AUTOMATION OF GAS CLEANING PLANT IN

BLAST FURNACE
A PROJECT REPORT

Submitted by

ERSHAD.C.H Reg NO:91304107004

RAJA.T Reg NO:91304107016
RAJASHRIRAM.V Reg NO:91304107017

in partial fulfillment for the award of the degree

of
BACHELOR OF ENGINEERING
IN

ELECTRONICS AND INSTRUMENTATION ENGINEERING

RVS COLLEGE OF ENGINEERING AND TECHNOLOGY

DINDIGUL

ANNAUNIVERSITY:CHENNAI 600 025

APRIL-2008
AUTOMATION OF GAS CLEANING PLANT IN
BLAST FURNACE
A PROJECT REPORT

Submitted by

ERSHAD.C.H Reg NO:91304107004

RAJA.T Reg NO:91304107016
RAJASHRIRAM.V Reg NO:91304107017

in partial fulfillment for the award of the degree

of
BACHELOR OF ENGINEERING
IN

ELECTRONICS AND INSTRUMENTATION ENGINEERING

RVS COLLEGE OF ENGINEERING AND TECHNOLOGY

DINDIGUL

ANNAUNIVERSITY: CHENNAI 600 025

APRIL-2008
 ANNAUNIVERSITY: CHENNAI- 600 025

BONAFIDE CERTIFICATE

Certified that this project report “AUTOMATION OF GAS CLEANING

PLANT IN BLAST FURNACE” is the bonafide work of
ERSHAD.C H
RAJA.T
RAJASHRIRAM.V
who carried out the project work under my supervision.

SIGNATURE
SIGNATURE
Mr.R.GANESAN Mr.M.VADIVEL
HEAD OF THE DEPARTMENT SUPERVISOR

Lecturer,
EIE Department, EIE Department,
RVS Nagar, RVS Nagar,
RVS CET, RVS CET,
Dindigul-5. Dindigul-5.

Submitted to the Viva-Voce Examination held on_________________.

Internal Examiner External Examiner

ii
 ACKNOWLEDGEMENT

We express our profound thanks to our Principal Prof. Dr.

C.G.RAVICHANDRAN M.E.,Ph.D., RVS College of Engineering and
Technology, for his kind cooperation in all aspects of our project work.

We are deeply obliged to Mr. R.GANESAN M.E.,(Ph.D), Head of

the Department, Department of Electronics And Instrumentation, for the
generous help and sustained interest throughout the period of project.

We express our deep sense of gratitude to our internal guide Mr.

M.VADIVEL, B.E., for his enthusiastic encouragement and continuous
support which helped us in finishing this project.

We are also grateful to Mr. RAVINDRA HEGDE, Senior Manager,

Electrical Department, JINDAL SOUTH WEST (SOUTHERN IRON
AND STEEL COMPANY LIMITED, Mettur) for guiding us to complete
our project successfully.

We extend our cordial thanks to all the staff members of the

Department of Electronics and Instrumentation Engineering of our college
for their continuous support and help throughout the course of the project

iii
 ABSTRACT

The objective of our project is “CLEANING THE BLAST FURNACE

GAS FROM DUST PARTICLES and automating the process using

PROGRAMMABLE LOGIC CONTROLLER”.

The blast furnace is using very hot gases for melting the ore. After the

heating process the hot air at the outlet of the blast furnace is called as the

blast furnace gas or BF gas. This BF gas is mixture of several gases like

CO2, CO, N2, O2, Hydrocarbons and dust. In order to recycle the BF gas for

running another blast furnace or for running a power plant the BF gas should

be separated from dust. For cleaning the BF gas from dust the ‘GAS

CLEANING PLANT’ is needed.

The PLC used here is SIEMENS SEMATIC S7 300. Continuous

controller is used on S7 300 PLC to control technical processes with

continuous input and output variables.

