700e701 Mechanical dust collector units, 49 induced-draft type cooling tower, 119e120 installation of instruments, 799e815 vibration-type fatigue, 63e64 Mechanical flow meter, 259, 275 nutating disk meter, 277 oval gear meter, 276e277 piston meter, 276 turbine flow meter, 277 variable area meter, 275e276 Media access control (MAC), 446 Medium voltage (MV), 816 Metals, 148 Methyl diethanolamine, 393e394 Mill cutting, 760e761 Mill drum-level control loop, 613e615 sound detector, 615e616 Mill outlet temperature, 607e608, 607f for TT boiler, 608e609 Mill selection, 578 Mill temperature control, 606e609 Mill-wise secondary air flow, 590 Mills/pulverizers, 39, 44, 54e57 Mimic/P&ID display, 555e556, 558f Ministry of Environment and Forests, 119, 139 Miscellaneous boiler equipment See also Steam generator (SG) blowdown valves, 74 drain valve, 74 electromagnetic safety valve, 74 MSSV, 73 nonreturn valve, 73 safety valves, 73 spring-loaded safety valve, 74 startup vent valve, 73 steam separator, 74 steam trap, 74 swing check valve, 74e75 Miscellaneous turbine auxiliaries, 91e100 circulating water pumps, 94 gland exhaust fan, 92e93 packing, 92e93 steam condenser, 92e93 online condenser tube-cleaning system, 95e96 priming system for water box, 94 turbine bearings, 91e92 vacuum breaker valve, 94e95 vacuum trip device and solenoid, 99e100 Mixed bed exchanger, 98, 129 Mixed bed regeneration, 131 MODBUS Protocol, 459e461 Modern plant control systems, 236 Monitoring module, 320 Motor control center (MCC), 425e426 Multi-hole pressure probes, 259 Multiple grounding, 821 Multiple identical modules selection, 740 Multiple nozzles, 724 ejectors, 84e85 N National Fire Protection Association (NFPA), 618e619, 677 Natural circulation See Forced circulation Natural gas, 688 Natural oxidation, 658e659 Natural water circulation, 72 Natural-draft cooling tower, 120 Near-atmospheric pressure, 618 Negative temperature coefficient, 249 Net Positive Suction Head (NPSH), 110e111 Network control and communications, 229e232 interface layer, 448 network-connecting devices, 448 networking capability, 321 Transmission Technologies, 450e456 Nickel alloys, 148e149 Nitrogen, 652 Noise susceptibility level (NSL), 820 Noise-minimizing techniques, 820 www.EngineeringBooksPDF.com 915 Nominal bore (NB), 787 Non-feedback control, 673 Nonflammable fluid See Fire retardant fluid (FRF) Nonreturn valve (NRV), 10, 73, 163e164, 778 Normal temperature and pressure (NTP), 239 Normally closed (NC), 901, 768 Normally open (NO), 768 Nozzle governing system, 740e741 Nutating disk meter, 277 O Object linking and embedding (OLE), 472e473 Oil transfer system, 58 Oil-handling plant, 39 OLE for process control server (OPC server), 472e473 On load operation, 705 On-demand log, 563e564 On/Off dampers and valves, 674e675 differential, 239 valves, 718 Once-through (OT), 599e600 boilers, 155 circulating water system, 118e119 oil vacuum pump, 85, 94 process, 877 Online condenser tube-cleaning system, 95e96 Opacity instrument, 341t Open loop control, 673, 675 boiler OLCS, 673e693 Open loop control system (OLCS), 186, 501e503, 521e536, 695, 780 for auxiliaries and miscellaneous systems, 531e536 displays, 560e561 functions, 525e526 graphics, 528e531 input and output types, 531 miscellaneous OLCS functions, 534f Open System Interconnection (OSI), 445e447 Open transition method, 459 Open type See Local instrument rack (LIR) Open-type regenerative feedwater heaters, 116 Open/nonpressurized vessel level measurement displacer/float instruments, 810e812 DPT with/without instrument seal, 812e813 Operating system (OS), 472 Opposed firing, 52 Opposite directional impellers, 111e112 Optical fiber in Gigabit Ethernet, 229e230, 230t Optical pressure measurement, 237 