BHEL

FBC & HRSG

ELECTRICAL, CONTROLS
&
INSTRUMENTATION
Bharat Heavy Electricals Limited
Tiruchy 14

WELCOME

Bharat Heavy Electricals Limited

Tiruchy 14

HRSG Under Erection

Bharat Heavy Electricals Limited

Tiruchy 14

HRSG Installation
at Tata Electric Co, Trombay (V 94.2 GT)

Bharat Heavy Electricals Limited

Tiruchy 14

Combined Cycle Plant

Compressor Gas turbine

Steam turbine

G
condenser

HRSG

Feed pump

To Chimney
Bharat Heavy Electricals Limited
Tiruchy 14

CO-GENERATION PLANT
FUEL

GENERATOR

COMPRESSOR

TURBINE
STEAM
FOR PROCESS

AIR
FUEL(If reqd)

HRSG
Bharat Heavy Electricals Limited
Tiruchy 14

EXHAUST
6

Dual Pressure HRSG

Triple Pressure HRSG

Supplementary Fired HRSG

AIR & FLUE GAS FLOW

DIAGRAM

Bharat Heavy Electricals Limited

Tiruchy 14

11

MUH

ECO

EVAP

SH I

DESH

SH II

EVAP

DUCT BURNER

SH III

FD FAN

Bharat Heavy Electricals Limited

Tiruchy 14

12

Finished components at our works

Completed
Box assy.

HRSG
Drum
Bharat Heavy Electricals Limited
Tiruchy 14

13

PROCESS MEASUREMENT

PRESSURE
TEMPERATURE
FLOW
LEVEL
POSITION

Bharat Heavy Electricals Limited

Tiruchy 14

14

IMPORTANT MEASUREMENTS
IN AIR AND FLUE GAS PATH

Gas Temperature at HRSG Inlet.

Gas Temperature after Duct Burner
Gas Temperature before Chimney

Bharat Heavy Electricals Limited

Tiruchy 14

15

GAS TEMP. MEASUREMENT

(HRSG INLET)
Arrangement of temperature tapping from top ( Double width)

Bharat Heavy Electricals Limited

Tiruchy 14

16

STEAM AND WATER FLOW DIAGRAM

DRUM
DESH

Main Steam

SH3

Feed Water

SCREEN
EVA

SH2

SH1

EVAPORATOR

ECONOMISER

Bharat Heavy Electricals Limited

Tiruchy 14

17

Bharat Heavy Electricals Limited

Tiruchy 14

18

Bharat Heavy Electricals Limited

Tiruchy 14

19

BOILER INTERLOCK LOGIC

Bharat Heavy Electricals Limited

Tiruchy 14

20

AUTO TRIP TRANSFER LOGIC

Trip transfer initiated
Start FD fan
Fuel flow control
valve kept in stay put
condition
Monitor DP between
FD fan outlet and
HRSG inlet duct
1

Bharat Heavy Electricals Limited

Tiruchy 14

21

DP >
50MMWC
within
20sec

Y
Close divertor
damper towards
HRSG

Open FD fan O/L

damper once
FD fan reaches
80% of full load

2
Bharat Heavy Electricals Limited
Tiruchy 14

22

2
2
Open FD fan I/L damper

Total transfer
time < 35sec

Trip transfer
failed

Y
Trip transfer completed
Bharat Heavy Electricals Limited
Tiruchy 14

23

SOOT BLOWER CONTROLS

STEAM SOOT BLOWERS ARE

APPLICABLE FOR HRSGs USING
DIRTY FUELS SUCH AS FURNACE
OIL OR LSHS IN THE
SUPPLEMENTARY FIRING SYSTEM.

Bharat Heavy Electricals Limited

Tiruchy 14

24

SOOT BLOWER CONTROLS

- CONTD.
Soot Blowers Are Sequentially Operated.
To Facilitate This, Microprocessor Based
PLC Panel Is Provided.

