Combustion control:

Maintain proper, efficient fuel/air ratios.

Combustion optimization is achieved through automatic adjustment of
unit air flow
demand in response to measured flue gas O2. The setpoint to a PI
oxygen controller is

Table of main thermal data at 100% TMCR with references site

conditions

Boiler Firing System

The fuel firing system consists of:
 Four tangential fired windboxes;
 Separated Over Fire Air (SOFA) windboxes,
 Ignition system;
 Scanners.
Tangential Firing System the fuel and air are directed towards the
tangent of an
imaginary circle in the centre of the furnace. During
Here are some of the specific benefits of using a SOFA system:

 Reduced NOx emissions: By providing additional control over the

combustion process, SOFA systems can significantly reduce NOx
emissions, often by 20-50% or more. This can help power plants
comply with environmental regulations and improve air quality.

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  Improved combustion efficiency: SOFA systems can also help to
improve overall combustion efficiency by providing better mixing of
air and fuel. This can lead to reduced fuel consumption and lower
operating costs.

Air and Flue Gas Systems:

The air and fuel gas systems are designed to provide combustion air,
cooling air, sealing air, and to remove the flue gases resulting from the
combustion.

Two Primary Air fans provide the primary air stream to the pulverizers for
drying and
transporting the coal to the boiler burners. The primary air stream is
heated in two rotary
Air Pre Heaters against the boiler exhaust flue gas.
Two Forced Draft fans provide the secondary air for combustion. The
secondary air from
each Forced Draft fan is directed through a set of Steam Coil Air Heater
and then this
preheated air is raised to higher temperatures by the flue gases in the
rotary Air Pre
Heaters.
Two Induced Draft fans remove flue gasses from the furnace while
controlling a furnace
pressure to slightly below atmospheric. The flue gas stream leaving the
boiler is cleaned
by reducing the SO3 and NOx content in the Selective Catalytic
Reduction system. The
flue gas, transported by the induced draft fan is cooled in the rotary Air
Pre Heaters. The
Induced Draft fans are located downstream of the electrostatic
precipitator and deliver the
flue gas to the stack via the seawater flue gas desulfurization system.
Selective Catalytic Reduction System
The NOx emissions are controlled by the low NOx firing system and the
Selective Catalytic

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Reduction System, using anhydrous ammonia. The flue gas NOx is
reduced by mixing.
ammonia vapor at the boiler outlet. The Selective Catalytic Reduction
System is composed.of layers of catalyst and a catalyst chamber.

Differentiate between analog and digital signals.

Analog signals are continuous and vary, while digital signals are
discrete and represented as binary values.

What is the HART protocol used for?

HART protocol enables communication with smart devices,

allowing digital and analog data exchange for diagnostics and
control.

HART (Highway Addressable Remote Transducer) Protocol is an open

standard used globally to send and receive digital information using
analogy wiring between smart devices and control systems. With over 30
million devices installed, it is the most popular protocol used in the field.

Difference between 2-wire, 3-wire, and 4-wire

transmitter.

In a 2-wire transmitter, power and signal are transmitted

through one common cable. In a 3-wire transmitter, data signal
and power are always proportional to the common ground. In a
4-wire transmitter, 2 wires are used for power supply, and two
separate ones are used for signals.

What’s the purpose of a control loop?

Control loops adjust processes by continuously measuring

variables and making corrections to maintain desired setpoint

Discuss the importance of Intrinsically Safe (IS)

equipment.

IS equipment preventing sparks and explosions in hazardous

areas, ensuring safety when using electronic instruments.

How do you prevent electromagnetic interference

(EMI) in instrument systems?

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Shielding cables and using twisted pairs minimize EMI, ensuring accurate
measurements and reliable instrument operations.

What’s the function of a signal isolator in an

instrumentation system?
A signal isolator protects instruments from voltage fluctuations and ground
loops, ensuring accurate measurements and safe operation.

Explain PID Control in Instrumentation.

Answer: PID control (Proportional-Integral-Derivative) adjusts process

variables by considering proportional, integral, and derivative terms. It
maintains desired setpoints, enhancing accuracy and stability in industrial
systems.

Can you describe the working principle of a thermocouple?

A thermocouple works on the principle of the Seebeck effect. It generates a

voltage when its junction of two different metals is heated or cooled.

What is the difference between PLC and DCS?