Orifice plate, 258, 262e266, 796, 808 Oscillatory motion, 299f Outlet damper control, 46e47 Outside diameter (OD), 796e799 916 Index Oval gear meter, 276e277 Over fire air (OFA), 196e197 Over speed trip system, 715 trip system, 715e716 trip testing system, 716 Overfire air, 656 damper control, 643 Oxides of nitrogen (NOx), 17 analyzer, 338, 339t control, 384e385, 650e657, 653f, 655te656t Oxygen analyzer, 343e344 ammonia analyzer data sheet, 342t paramagnetic, 334f, 345te346t zirconia, 344, 344f, 345t Oxygen-trimming controller, 590e592, 591f Oxygenated treatment (OT), 349e350 P Packet-filtering firewall, 232 Parameters, 32 measurements, 33 efficient running/control of plant, 34e35 plant safety, 34 Parshall flume, 36, 268e269 Parson’s reaction turbine, 78 Particulate matter (PM), 24 Particulate matter, 98 Pass out turbine, 29 Passivation of DM water, 120 Peak value, 298 Pegging pressure, 775 Perfect gas, Perfect intercooling, 16 Performance log, 563 pH analyzer, 357e361 Phase, 101e102 angle See Phase measurement, 304 Phosphate analyzers, 367e369, 370t Phosphate ester See Fire retardant fluid (FRF) Physical medium, 453 Piccolo tube, 259 Piezoelectric sensor, 315 Piezoelectricity, 237 Piezoresistive strain gauge, 236 Pipes, 800 dimensions, 797, 798t valve fitting material, 796e799 Piping and instrumentation diagram (P&ID), 1, 147e149 air and flue gas system, 193e206 cogeneration, 206e213 condensate system, 180e188 control oil, 216f equipment, 148 extraction steam system, 162e165 FW steam, 170e180 heater drain and vent system, 188e193 instrumentation symbols, 147 MS system, 151, 152f piping representation, 147e148 power and process plant steam circuit, 153f process parameter, 148 redundancies for transmitters, 149e151 reheat steam system, 156 SG-related, 222e228 AS system, 165e170 TG-related, 213e222 Piston cylinders, 421e422 Piston meter, 276 Piston type flow switch, 279, 282t Pitot tube, 258, 267 Plain water dust suppression system, 136 Plastics, 147e148 Plate heat exchangers, 119 Platinum resistance thermometer (PRT), 37 Pneumatic positioner, 431e433 Point display, 562 Point-to-Point Protocol (PPP), 448 Pollution control, 384 Pollution-related analysis, 298 Pop-up valve See Safety valve Position controller, 702 indicator, 435 signal, 586 transmitter, 435 Positioner, 431e435 Positive displacement gear type pump, 728 Positive temperature coefficient, 249 Potential transformer, 701 Potentiometric pressure measurement, 237 Power, standard units for, 839t Power plant, 1, 749 Power plant off-site controls, 508 ash-handling plant, 510 circulating water system, 511 coal-handling plant control systems, 509e510 ECW system, 511 fire detection and protection system, 511 fuel oil-handling system, 511 WTPs, 510e511 Power system stabilizer (PSS), 732 Predictive adaptive controller, 629e630 Pressure elements, 35e36 gauge, 239e240, 241t level gauge, 293 pressure-based measurements, 257e259 pressure-compounded impulse turbine, 75e76 pressure-reducing and control valves, 722 restriction, 672 set point, 754e755 spring type temperature gauges, 229 standard units for, 33t switch, 237e239, 240t tapping, 790 transmitter, 232e235 data sheet, 238t force collector types, 236e237 point measurement for, 233te235t velocity-compounded turbine, 76 Pressure instrument installations, 802 www.EngineeringBooksPDF.com DPT/switch installations, 806e807, 807fe808f pressure gauge installation, 802e803 pressure switch installation, 803, 803f pressure transmitter/switch installations, 804e806, 804f Pressure measurements, 229 , , See also Temperature measurement pressure gauge, 239e240 pressure switch, 237e239 pressure transmitter, 232e237 Pressure sand filters, 125 Pressure-reducing and de-superheating station (PRDS), 29, 148e149, 