Bharat Heavy Electricals Limited

Tiruchy 14

25

INSTRUMENTATION
USED
PRESSURE GAUGES,TEMPERATURE
GAUGES
PRESSURE ,FLOW,TEMP,LEVEL
TRANSMITTERS
T/C,RTDs
SO2,NOx,HC,SPM, pH,COND,SILICA
POSITION TRANSMITTERS,I/P
CONVERTERS
Bharat Heavy Electricals Limited
Tiruchy 14

26

FUNCTIONAL BLOCKS

Bharat Heavy Electricals Limited

Tiruchy 14

27

MIDDLE VALUE
SELECTION
ASSUMED THAT ATLEAST 2
TRANSMITTERS WILL BE O.K

Bharat Heavy Electricals Limited

Tiruchy 14

28

AVERAGING
DEVIATION ALARM IS
NECESSARY
SWITCHING OVER TO HEALTHY
INSTRUMENTS NECESSARY

Bharat Heavy Electricals Limited

Tiruchy 14

29

COMPENSATION
PRESSURE COMPENSATION FOR
DRUM LEVEL
PRESSURE &TEMP COMPENSATION
FOR STEAM FLOW
TEMP COMPENSATION FOR FEED
WATER FLOW
Bharat Heavy Electricals Limited
Tiruchy 14

30

MAJOR ANALOG CONTROLS

A)
B)
C)
D)

Drum Level Control (3 Element)

Steam Temperature Control
Supplementary Firing Control
CBD Tank Level Control

Bharat Heavy Electricals Limited

Tiruchy 14

31

ANALOG CONTROL MODE

AUTO
MANUAL

Bharat Heavy Electricals Limited

Tiruchy 14

32

AUTO MODE OF CONTROL

PROPORTIONAL ,INTEGRAL
&DERIVATIVE

Bharat Heavy Electricals Limited

Tiruchy 14

33

DRUM LEVEL
HIGH TRIP-175MM
HIGH ALARM -100 MM
NWL
LOW ALARM 260 MM
LOW TRIP - 406 MM

Bharat Heavy Electricals Limited

Tiruchy 14

34

DRUM LEVEL CONTROL

(DRUM)
CONTROLLER

MAIN STEAM
FLOW

LEVEL

S.P

FEED WATER
FLOW

CONTROLLER

CONTROL

30%
FEED CONTROL VALVE

FEED CONTROL VALVE

Bharat Heavy Electricals Limited
Tiruchy 14

100%

35

DRUM LEVEL CONTROL

(3 ELEMENT)
1 Drum Level Is Compared Against Set Point
In First Controller
2 This Drum Level Deviation Signal Is Added
To Main Steam Flow Signal And Forms The
Set Point For Second Controller Which
Controls The Feed Control Valve.
3 Feed Water Flow Signal Is The Feedback.
Bharat Heavy Electricals Limited
Tiruchy 14

36

STEAM TEMPERATURE CONTROL

SH-I

DESUPER HEATER

MAIN STEAM

TURBINE

TE

SPRAY CONTROL
VALVE

SETPOIN
T

CONTROLLER

FEED WATER

Bharat Heavy Electricals Limited

Tiruchy 14

37

STEAM TEMPERATURE CONTROL

Main Steam Temperature Is Compared

Against Set Point In The Controller.

Desuperheating Spray Control Valve Is
Positioned As Per The Deviation Between
Set Point And The Prevailing Temperature
Value.

Bharat Heavy Electricals Limited

Tiruchy 14

38

From drum

CBD
TANK

CBD TANK LEVEL

SET POINT

LEVEL

controller

Bharat Heavy Electricals Limited

Tiruchy 14

39

CBD TANK LEVEL CONTROL

The CBD Tank Level Is Compared

Against Set Point In Controller.

Drain Control Valve Is Positioned As Per
The Deviation Between Set Point And
Prevailing Level.