There are four separate processes involving six sequence of

operations. Three of them can be done in ON/OFF mode , then the rest of

them can be done in continuous mode.

iv
 TABLE OF CONTENTS
CHAPTER NO. TITLE PAGE NO.
ABSTRACT iv
LIST OF TABLE ix
LIST OF FIGURES x
LIST OF ABBREVIATIONS xii
1 Introduction 1
1.1 Objective 1
1.2 Major blocks in GCP 1
1.2.1 Block diagram 2
1.3 Overview of GCP processes 2
1.4 Role of PLC 3
1.5 How the objective of the project
is satisfied 4
2 Project description 5
2.1 Operation 5
2.2 P&I diagram 7
2.2.1 P&I instrument details 8
2.3 Description of individual blocks 10
2.3.1 Dust catcher 10
2.3.2 Quenching 11
2.3.3 Venturi scrubbers 14
2.3.4 Cyclonic separator 15
2.3.5 Seal pot 16
2.4 Measuring instrument details 18
2.4.1 Temperature measurement 18
vi
 2.4.1.1 Equipment details 18
2.4.1.2 Resistance thermometers 19
2.4.1.4 Thermocouple 24
2.4.2 Pressure sensors 27
2.4.2.1 Equipment details 27
2.4.2.2 Bourdon tube 28
2.4.2.3 Diaphragm 30
2.4.3 Flow meter 31
2.4.3.1 Equipment details 31
2.4.3.2 Orifice plate 33
2.4.4 Position sensors 35
2.4.4.1 Inductive sensor 35
2.4.4.2 LVDT 36
2.4.4.3 Hall effect sensor 39
2.4.5 Transmitter details 42
2.5 Valve details 44
2.5.1 Gate valves 44
2.5.2 Isolation valves 45
2.5.2.1 Ball valves 46
2.5.2.2 Butterfly valves 47
2.6 Actuator details 48
2.7 Programming instruments 55
2.7.1 PLC details 55
2.7.2 Siemens S7 300 PLC 59
2.7.3 PID Controller 63
2.8 Software details 66
vii
 2.8.1 Sequence of operation 66
2.8.2 Program 68
2.9 Advantages of GCP 70
3 3.1Conclusion 71
APPENDIX 72

REFERENCES 75

viii
 LIST OF TABLE

TABLE NO DESCRIPTION PAGE NO

1 P&I diagram symbols 8
2 P&I diagram control room signals 9
3 Temperature Transmitter details 18
4 Location of temperature transmitters 19
5 Temperature sensor details 19
6 Location of temperature sensors 19
7 Pressure gauge details (water line) 27
8 Location of pressure gauge (water line) 27
9 Pressure gauge details (gas line) 27
10 Location of pressure gauge (gas line) 27
11 Orifice plate details (water) 31
12 Location of orifice plate (water) 31
13 Orifice plate details (Gas) 32
14 Pressure/Flow/Differential pressure transmitter
details 42
15 Location of pressure/flow/differential pressure
transmitters: 43
16 S7 Modules 61
17 Arrangement of modules 61
18 Components of S7 PLC 62

ix
 LIST OF FIGURES
FIGURE NO DESCRIPTION PAGE NO
1.1 Block diagram 2
2.1 P&I diagram 7
2.2 Dust catcher 10
2.3 Quencher 12
2.4 Venturi scrubber 14
2.5 Cyclonic separator 15
2.6 Seal pot 17
2.7 RTD 21
2.7 RTD wire connection 22
2.9 Thermo couple 24
2.10 Membrane type manometer 29
2.11 Indicator slide with card and dial 29
2.12 Mechanical slide with Bourdon tube 29
2.13 Diaphragm 30
2.14 Flat-plate, Sharp-edge orifice 33
2.15 Orifice plate 33
2.16 Inductive sensor 35
2.17 LVDT 36
2.18 Working of LVDT 38
2.19 Hall effect sensor 40
2.20 Hall effect sensor 41
2.21 Gate valve 44
2.22 T and L type ball valves 46
2.23 Industrial electric actuator 48
x
2.24 Electric multi-turn actuator on gate valve 49
2.25 Electric part turn actuator on butterfly valve 50
2.26 PLC 55
2.27 Block of PLC 57
2.28 S7 Modules 59
2.29 S7 Module arrangements 60
2.30 Block diagram of PID Controller 64
2.31 PLC Program 68

xi
 LIST OF ABBREVIATIONS
ABBREVIATIONS EXPANSIONS PAGE
GCP Gas Cleaning Plant 1
BF Blast Furnace 1
P&I Process and Instrumentation 8
RTD Resistance Temperature Detectors 19
LVDT Linear Variable Differential Transformer 36
PLC Programmable Logic Controller 55
PID Proportional Integral Derivative Controller 63

xii
 CHAPTER 1

1. INTRODUCTION

The blast furnace is using very hot gases for melting the ore. After the
heating process the hot air at the outlet of the blast furnace is called as the
blast furnace gas or BF gas. This BF gas is mixture of several gases like
CO2, CO, N2, O2, Hydrocarbons and dust.