414, 644, 722, 783 objective, 29 system description, 30 Pressure-reducing valve (PRV), 13, 645, 783, 797e799 Pressureevolume diagram, Pretreatment plant, 510 Primary /platen superheater (PSH), 67 Primary air (PA), 39, 53, 56e57, 193, 316, 606 flow, 596e597 controller, 598 header pressure controller, 598 Primary air fan, 45, 596, 756 Primary coal crusher, 135 Primary technology, 653 Priming air ejector, 86, 94 Priming system, 94 Printers, 551e553 Probe node, 471 Probe response, 471 Process boiler, 28 See also Recovery boilers back-pressure turbine, 28e29 pass out turbine, 29 Process instrumentation, 735e736 Process tap, 787 PROFIBUS Application, 462e466 PROFINET, 466e467, 467t, 492 Programmable logic control (PLC), 137, 443e444, 476, 659, 677 See also Distributed control system (DCS); Intelligent control system in ATRS turbine protection and ATT, 501e503 basics, 477e480 in BMS, 495e501 configurations, 482e487, 482f CPU Tasks, 478t in electrical system, 504e508 with Fieldbus systems, 484f hardware considerations, 487e492 I/O connections, 495 I/P output signals, 477f integrated plant control system, 485f integrated system, 494f memory divisions, 488fe489f networking, 483f in off sites, 508e511 operating principles, 478f redundancy criteria, 494e495 Index salient features, 481 software considerations, 492e493 Proportional-integral-derivative (PID), 592 Pull chord switch, 138 Pulverized coal boilers (PC boilers), 387 Pulverized fuel (PF), 56, 596, 663, 687 Pulverized fuel-firing logic, 681e683 Pumps, 728e729 Purging, 679 connections, 788 process connections, 801 Push button (PB), 679 R Radial oil seal, 729 Radial vibration, 321, 324 measurement, 304 Radial/centrifugal fans, 47 Radiative coupling, 818 Rankine cycle, Rankine engine efficiency, Rapid Spanning Tree Protocol, 236 Rateau turbine, 75e76 Raw water, 122 Reburning, 657 Recapitulation Carnot cycle application, Carnot theorem, entropy of phases, 6e7 reversible cycle, 4e5 steam properties, 5e6 temperatureeentropy diagram, 6e9 Recirculating water system See Closed-cycle type water system Recirculation control BFP, 767e770 CEP, 770e774 Recommended Standard, 448e450 Recorders, 553e555, 553f Recovery boilers, 27e28 Recuperative air heaters, 48 Recursive least squares, 629 Redundant instrument selection method, 150f Reference earth, 822 Reference grounding, 820e821 Regenerative air heaters, 48e49 Regenerative cycle, 9, 81 steam separator, 11 steam trap, 11 valves and operations, 10e11 Regenerative feed heaters, 113, 115e117 closed-type, 116e117 comparison, 116e117 feed heating, 9, 81 open-type, 116 Regenerative heater, 81 Reheat cycle in utility boiler, 11e13 Reheat spray control valve function, 641e642 Reheat steam system CRH steam system, 156e159, 157f HRH steam system, 159e162, 160f Reheat temperature control, 634e635 See also Air flue gas path equipment burner tilt mechanism, 636 control loop description, 636e642 with gas dampers, 59 gas recirculation damper, 59e60 gas-damper, 635 main path gas dampers, 636 spray water injection system, 635 tangential tilting burner assembly, 59 three-element controls, 642 Reheater (RH), 47, 69e71, 149, 635, 799 Reinforced concrete cement (RCC), 134 Relative vibration of shaft, 102e103 Relay module, 320 Relief valve See Electromagnetic safety valve Reluctance, 237 Remote control valve, 768 Remote pressure transmitters, 229e230 Remote temperature transmitters, 230 Remote terminal unit (RTU), 444 RTU Encode, 461t Reserve feed water (RFW), 736 Residual hydrazine analysis system, 365e367, 366f, 367t Resins regeneration, 99 Resistance temperature detector (RTD), 37, 149, 230, 240e247, 307 Reverse osmosis (RO), 98 Reynolds number (Re), 274 Ring granulator, 135e136 Ring type de-superheater, 723 Ring-roll