Bharat Heavy Electricals Limited

Tiruchy 14

40

SUPPLEMENTARY FIRING CONTROL

Main Steam Pressure Is Compared Against Set

Point In Master Controller To Generate Fuel

Demand.
Steam Flow Signal Is Given As Anticipatory
Signal. That Is, Added To Fuel Demand.
The Fuel Demand Is Routed To Fuel Oil/gas
Controllers For Positioning The Fuel Control
Valves. Fuel Oil Gas Flow Is The Feed Back.
Bharat Heavy Electricals Limited
Tiruchy 14

41

ANALYSERS

PH
CONDUCTIVITY
SILICA

SO2
NOx
HC
SPM

Bharat Heavy Electricals Limited

Tiruchy 14

42

SO2,NOx,HC

SO2

NOx

HC

Bharat Heavy Electricals Limited

Tiruchy 14

43

SO2, NOx
MEASURING BY :
NDIR ABSORPTION.
WAVE LENGTH:
2.5 TO 8 MICROMETER

Bharat Heavy Electricals Limited

Tiruchy 14

44

HC
MEASURING TECHNIQUES-FID

Bharat Heavy Electricals Limited

Tiruchy 14

45

COMPONENTS OF SO2,NOx
& HC ANALYSER

ANALYSER MODULES
PNEUMATIC MODULES
ELECTRONICS MODULES
I/O MODULES
POWER SUPPLY MODULES
DISPLAY&CONTROL MODULE
SYSTEM BUS
Bharat Heavy Electricals Limited
Tiruchy 14

46

FUNCTONS OF
ELECTRONICS MODULE
PROCESSING &COMMUNICATING PVS
COMPENSATING MEASURED VALUES
CALIBRATION
DIPLAY & CONTROL FUNCTIONS
CONTROL ASSOCIATED SYSTEM
COMMUNICATING WITH EXTERNAL
SYSTEMS
Bharat Heavy Electricals Limited
Tiruchy 14

47

COMPONENTS OF SAMPLING
SYSTEM-SO2,NOx & HC1/2

PROBE
FILTERS
HEATED SAMPLE TRANSPORT TUBE
SCAVENGING PANEL
PUMPS
SAMPLE COOLERS
CONDENSATE MONITOR
Bharat Heavy Electricals Limited
Tiruchy 14

48

COMPONENTS OF SAMPLING
SYSTEM SO2,NOx & HC2/2

FLOW INDICATOR
PRESSURE REGULATOR
CALIBRATION CYLINDERS
ANALYSERS
PLC

Bharat Heavy Electricals Limited

Tiruchy 14

49

NOTES
HEAT TRACE
TO KEEP THE GAS
SAMPLE ABOVE ACID DEW
POINT(150 Deg C)
COOLER
TO ELIMINATE
MOISTURE BY BRINGING TEMP TO
2 TO 4 Deg C.

Bharat Heavy Electricals Limited

Tiruchy 14

50

DUST & OPACITY MONITOR

BEER LAMBERTS LAW
Transmittance = Intensity of light in medium
Intensity of light out of medium
=e-attenuation coefficient x concentration of pollutant x distance of medium

Bharat Heavy Electricals Limited

Tiruchy 14

51

GENERAL INSTALLATION
Light Source Io

Sp
lit

ter

Reflector

Detector
Bharat Heavy Electricals Limited
Tiruchy 14

52

SWAS
PH
CONDUCTIVITY
SILICA

Bharat Heavy Electricals Limited

Tiruchy 14

53

SHS FOR PH &

CONDUCTIVITY

SAMPLE COOLERS
PRESSURE REDUCER
FLOW INDICATORS
CAT ION COLUMNS

Bharat Heavy Electricals Limited

Tiruchy 14

54

NOTES-

1/3

PH-TO KNOW ACIDITY/ALKALINITY

& TREAT WATER
CONDUCTIVITY-TO KNOW IMPURITY,
EFFECTIVE CHECKON TDS&
EXERCISE BD
CATION CONDUCTIVITY-MORE
ACCURATE RELATIONSHIP BETWEEN
LEVEL OF CONTAMINANTS Vs
TREATMENT CHEMICALS
Bharat Heavy Electricals Limited
Tiruchy 14