1.1. OBJECTIVE:

Why GCP is used in Steel plants?

In order to recycle the BF gas for running another blast furnace or for
running a power plant the BF gas should be separated from dust. For
cleaning the BF gas from dust the ‘Gas cleaning plant’ is needed.
The BF gas coming out of the blast furnace is in the temperature range
of 15000C.When it is directly exposed to the atmosphere it gives rise to
serious thermal pollution. The BF gas consists of a lot of dust particles
which may also cause environmental problems.
The problems and hazards due to the direct exposure of BF gas to the
atmosphere can be minimized to a great extend by means of GCP.

1.2. MAJOR BLOCKS IN GCP:

The GCP will perform its operation using the following functional
blocks:
(1).Dust Catcher
(2).Quencher
(3).Venturies
(4).Cyclonic Separator
(5).Seal pot
1
1.2.1. BLOCK DIAGRAM:

Fig 1.1 Block Diagram

1.3. OVERVIEW OF GCP PROCESSES:

The dust catcher consists of a container in which there is a
suddenly bent tube. Due to the suddenly bent tube the velocity becomes
zero. When the velocity becomes zero the macro dust particles looses its
velocity and gets collected at the bottom of the dust catcher. It can be
removed periodically.
The quencher collects the BF gas from the dust catcher and sprays
water over it. Due to the sudden cooling using water as quenching agent
some amount of dust particles gets collected from the BF gas. The outlet of
the quencher is in the form of sludge. It can be removed using seal pot
periodically.
2
 Two venturies are used in the GCP. These venturies are supplied
with water and the BF gas. The water is sprayed over the BF gas so that
some amount of dust in BF gas gets eliminated in the form of sludge.
The cyclonic separator is having fan which can be rotated with high
speed. Water is passed through it. This will eliminate the remaining dust
particles in the form of sludge.
The seal pot is used for removing the sludge from the quencher,
venturi1 and cyclonic separator. The gate valve at the bottom of the seal pot
should be opened manually for every two hours to remove the sludge
collected in it. The sludge will be removed partially every time. The space in
the removed area should be filled with water in order to control the leakage
of hazardous BF gas.

1.4. ROLE OF PLC:

The various signals collected from the sensors and transmitters are sent
to the PLC using two wire 4-20mA transmission lines.
The PLC can be programmed logically for the automatic operation of
the GCP. There are three set of digital sequence of operations that can be
programmed by using the Siemens S7 300 PLC.
There are another three controlling operations which can be done
through PID controllers. According to the inputs and outputs, the PLC may
switch the controllers.
The signals from temperature, pressure and flow transmitters which
can also be fed to the PLC so that monitoring processes can be done in the
control room.

3
1.5. How the objective of the project is satisfied:
There are various digitally operated valves and pumps at various
stages of gas cleaning process that can be directly operated by logically
programming the PLC.
The analog controllers can be used to open and close the septum
valves and also it can be used for adjusting the venturi throat according to
the pressure ranges.
By doing these processes the objective of the project can be
achieved using the GCP.

4
 CHAPTER 2

2. PROJECT DESCRIPTION

2.1. OPERATION:
The gas generated in the blast furnace is taken to dust catcher, where
coarse suspended particles are separated out from gas. The semi clean gas,
i.e., the gas with finer suspended particles, from the dust catcher is then
passed through quencher and two venturi scrubbers positioned in series.

The first stage venturi is to be operated by manual control from remote

and local push buttons. The second stage venturi is having automatic control
to ensure set pressure drop across two venturies.