and ball-race mill, 55 Ringing, 285 Riser, 72 Root mean square (RMS), 298 Rotameters See Flow gauges Rotary piston See Piston meter Rotating paddle type level switch, 288 Rotating-type excitation system, 107 Rotor, 103e104 cooling, 105 excitation control, 733e735 field excitation, 732 Rotor de-excitation system, 735 Rotor eccentricity, 307e308 Rubber, 147e148 Run back condition, 765 demand, 759, 765 load, 759 system, 759e761, 760fe761f, 765 Run-of-mine, 132 S Safety valves, 11, 73 Salient pole rotors, 104 Sample conditioning system, 298, 374 See also Special instruments components, 376e379 primary, 374 primary sample conditioning P&ID, 375e376 secondary, 375 secondary sample conditioning P&ID, 376 www.EngineeringBooksPDF.com 917 SWAS rack/panels, 379e380 Saturated steam, 628e629 Saunders’ valves See Diaphragm valves SC/USC plants constant and variable pressure operation, 297 steam generators, 297 Scanner air fan, 45, 57, 686 Scanner cabinet, 684 Scavenging, 107, 679, 731 Scheduled communication, 471 Scoop tube, 47 actuator, 621 Screw pump, 728 Scroll fan See Squirrel cage Seal air fan, 45, 57, 686 Seal oil coolers, 729 system, 106e107, 726e727 Seal steam pressure control, 724e725, 725f Seals, 729 Seat leakage classification, 397 Seawater applications, filters for, 126 Seawater scrubbing, 660e661 Second law of thermodynamics, See also First law of thermodynamics; Zeroeth law of thermodynamics Clausius statement, Kelvin Planck statement, Second-stage attemperator outlet temperature control loop, 630e631 Secondary air, 53 Secondary air damper control (SADC), 593, 675, 686 control loop description, 687e688 for tangentially corner-fired boilers, 687 for wall-fired boilers, 686e687 Secondary air flow, 598 controller, 592e593 Secondary air/combustion air, 193 Secondary coal crusher, 135 Segregation requirements, 828e829 Seismic probe acceleration, 315e316 velocity, 313e314, 314f, 316t Selective catalytic reduction, 24e25, 47 Self-contained black start, 20 Self-excitation system, 733 Self-pressure regulating valve (PRV), 79 Semi-closed cycle, 13 Semi-positive displacement meters See Piston meter Semiconductor, 735 Semiwet bottom ash system SCC, 141e142 SFC, 140e141 Sensible heat, Separate over fire air (SOFA), 196e197 dampers, 656 Sequence of event (SOE), 511e512, 515 See also Annunciation; Intelligent control system features, 515e516 SER, 515t, 516 918 Index Sequence of event (SOE) (Continued) specification, 516 Serial Line Internet Protocol, 448 SG HFO system, 222e224 Shaft-sealing system failure, 729 Shield effectiveness, 819e820 Short recirculation line, 663 Short recirculation valve, 58 Short-term overheating, 62 Shrinking, 623 Shut-down operation, 705 program, 713 Shuttle type flow switch, 279, 281t Side stream filters, 121 Sight flow glass, 231, 283 Sight level gauge glass, 289e290 Signal cable shield grounding, 822e824 Signal conditioning system, 299 Signals and signal processing, 443e445 Silica analyzers, 367e368, 369t Simple cation bed exchanger, 99 Simple Mail Transfer Protocol (SMTP), 447 Single point grounding, 821 Single-element control, 625 Single-flow turbine selection, 740 Single-nozzle ejectors, 84 Sliding pressure control, 701e702 Smart noncontact position transmitter, 435 Smart/electro pneumatic positioner, 433e435 Socket weld (SW), 804 Sodium analyzer, 369e370, 371f, 372t Software functions, 677 Solenoid, 99e100 valve, 435e436 Soot-blower control system, 675e676 Soot-blowing (SB), 648 media, 691e692 steam pressure control, 648e649 system, 39, 44, 688e693 Sorbent injector, 660 Sound pressure level (SPL), 401 Source point, 789 See also Installation practices for flow elements, 795f for flow measurements, 793e796 for level measurement, 796, 797f for pressure type tapping, 790 