55

NOTES-

2/3

IN OTHER WORDS NORMAL

CONDUCTIVITY IS GENERAL
PURPOSE MEASURE OF DETECTING
CONTAMINATION,HENCE CAN NOT
DISTINGUISH BETWEEN EFFECTS OF
REAL CONTAMINANTS & AND
MASKING EFFECTS OF TREATMENT
CHEMICALS.
Bharat Heavy Electricals Limited
Tiruchy 14

56

NOTES-

3/3

CATION-TO KNOW THE TOTAL

IONISED INORGANIC IMPURITIES
DISSOLVED IN W&S
IT ENABLES THE MEASUREMENT OF
PARTICULAR IONS WHICH WOULD
NORMALLY BE MASKED BY THE
PRESENCE OF OTHER IONS.
Bharat Heavy Electricals Limited
Tiruchy 14

57

SILICA ANALYSERS
TO KNOW THE SILCA DEPOSITS ON
TUBES,TURBINE BLADES.

Bharat Heavy Electricals Limited

Tiruchy 14

58

SILICA ANALYSERS
SOLUBLE SILICA + AMMONIUM
MOLYBDATE
GIVES SILICOMOLYBDATE(Yellow)
ADD Agents
GIVES MOLIBDINAM (STRONG
BLUE)
PASS THROUGH PHOTOMETER
MEASURE OPTICAL DENSITY BY IR
LIGHTAT 820 nm
Bharat Heavy Electricals Limited
Tiruchy 14

59

SHS FOR SILICA-1/2

Reagent bottles for
Sulphuric acid
Ammonium Molibdate
Oxalic Acid
Fe II reducing agent

5 channel Peristaltic Pump

Bharat Heavy Electricals Limited

Tiruchy 14

60

SHS FOR SILICA-2/2

Delay Coils
5 min
30 Sec
60 sec

Photometer

Bharat Heavy Electricals Limited

Tiruchy 14

61

SILICA
Sample flow:180 ml/hr
Each reagents flow:9 ml/hr
Sulphuric acid +sample to pass
through 5 min delay coil.
This solution to be treated with oxalic
acid to reduce interference of
phospates & increase blue.
Bharat Heavy Electricals Limited
Tiruchy 14

62

Silica
Add Ferrous -ii reducing agent and pass
through 60 sec delay coil.
Finally to photometer.

Bharat Heavy Electricals Limited

Tiruchy 14

63

AREAS THAT NEED

ATTENTION.

ADEQUATE COOLING WATER

ADEQUATE SAMPLE FLOW
QUALITY OF COOLING WATER
NO LEAKAGE OF SAMPLE, COOLING
WATER & REFREGIRANT GAS
NO CHOCKING OF FILTERS
PERIODICAL MAINTENANCE
Bharat Heavy Electricals Limited
Tiruchy 14

64

TRICHY SCOPE
ELECTRICAL
INSTRUMENTATION

Bharat Heavy Electricals Limited

Tiruchy 14

65

ELECTRICAL-SCOPE 1/1

POWER CABLES
CONTROL CABLES
HRSG MCC
CABLE TRAYS-LADDER TYPE
MOTOR OPERATED VALVES

Bharat Heavy Electricals Limited

Tiruchy 14

66

INTELLIGENT ACTUATORS
Position
processor

Position

Set position
limits
Position
limits

Hall effect
sensor

Gate
array

Torque
limits
Torque
processor

Flux
Current

Infra-red
interface
processor

Set torque
limits
Torque

Bharat Heavy Electricals Limited

Tiruchy 14

67

INSTRUMENTATION-SCOPE
1/2

PRESSURE GAUGES
TEMPERATURE GAUGES
THERMOCOUPLES
RTDs
PRESSURE & DIFFERENTIAL
PRESSURE TRANSMITTERS
TEMPERATURE TRANSMITTERS
Bharat Heavy Electricals Limited
Tiruchy 14