PLC (Programmable Logic Controller) is ideal for discrete control tasks,

while DCS (Distributed Control System) is designed for process control
tasks. PLCs are used in applications that require robustness, simplicity,
and a lower cost. DCSs are preferred for complex control processes where
coordination between various processes is necessary.

What is a 4-20mA signal and why is it widely used in industrial

control systems?

A 4-20mA signal is a type of electrical current loop used in control

systems. It is preferred because it can overcome the resistance of the line,
is less susceptible to noise, and can provide a ‘live zero’ signal, where 4mA
represents the lowest measurable value, and zero current indicates a fault.

What is the difference between intrinsic safety and

explosion-proof?
Intrinsic safety refers to equipment and wiring that is inherently safe. In
other words, in an explosive atmosphere, it is incapable of causing an
explosion. On the other hand, explosion-proof equipment is designed to
prevent an internal spark or explosion from causing a much larger blast.

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What is a servo motor and where is it used?
A servo motor is a rotary actuator that allows for precise control of angular
position, velocity, and acceleration. It’s used in applications such as
robotics, CNC machinery, or automated manufacturing.

What is a fieldbus?
Fieldbus is a communication protocol used for real-time distributed
control of process or manufacturing automation. It allows for digital
communication between various field devices like sensors, actuators, and
controllers.

What is Profibus communication?

Profibus is a standard for fieldbus communication in automation
technology, initially promoted by Siemens. It’s used to exchange data
between controllers and devices such as I/O devices, transducers, drives,
etc.

What is the purpose of a flame scanner in a boiler?

A flame scanner is used in a boiler to monitor the flame condition, typically
using ultraviolet or infrared sensors. It ensures that a flame is present when
fuel is being burned and triggers a shutdown if the flame goes out to
prevent a dangerous situation.

Can you explain the principle of operation of a

radar-level transmitter?
A radar-level transmitter works on the principle of time-of-flight. It sends a
radar pulse toward the product surface, which then gets reflected back. The
time taken by the pulse to return is proportional to the distance and hence,
the level of the product.

What is a Coriolis flow meter and how does it work?

A Coriolis flow meter measures the mass flow and density of a fluid based
on the Coriolis effect. It uses a vibrating tube, through which the fluid flows.
When the fluid moves through the vibrating tube, a Coriolis force acts on

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the tube, causing it to twist. This twisting is proportional to the mass flow
rate of the fluid.

How do you select a control valve for a specific

application?
Selecting a control valve for a specific application depends on factors such
as the type of fluid, flow rate, pressure, temperature, the desired flow
control characteristics, and the available actuation method.

What is the difference between a potentiometer and

a rheostat?
A potentiometer is a variable resistor with three terminals, used to measure
voltage, while a rheostat is a variable resistor with two terminals, used to
control current. Potentiometers are typically used for voltage division,
whereas rheostats are used for current control.

What is a turbidity meter?

A turbidity meter is a device that measures the cloudiness or haziness of a
liquid caused by suspended particles. It measures the intensity of light
scattered by the particles present in the fluid.

How does a conductivity meter work?

A conductivity meter works by measuring the ability of a solution to conduct
an electric current between two electrodes. The conductivity is directly
related to the concentration of ions in the solution, which can be used to
determine the concentration of a specific substance.

What is the principle of a pH meter?

A pH meter measures the hydrogen-ion activity in water-based solutions.
It uses a pH-sensitive electrode (usually glass) to measure the voltage
caused by the ion concentration, and this is used to determine the pH.

Can you explain Bernoulli’s principle in terms of

flow measurement?
Bernoulli’s principle states that an increase in the speed of a fluid occurs
simultaneously with a decrease in pressure. This principle is used in flow
measurement, where a restriction in the flow path causes an increase in

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fluid velocity and a decrease in pressure. This pressure difference can then
be used to calculate the flow rate.

What is a vibration sensor and how does it work?

A vibration sensor, also known as a vibration transducer, converts
vibrations into an electrical equivalent output. Common types of vibration
sensors include piezoelectric and accelerometer sensors. They work by
producing an electrical signal proportional to the vibration

How does a piezoelectric sensor work?

A piezoelectric sensor works based on the piezoelectric effect. When force,
pressure, or acceleration is applied to the sensor, it produces an electrical
charge that is proportional to the applied force.

What is the principle of a magnetic flow meter?

A magnetic flow meter, also known as a mag meter, measures flow by
using Faraday’s Law of electromagnetic induction. It applies a magnetic
field to a conductive fluid flow, and the voltage induced across the fluid flow
is proportional to its velocity.