for temperature element, 793f for temperature tapping, 790e793 valve manifold, 791f SoxeNOx removal, 662e663 Spanning Tree Protocol, 236 Special instruments, 297e298 blow down control, 380e382 system, 298 CO and CO2 analyzers, 344e347 conductivity analysis system, 355e356 DO analyzer, 362e364, 364te365t dosing control, 298, 382e384 gas analysis, 297 gas analyzers, 325e373 H2 (purity) gas analyzer, 347 miscellaneous special analysis systems, 367e373 oxygen analyzer, 343e344 pH analyzer, 357e361 pollution control, 384 pollution-related analysis, 298 residual hydrazine analysis system, 365e367 sample conditioning, 298 steam analysis, 297 steam and water analysis system, 348e355 turbovisory instruments, 297e325 vibration measurements, 297e325 water analysis, 297 Specific heat, Speed controller, 699 measurement, 102 speed/load control systems, 26 switch, 138 Speed control, 417e419 hydraulic coupling, 417e418 loop, 697e699 VFD for, 418e419 Spindle-operated ejector, 85 dry vacuum pump, 85 liquid-ring vacuum pump, 85 once-through oil vacuum pump, 85 Spray dry scrubber, 660 Spray water attemperation, 636e638 injection system, 635 valves, 642 Spray-type deaerator, 115 Spring-loaded injection nozzles, 724 safety valve, 11, 74 Squirrel cage, 47 Stainless Steel tubing, 787 Stack inlet damper function, 637e638 Standalone controller unit, 536e538 communication, 538 data sheet, 539t standalone controller block diagram, 537e538 support functions, 540 universal input/output, 537f Standard electronic position transmitter, 435 Standard temperature and pressure (STP), 239 Standby liquid control system, 695 Starting air ejector, 86, 711 Startup control mode, 750 procedure, 86 and synchronization, 704e705 thermocouples, 64 vent valve, 10e11, 73 Startup and thermal stress, 86e91 damage mechanisms, 86e87 startup procedure, 86 stress, temperature, and startups relationship, 87e91 State variable control, 630 www.EngineeringBooksPDF.com Static-type excitation system, 108 Station service transformer, 901 Stator, 104 bar, 743 coolant flow, 745e746 cooling, 105 Stator cooling water system, 41, 221e222, 222f, 745e746, 746f Steam analysis, 297 conditioning control valves, 414 ejectors, 41, 783 jet air ejectors, 83e84 multiple-nozzle ejectors, 84e85 single-nozzle ejectors, 84 pressure control, 586e589, 588f mode, 758 properties, 5e6 separator, 11, 74 service, 802e803 Station service transformer level control, 302e309 system, 40, 43 table, temperature control, 298e299 trap, 11, 74 and water service, 788 Steam and water analysis system (SWAS), 298, 348e355, 355t, 408, 790 Steam coil air preheater (SCAPH), 49, 166, 593 Steam generator (SG), 8, 42, 73 air flue gas path equipment, 47e51 boiler circulating water system, 44 boiler drum, 67e73 deaerator, 43e44 fans, 45e47 mills and pulverizers, 44 plants, 875e876 control and monitoring of parameters, 297 dry mode of operation, 298 fuel/water ratio control, 299 load/fuel control, 299f OT SC boiler chemistry, 298e325 SC/USC, 297 water circulation and start-up procedure, 297 pumps and heating units, 45 soot-blowing system, 44 subsystems, 42e43 Steam turbine, 300, 739 condensers, 742 constant pressure controls, 741 cycle optimization package, 581 double-flow turbines selection, 740 fossil-fired power plants, 742 governing system, 740e741 HPT/IPT and LPT blading, 741 modules selection, 740 multiple identical modules selection, 740 nuclear thermal power plants, 742 single-flow turbines selection, 740 sliding pressure controls, 741 subcritical critical steam parameters, 742 Index super critical steam parameters, 742 turbine selection, 740 vales regulation and ESVs, 741 Steam turbo generators (STGs), 300 Steam-assisted de-superheaters, 723e724 Stoichiometric air‒fuel ratio, 51 