Both the venturies possesses electromechanical actuator for adjustment

of throat opening to keep the dust loading of 5mg/Nm3 in the final gas. Since
outlet gas from second venturi contains lot of moisture, the gas is taken in
the cyclonic separator for removal of moisture. Clean gas is then taken
finally to the blast stove. Adequate quantity of water is sprayed in quencher
and venturi scrubbers. Seal pots with sufficient dip length are provided at the
bottom of the quencher, venturi and cyclonic separator to prevent gas
leakage.

Septum valve is provided to regulate/ maintain BF top pressure over a

wide range of flow. The range of BF top pressure to be maintained also
varies from 0 to 1.5 kg/cm2.

5
 The pressure on down stream side is normally 800 to 1000mmWC.
Considering this it can be seen that the control range is very wide.

The septum valve is specially designed to operate in this wide range, at

the same time giving good controllability. Septum valve is the combination
of four number of specially designed butterfly valve.

The contaminated water from quencher and venturi scrubbers is

continuously removed for continuous operation without malfunctioning. The
operation of GCP is explained in the P&I diagram shown in the next page in
the figure2.1.

6
2.2. P&I DIAGRAM:

7
2.2.1 P&I INSTRUMENT DETAILS:
Table 1 P&I Diagram symbols:
Symbol Name of the Instrument
Gate valve(GV)
Isolation valve(IV)
Water pipe line
Signal line(4-20mA)
Display/Control on PLC

system
Diaphragm seal
Field instrument
Non return valve(NRV)
Electrical line
Digital signal
Control signal

8
Table 2 P&I Diagram control signals:
Tag name First affix Second affix Third affix
Level L
Flow F
Temperature T
Pressure P
Position Z
Differential DP
Pressure
Alarm A
High H
Low L
Transmitter T
Indicator I
Totalizer Q
Element E
Controller C
Manual HC

loader
Electrical EA
Actuator

9
2.3. DESCRIPTION OF INDIVIDUAL BLOCKS
The general description of individual blocks is explained in the
following:

2.3.1. DUST CATCHER:

The dust catcher is the instrument used to separate macro particles
from air or a gas. The dust catcher here used is dry type dust catcher.

Fig2.2 Dust catcher

This is the first step used in Gas cleaning plant (refer to fig-1).The
blast furnace gas at the outlet of blast furnace will contain large amount of
dust particles. The dusts in the BF gas are at various sizes. The GCP will
have dust catcher at its front to remove large sized dusts. The dust catching
process will have BF gas with higher pressure at its inlet. And so it will
travel with higher velocity.
10
 The dust catcher is constructed such that the narrow pipe consisting of
the BF gas is opened to an enlarged vessel. This in turn will suddenly
decrease the pressure of the BF gas (i.e. pressure=0).When the pressure is
zero; it will also make the velocity to zero. When the velocity=0 the macro
dust particles combined with BF gas will loose its grip and fell to the bottom
of the dust catcher. The BF gas without macro dust particles can be removed
through the outlet provided on the side of the dust catcher.
The macro dust particles are let to be collected at the bottom of dust
catcher. It can be removed through a hole provided at the bottom
periodically using the conveyor belt.The outlet of the Dust catcher is the BF
gas without macro dust particles.

2.3.2. QUENCHING:
Quenching refers to the rapid cooling process. But in GCP the
quenching process is used to remove the micro dust particle from BF gas.
The quenching is the first process in wet GCP.
The process consists of a large container in which the BF gas is
opened after passing the dust catcher. It consists of a sprayer supplied with
water. An outlet is provided at the middle portion of the side wall of
quencher to remove BF gas after completion of quenching process.
During the process, BF gas is allowed to pass from the top inside the
quencher. If the gases entering the scrubber are too hot, some liquid droplets
may evaporate before they have a chance to contact dust in the exhaust
stream, and others may evaporate after contact, causing captured particles to
become re-entrained.

11
 Fig2.3 Quencher

Water is supplied to the sprayer continuously. The BF gas is sprayed

with water. When water is sprayed with very high velocity, it will pick of
many micro dust particles mixed with BF gas. The moderately cleaned BF
gas is then sent out through the outlet provided for that.
The smaller dusts react with water to form slag. The slag is removed
through the outlet provided at the bottom. Slag should be removed
periodically using seal pot, without letting the Bf gas to pass out. In some
cases, quenching can actually save money.
Cooling the gases reduces the temperature and, therefore, the volume
of gases, permitting the use of less expensive construction materials and a
smaller scrubber vessel and fan.