68

INSTRUMENTATION-SCOPE
2/2
INSTRUMENT CABLES
PH, CONDUCTIVITY& SILICA
ANALYSERS
SO2,NOx &HC ANALYSERS
SMOKE DENSITY ANALYSERS

Bharat Heavy Electricals Limited

Tiruchy 14

69

SALIENT FEATURES-1/7
POWER& CONTROL& INST CABLES
-EXTRUDED PVC TYPE 1+FRLS
OUTER SHEATH,ARMOURED

Bharat Heavy Electricals Limited

Tiruchy 14

70

SALIENT FEATURES-2/7
ALL CABLES CONFIRMING TO

OXYGEN INDEX- MIN 29%

TEMPERATURE INDEX 250 DEG C
SMOKE DENSITY- 60%
ACID GAS GENERATION- MAX 20%
FLAMILITY-MIN 300 MM/FLAME
SHOULD NOT REACH TOP OF TRAY
Bharat Heavy Electricals Limited
Tiruchy 14

71

SALIENT FEATURES-3/7
3 ELEMENT DRUM LEVEL
CONTROL
GAS TEMP MEASUREMENTS FROM
TOP OF DUCT AT CRITICAL
POSITIONS

Bharat Heavy Electricals Limited

Tiruchy 14

72

SALIENT FEATURES-4/7
TRANSMITTERS-SMART
LT MOTORS&ACTUATORS-SQ.CAGE
INDUCTION
ACTUATORS-INTEGRAL STARTERS
MCC-DRAW OUT,DOUBLE FRONT

Bharat Heavy Electricals Limited

Tiruchy 14

73

SALIENT FEATURES-5/7
PGs WITH +/- 0.5% ACCURACY
PGs WITH 130%OPR
PGs WITH DRAWN TYPE BOURDON
FOR PRES LESS THAN 70 KG/SqCM
PGs WITH BORED TYPE BOURDON
FOR PRES MORE THAN 70

Bharat Heavy Electricals Limited

Tiruchy 14

74

SALIENT FEATURES-6/7

IMMERSION LENGTH-280/320 MM
MINIMUM FLANGE RATING -#300
THERMOWELLS FOR PP-SS 316
THERMOCOUPLES FOR METAL
TEMPERATURE MEASUREMENT
RTDS-3 WIRE,Pt-100
THERMOWELLS-FLANGED
Bharat Heavy Electricals Limited
Tiruchy 14

75

SALIENT FEATURES-7/7
PROTECTING TUBES FOR NPP-SS 446
THERMOCOUPLES- K TYPE ,
GROUNDED

Bharat Heavy Electricals Limited

Tiruchy 14

76

SELECTION THERMOCOUPLES
BY TEMP

IRON/CONS(J)
CR/AL(K)
PL 10%RH/PL(S)
PL 13%RH/PL(R)
PL 30%RH/PL 6 %
RH(R)E

600 Deg C
1200 Deg C
1600 Deg C
1600 Deg C
1750 Deg C

Bharat Heavy Electricals Limited

Tiruchy 14

77

SELECTION OF SHEATH
MATERIAL FOR TEMP SENSORS
METAL

MAX RECO

MELTING

SS316

899

1371

SS304

899

1427

SS446

1093

1399

SS310

1093

1399

INCONEL

1149

1427

INCONEL702 1316

1410

Bharat Heavy Electricals Limited

Tiruchy 14

78

Bharat Heavy Electricals Limited

Tiruchy 14

79