Stoichiometric ratio, 589 Storage and transfer system, 58 Stress corrosion cracking, 61 Stress rupture, 62 DMW, 63 high temperature creep, 62e63 short-term overheating, 62 Strong acid cation (SAC), 124 exchanger resins, 127e128 Strong base anion (SBA), 124 exchanger resins, 128e129 Strouhal number (S), 274 Subcooling zone, 117 Subcritical critical steam parameters, 742 Subloop controls, 502 Submerged flight conveyor, 140e141 Suction heater, 58 Sulfur dioxide (SO2), 650 analyzer, 340t Sulfur oxide (SOx), 643, 653f, 657e661 Sulfur trioxide (SO3), 650 Super critical power plants (SC power plants), 297e298, 875 historical developments, 297 steam generators, 297 Super critical steam generators, 68 parameters, 742 Superconducting field coil, 743e744 Supercritical systems (SC systems), 42 Superheated steam, Superheater (SH), 47, 69e71, 149, 587, 799 fireside ash corrosion, 61e62 temperature control, 628e629, 631f control loop description, 630e634 Recursive least squares, 629 Supervisory Control and Data Acquisition (SCADA), 504 components, 504e507 EPA layered structure, 506f first generation, 505f history and architecture, 507 protocol, 507e508 second generation, 505f security, 508 third generation, 506f Suspended matter, 98 Swelling, 623 Swing check valve, 74e75 Swirl flow meters, 274 Switched Ethernet, 453e454 Switches, 229 Synthesized gas (Syn gas), 387 clean up, 393 cooling, 392 System, 443 capacity, 668e669 controllers, 590e593 properties, System management (SM), 470 T Tangential firing See Corner firing Tangential tilt (TT), 589 burners, 52e53, 58e59 TCP/IP reference model, 447e448 Temperature, 2, 103 control, 26, 745e746 element, 240e251 RTDs, 240e247 THCs, 247e248 thermistors, 248e249 gauges, 229, 254e255 bimetallic gauges, 255 data sheet, 256t mercury in glass, 254e255 mercury or alcohol in steel, 255 measurement, 37, 240, 241te244t connection types, 249e251 immersion length, 249 temperature transmitter, 251e252 sensors, 788 standard units for, 33t switches, 252e253, 255t temperature-based operation, 675e676, 689e690 temperature-equalizing column, 810 transmitter, 231, 251e252, 253te254t Temperatureeentropy diagram, boilers classifications, 8e9 pressureevolume diagram, of steam, 7e9 steam generators, “Test reset” valve, 718e719 Thermal conductivity gas detection system, 334e335 Thermal fatigue, 64 Thermal mass flow type, 279e280 Thermal shock, 64 Thermal stress, 720 Thermal stress evaluator (TSE), 669, 719e721, 752 Thermistors, 37, 248e249 Thermocouple (THC), 37, 230, 247e248 cold junction compensation, 248 connection to instruments, 248 junction types and response time, 251f properties and color codes, 250t temperature ranges, 249t voltageetemperature relationship, 247e248 Thermocouples (T/Cs), 149 Thermodynamic system, Thermosiphoning, 72 Three-breaker scheme, 457e458 Three-element controls, 625e628, 628f, 642 Three-phase, 104 Three-valve manifolds, 790 Throttle governing system, 741 Thrust bearing, 91e92 Thrust position, 101, 304e305 Thrust-bearing trip function, 717 Thrust-bearing/axial shift high trip, 717 www.EngineeringBooksPDF.com 919 Thyristors, 735 gate control, 735 Time distribution, 471 Time division multiplexer (TDM), 443e444 Time-based log/report, 563 Timing diagram, 459e461 Token Bus, 455 Token Passing, 455 Token Ring, 456 Torque switches, 436 Total dissolved solids (TDS), 97, 121 Total organic compound (TOC), 98 Total plant optimization, 581e582 Touchscreen technologies, 548te549t Track hopper unloading system, 134 Tracking integrator, 670, 759e760 Transaction methodology, 460 Transition section, 19 Transmission control protocol (TCP), 448 Transmission fluid, 229 Transmitter enclosure, 814e815, 815f mounting, 813e814, 815f redundancy considerations, 149 without seal, 812 