12
 A quenching system can be as simple as spraying liquid into the duct
just preceding the main scrubbing vessel, or it can be a separate chamber (or
tower) with its own spray system identical to a spray tower.
Quenchers are designed using the same principles as scrubbers.
Increasing the gas-liquid contact in them increases their operational
efficiency. Small liquid droplets cool the exhaust stream more quickly than
large droplets because they evaporate more easily. Therefore, less liquid is
required. However, in most scrubbing systems, approximately one-and-a-
half to two and- a-half times the theoretical evaporation demand is required
to ensure proper cooling. Evaporation also depends on time; it does not
occur instantaneously.
Quenching with re-circulated scrubber liquor could potentially reduce
overall scrubber performance, since recycled liquid usually contains a high
level of suspended and dissolved solids. As the liquid droplets evaporate,
these solids could become re-entrained in the exhaust gas stream. To help
reduce this problem, clean makeup water can be added directly to the quench
system rather than adding all makeup water to a common sump.
Thus Quencher is helping the GCP to remove partially micro dust
particles from the BF gas.

13
2.3.3. VENTURI SCRUBBERS:
Venturi Scrubber is a compact scrubber. It comprises of convergent
inlet section, constricted throat followed by divergent outlet section.

Fig2.4 Venturi Scrubber

The scrubbing liquid is fed into the inlet section tangentially through a
number of pipes & ensures that entire surface area of section is flooded with
scrubbing liquid.
The dust laden gas enters the scrubber vertically from top &
immediately hits the film of scrubbing water where some separation takes
place. The Gas then enters the venturi throat which has annular shape. This
ensures that the highest possible volume of water is taken up by gas, which
becomes saturated in this area.
14
 At the narrowest cross section of throat there is a sharp tear off edge
where because of sudden change in gas speed the scrubbing water is
atomized into tiny droplets. Because of high relative speed between the gas /
dust mixture & the droplets the dust particles strike the droplets at high
speed & are entrained by them.

2.3.4. CYCLONIC SEPARATOR:

Cyclonic separation is a method of removing particulates from an air
stream, without the use of filters, through vortex, separation. Rotational
effects and gravity are used to separate mixtures of solids and fluids.

Fig2.5 Cyclonic Separator

15
 A high speed rotating air-flow is established within a cylindrical or
conical container called a cyclone. Air flows in a spiral pattern, beginning at
the top (wide end) of the cyclone and ending at the bottom (narrow) end
before exiting the cyclone in a straight stream through the center of the
cyclone and out the top. Larger (denser) particles in the rotating air stream
have too much inertia to follow the tight curve of the air stream and strike
the outside wall, falling then to the bottom of the cyclone where they can be
removed. In a conical system, as the rotating air-flow moves towards the
narrow end of the cyclone the rotational radius of the air stream is reduced,
separating smaller and smaller particles from the air stream. The cyclone
geometry, together with air flow rate, defines the cut point of the cyclone.
This is the size of particle that will be removed from the air stream with a
50% efficiency. Particles larger than the cut point will be removed with a
greater efficiency and smaller particles with a lower efficiency.

2.3.5. SEAL POT:

The seal pot is an instrument used to remove the slag from the GCP.
The instrument consists of inlet tube, outlet tube, collection cylinder, water
inlet tube and a manual gate valve.
The sprayed water quencher, venturi, cyclonic separator reacts with the
micro dust particles of BF gas forming slag. This slag formed should be
removed periodically for continuous operation of GCP. It can be removed
manually or logically programmed using the gate valve.