Difference between 2 wire, 3 wire and 4 wire transmitter.

In 2 wire transmitter the power and signal are transmitted through same
cable.
In 3 wire transmitter the data signal and power are with respect to
common ground.
In 4 wire transmitter two wires for power supply and two for signals.

What is Field bus ?

Fieldbus is a general term for a digital only, high speed communications

protocol. The key attribute to Fieldbus communications is higher speed
communications with the possibility of addressing multiple transmitters all
on the same field wiring.

What is Cold Junction compensation?

The industry accepted standard for the temperature at open end is 0 deg
C. Therefore most tables and chart make the assumption that the temp at
open end is 0 deg C. In industry the open ends are always at actual room
temperature and not 0 deg C.

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In a PID Controller, P stands for Proportional, I stands for Integral, and D
stands for Derivative.

The PID Controller is responsible for ensuring that the Process remains as
close to the desired value as possible regardless of various disruptions.

– The PID controller determines how much and how quickly correction is
applied by using varying amounts of P, I, and D action.

– The proportional block creates an output signal proportional to the

magnitude of the Error Signal.

– The integral block creates an output proportional to the duration and

magnitude of the Error Signal.

– The derivative block creates an output signal proportional to the rate of

change of the error signal.

– Controller Tuning involves correctly setting the controller P, I, and D

values for specific process requirements either manually or automatically.

In temperature control loop tuning, the primary control method used is

often Proportional-Integral-Derivative (PID) control. PID controllers are
widely employed in industrial processes, including temperature control,
due to their ability to regulate systems with feedback.

Here's a brief overview of each component in a PID controller:

1. Proportional (P): This component responds to the current error,

which is the difference between the desired setpoint and the actual
temperature. The proportional term determines the immediate
response to a change in error.
2. Integral (I): The integral term considers the accumulation of past
errors over time. It helps eliminate any steady-state error that may
persist in the system.
3. Derivative (D): The derivative term anticipates future errors based
on the rate of change of the error. It helps prevent overshooting and
stabilizes the system.

The tuning of a PID controller involves adjusting the P, I, and D parameters

to achieve the desired balance between responsiveness and stability. The
tuning process is often iterative, and it may involve manual tuning or the
use of automated tuning methods.

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Apart from PID control, there are other advanced control strategies, such
as model predictive control (MPC), fuzzy logic control, and adaptive
control, which can be used in temperature control applications depending
on the specific requirements and characteristics of the system. However,
PID control remains a common and effective choice for many temperature
control applications due to its simplicity and robust performance in
various scenarios.

Modbus:
 A serial communication protocol commonly used in industrial
applications for communication between electronic devices. It is
often used in SCADA (Supervisory Control and Data Acquisition)
systems.

1. Voltage Drop Across the Resistor:

 In a typical 4-20 mA loop, a power supply provides a voltage
to the loop, and the loop resistor is connected in series with
the field device. According to Ohm's Law (V = I * R), the
voltage drop across the resistor is directly proportional to the
current flowing through it.
2. Current-to-Voltage Conversion:
 A 250-ohm resistor is chosen because it produces a voltage
drop of 1 volt when a current of 4 mA flows through it (4 mA *
250 ohms = 1 V). This voltage drop serves as a baseline or
"zero" reference for the analog signal.

CODES AND STANDARDS The plants will be designed, constructed and tested in
accordance with internationally recognized standards and codes for
instrumentation equipment or VENDOR standards that reflect best international
utility practice. In general terms, consistent set of standards will be used
throughout the plants. The latest edition of standards and codes will apply to the
project. To the extent reasonably possible, the standards used to design specific
facilities will also be used to inspect and test these facilities. International
Standards : ISO International Standardization Organization IEC International
Electro technical Commission ISA International Society of Automation Industry
Standards : ANSI American National Standards Institute DIN Deutsches Institut
Fur Normung EN European Norm National Standards : BS British Standard

Please provide kW of the related pump.EPC to note that the

requirement for pumps above 100kW as per MCMS specification
in EPC Contract is as below:

• Journal bearings shall have radial shaft relative

displacement sensors (X-Y probes) mounted at 45º from the
vertical centreline;

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• Bearing housings shall have a velocity seismic transducer
displaying vertical velocity in RMS; and

• Thrust bearings shall have dual probes with voting logic

monitoring the axial position.

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