with seal, 812e813 selection, 585 Transport layer, 448 Tray spacing, 828e829 Tray-type deaerator, 114e115 Trend display, 557e558, 558f Triple modular redundancy (TMR), 302e303, 485e487, 677 Trips, 443e445 TT burner-type boilers, 599e604 Tubes, 800 inside corrosion, 61 outside corrosion, 61e62 tubing materials, 787 Tubular-type air heaters, 48 Tuning fork type level switch See Vibration level switch Turbine, 40 bearings, 91e92 main bearing, 91 thrust bearing, 91e92 condenser and evacuation systems, 82e86 demand, 763 evacuation system, 219 extraction and gland-sealing system, 81e82 firing temperature, 17 flow meter, 277 follow mode, 701, 750, 758 gear/barring gear, 40 gland sealing systems, 40 governor and isolation valves, 40 HP/LP bypass system, 40 inlet temperature, 17 jacking oil system, 214e215 LO system, 213e214, 214f load control loop, 699e701, 700f load demand, 756, 757f master demand, 753e754 miscellaneous turbine auxiliaries, 91e100 920 Index Turbine (Continued) oil subsystem, 695 oil supply, 711 oil system, 40 oil systems, 79e81 control oil, 80e81 jacking oil, 81 LO, 79e80 pressure control loop, 701e702 pressure ratio, 17 protection system, 503, 705, 706f active protective devices, 705 generator protection, 708 turbine tripping input signals, 706e708 unit protection, 708 seal steam system, 217, 218f start-up, 710 startup and thermal stress, 86e91 supervisory instrumentation, 100e103 eccentricity, 101 expansion measurement, 102 phase, 101e102 speed measurement, 102 temperature, 103 thrust position, 101 turbine-governing valve position, 103 vibration measurement, 102e103 trip cause and effect, 899 tripping, 714 input signals, 706e708 turbine oil systems, 79e81 turbine supervisory instrumentation, 100e103 types, 75e78 warm up, 712e713 Turbine auxiliary steam, 151, 644, 783 Turbine control system, 325, 710e713, 724e726 oil system, 215e217 subsystem, 695e696 Turbine generator control system (TG control system), 695e696 ATRS, 708e713 ATT system, 713e719 condenser level control system, 736e739 control loops, 744e746 cooling media, 743 critical temperature, 743e744 cylindrical rotors for, 742 deaerator level control system, 738e739 differential pressure control, 726e732 EHG, 696e705 field coil excitation, 744 generator control system, 732e736 hydrogen seal oil system, 726e732 insulation, 743 LPBP system, 721e724 operational modes, 698t power output ranges, 742e743 stator bar, 743 steam cycle with, 697f steam turbines, 739e742 subsystem, 695e696 superconducting field coil, 743e744 testing process by ATT, 696 TSE, 719e721 turbine controls, 724e726 Turbine maximum continuous rating (TMCR), 298 Turbine stress evaluator (TSE), 696 Turbine water damage prevention (TWDP), 642 Turbine-driven boiler feed pump (TDBFP), 622 Turbine-governing valve position, 103 Turbo generator (TG), 897, 79e80, 297, 629, 709 Turbo generator control system, 767 Turbo supervisory instrument (TSI), 717 Turbofan, 14 Turbojets, 14 Turboshaft engine, 17 Turbovisory instruments, 297 application notes, 324e325 BFPT TSI specification, 323 casing expansion, 323 frequency range, 309 GT, 300, 303t, 304f measurement issues, 302e309 measuring sensor/transducer types, 309e310 speed measuring system, 305f steam and gas instruments, 321e322 steam turbine, 300, 300f, 301te302t STG TSI specification, 322e323 system configuration, 325 valve position, 323e324 Turbulence, 723 Turning gear See Barring gear Twisted pair cable category, 565 Two-breaker (main tie) system, 456e459 Two-valve manifolds, 790 U Ultra supercritical power plants (USC power plants), 297e298, 875 historical developments, 297 steam generators, 297 Ultrasonic type measurement, 271e272 Doppler, transit time, and, 271 Doppler frequency shift method, 271e272 level