16
 Fig2.6 Seal Pot
The sprayed water quencher, venturi, cyclonic separator reacts with the
micro dust particles of BF gas forming slag. This slag formed should be
removed periodically for continuous operation of GCP. It can be removed
manually or logically programmed using the gate valve. There is a problem
when completely removing slag from seal pot. When it is fully removed the
CO gas will escape along with it. So it should be partially removed and
filling the free space left with water for precautionary operation. The Gate
valve must be opened every 2 hours and a half the amount of collected slag
should be removed by filling the remaining space with water. Thus Seal pot
doing a special work in GCP.
17
2.4. MEASURING INSTRUMENT DETAILS:
The instruments used for measuring temperature, pressure, flow and
position that are used for various measuring, sensing, controlling and
monitoring purposes are detailed in the following.

2.4.1. TEMPERATURE MEASUREMENT:

In GCP the instruments used for temperature measurement are
thermocouple and RTD.
2.4.1.1. EQUIPMENT DETAILS:
Table 3 Temperature Transmitter details:
Type Analog Electronics Microprocessor based
SMART system
Power supply 12-20VDC
Input RTD Pt100
Operating Temperature 50˚C
Accuracy + 0.2% of span
Output 4-20mA DC
Ambient Temperature limit 60˚C
Relative Humidity 95%
Indicator Digital
Case material Cast Aluminium
Electrical safety Safe
Electrical connection 1/2inch NPT(f)
Cold junction compensation No
Burn out protection Yes

18
Table 4 Location of Temperature Transmitters:
TT101 0-400˚C Quencher inlet Gas line
TT102 0-200˚C 1st Venturi outlet Gas line
TT103 0-200˚C GCP outlet Gas line
Table 5 Temperature Sensor details:
Element Platinum-Nickel
Type Simplex
Lead wire Silver
Insulation Mineral insulated
Sensor length 550mm
Extension length 75mm
Shape Tapered
Electrical 3wire & 1/2inch NPT
connection

Table 6 Location of Temperature Sensor:

TE101 0-400˚C Quencher inlet Gas line
TE102 0-200˚C First Venturi inlet
TE103 0-200˚C GCP outlet Gas line

2.4.1.2. RESISTANCE THERMOMETERS:

Resistance thermometers, also called resistance temperature detectors

(RTDs), are temperature sensors that exploit the predictable change in
electrical resistance of some materials with changing temperature. As they
are almost invariably made of platinum, they are often called platinum
resistance thermometers. They are slowly replacing the use of
thermocouples in many industrial applications below 600 °C.

19
There are two broad categories, "film" and "wire-wound" types.

• Film thermometers have a layer of platinum on a substrate; the layer

may be extremely thin, perhaps 1 micrometer. Advantages of this type
are relatively low cost and fast response. Such devices have improved
in performance although the different expansion rates of the substrate
and platinum give "strain gauge" effects and stability problems.
• Wire-wound thermometers can have greater accuracy, especially for
wide temperature ranges. The coil diameter provides a compromise
between mechanical stability and allowing expansion of the wire to
minimize strain and consequential drift.

How do resistance thermometers work?

Resistance thermometers are constructed in a number of forms and

offer greater stability, accuracy and repeatability in some cases than
thermocouples. While thermocouples use the Seebeck effect to generate a
voltage, resistance thermometers use electrical resistance and require a small
power source to operate. The resistance ideally varies linearly with
temperature. Resistance thermometers are usually made using platinum,
because of its linear resistance-temperature relationship and its chemical
inertness. The platinum detecting wire needs to be kept free of
contamination to remain stable. A platinum wire or film is supported on a
former in such a way that it gets minimal differential expansion or other
strains from its former, yet is reasonably resistant to vibration. RTD
assemblies made from iron or copper are also used in some applications.

20
Resistance Thermometers:

Resistance thermometer elements are available in a number of forms. The

most common are:Wire wound in a ceramic insulator - wire spiral within
sealed ceramic cylinder, works with temperatures to 850 °C

• Wire encapsulated in glass - wire around glass core with glass fused
homogenously around, resists vibration, more protection to the
detecting wire but smaller usable range
• Thin film - platinum film on ceramic substrate, small and inexpensive
to mass produce, fast response to temperature change

Resistance thermometer construction

Fig2.7 RTD

These elements nearly always require insulated leads attached. At low

temperatures PVC, silicon rubber or PTFE insulators are common to 250°C.
Above this, glass fibre or ceramic are used. The measuring point and usually
most of the leads require a housing or protection sleeve. This is often a metal
alloy which is inert to a particular process. Often more consideration goes in
to selecting and designing protection sheaths than sensors as this is the layer
that must withstand chemical or physical attack and offer convenient process
attachment points.