excursion type, 272 level transmitters, 285 Unburnt carbon, 654e656 Unit control board, 677 Unit load demand, 751e754, 751f auto manual selection, 752 blocking of increase and decrease, 752e753 limiting, 765e766 upper and lower limit, 752 Unit protection system, 443 Universal gas constant, Unloading, 133e134 Unscheduled communication, 471 User Datagram Protocol, 448 www.EngineeringBooksPDF.com V V cone flow device, 259, 267e268, 269f Vacuum, 83 breaker, 41 valve, 94e95 condenser, 30 service, 788 trip device, 99e100 Vacuum pumps See Steam ejectors Valves, 387e405 lift controller, 702 manifold, 790 position, 309 Vane/damper control, 415e416 Variable area meter, 275e276 type, 283 Variable frequency drive (VFD), 21e22, 47, 598 Variable inlet vane, 415e416 Variable orifice type, 283 Variable pressure control, 701e702 Variable-pitch control, 46e47 Velocity probe, 313e315 Velocity-compounded impulse turbine, 76 Vena Contracta, 260 Vent system, 188 Venturi meter, 257e258, 260e261, 808 Verband der Elektrotechnik (VDE), 677 Vertical centrifugal pump, 112 Vertical roller mill, 55 Vibration level switch, 287 Vibration measurement, 102e103, 297e299, 298f absolute vibration, 103 application note, 316e318 building blocks for, 299 casing vibration, 311 condition monitoring, 299e300 frequency range, 309 influencing factors, 310 interpretation, 310 machine health/condition monitoring system, 318e321 machine vibration analysis system, 321 measuring sensor/transducer types, 309e310 monitoring system, 319f proximity probes, 311e313 relative vibration of shaft, 102e103 seismic probe, 313e316 sources of, 311t Vibration transducer, 299 Virtual field device, 471 Virtual Private Network, 235, 481 Viscosity, dynamic, index, 846 kinematic, standard units for, 839t Volatile organic compounds, 24 Volt ampere, 733 control, 735 Volume booster, 436e439 Index standard units for, 36t Von Karman Vortex Street principle, 274 Vortex flow meter, 274 W Wagon tippler unloading system, 134 Wall firing See Front firing Warm start, 669 Warm-up process, 709e710 Washing medium, 692e693 Water analysis, 297 induction, 778 tubes, water-cooled dump condenser, 31 Water circulation valve, 298 Water gas shift, 393 Water treatment plants, 510e511 Waterside corrosion See Tube inside corrosion Waterwalls, fireside corrosion, 62 Weak acid cation (WAC), 124 exchanger resins, 128 Weak base anion (WBA), 124 exchanger resins, 129 Wellman-Lord process, 659 Wet bottom ash system, 140 Wet mode operation, 298 Wet steam, Wet-type fly ash handling system, 144 Wide Area Network (WAN), 445 Wind box (WB), 57, 675 Wireless Local Area Network (WLAN), 445 Wiring practices, 824e828 Work, Workstation, 540e551, 542f, 547t browser bar and frame, 545f controller face plate details, 546f display features, 550t www.EngineeringBooksPDF.com 921 operation and monitoring area, 544f, 547t Touchscreen technologies, 548te549t WS software architecture, 549f World FIP, 472, 472t X X-Y vibration, 324 X-Y Plot, 553 Z Zeroeth law of thermodynamics, See also First law of thermodynamics; Second law of thermodynamics energy, perfect gas, specific heat, work, Zirconia oxygen detection system, 334 .. .Power Plant Instrumentation and Control Handbook A Guide to Thermal Power Plants Swapan Basu Systems & Controls Kolkata, India Ajay Kumar Debnath Systems & Controls Kolkata, India AMSTERDAM... thermal power plant instrumentation and controls This book endeavors to act as a way to balance two extreme lines of thinking, giving a comprehensive approach to plants? ?? measurements and controls... colleagues D K Sarkar, J K Sarkar, D J Gupta, S Chakraborty, A Thakur, and Arijit Ghosh In addition, we convey sincere thanks to friends: A Bhattachariya (Kolkata), A Sarkar (Norway), A Tendulkar