21
Resistance thermometer wiring configurations

Fig2.8 RTD Wire connection

The simplest resistance thermometer configuration uses two wires. It is only

used when high accuracy is not required as the resistance of the connecting
wires is always included with that of the sensor leading to errors in the
signal. Using this configuration you will be able to use 100 metres of cable.
This applies equally to balanced bridge and fixed bridge system.

Temperature to resistance equation

The relation between temperature and resistance is given by the Callendar-

Van Dusen equation,

Here, RT is the resistance at temperature T, R0 is the resistance at 0 °C, and

the constants (for an alpha=0.00385 platinum RTD) are

22
Since the B and C coefficients are relatively small, the resistance changes
almost linearly with the temperature.

Advantages of platinum resistance thermometers:

• High accuracy
• Low drift
• Wide operating range
• Suitability for precision applications

Limitations:

• RTDs in industrial applications are rarely used above 660 °C. At

temperatures above 660 °C it becomes increasingly difficult to
prevent the platinum from becoming contaminated by impurities from
the metal sheath of the thermometer. This is why laboratory standard
thermometers replace the metal sheath with a glass construction. At
very low temperatures, say below -270 °C (or 3 K), due to the fact that
there are very few phonons, the resistance of a RTD is mainly
determined by impurities and boundary scattering and thus basically
independent of temperature. As a result, the sensitivity of the RTD is
essentially zero and therefore not useful.
• Compared to thermistors, platinum RTDs are less sensitive to small
temperature changes and have a slower response time. However,
thermistors have a smaller temperature range and stability.

23
2.4.1.3. THERMOCOUPLE:

Fig2.9 Thermocouple

Thermocouple plugged to a multimeter displaying room temperature in

°C. In electronics and in electrical engineering, thermocouples are a widely
used type of temperature sensor and can also be used as a means to convert
thermal potential difference into electric potential difference. They are cheap
and interchangeable, have standard connectors, and can measure a wide
range of temperatures. The main limitation is accuracy; system errors of less
than one degree Celsius (°C) can be difficult to achieve.

Principle of operation

In 1821, the physicist Thomas Johann Seebeck discovered that when

any conductor (such as a metal) is subjected to a thermal gradient, it will
generate a voltage. This is now known as the thermoelectric effect or
Seebeck effect. Any attempt to measure this voltage necessarily involves
connecting another conductor to the "hot" end. This additional conductor
will then also experience the temperature gradient, and develop a voltage of
its own which will oppose the original.

24
 Fortunately, the magnitude of the effect depends on the metal in use.
Using a dissimilar metal to complete the circuit creates a circuit in which the
two legs generate different voltages, leaving a small difference voltage
available for measurement. That difference increases with temperature, and
can typically be between one and seventy microvolts per degree Celsius
(µV/°C) for the modern range of available metal combinations. Certain
combinations have become popular as industry standards, driven by cost,
availability, convenience, melting point, chemical properties, stability, and
output. This coupling of two metals gives the thermocouple its name. It is
important to note that thermocouples measure the temperature difference
between two points, not absolute temperature. In traditional applications,
one of the junctions the cold junction was maintained at a known (reference)
temperature, while the other end was attached to a probe.

Having available a known temperature cold junction, while useful for

laboratory calibrations, is simply not convenient for most directly connected
indicating and control instruments. They incorporate into their circuits an
artificial cold junction using some other thermally sensitive device, such as a
thermistor or diode, to measure the temperature of the input connections at
the instrument, with special care being taken to minimize any temperature
gradient between terminals. Hence, the voltage from a known cold junction
can be simulated, and the appropriate correction applied. This is known as
cold junction compensation. Additionally, a device can perform cold
junction compensation by computation. It can translate device voltages to
temperatures by either of two methods. It can use values from look-up tables
or approximate using polynomial interpolation.

25
 A thermocouple can produce current, which means it can be used to
drive some processes directly, without the need for extra circuitry and power
sources. For example, the power from a thermocouple can activate a valve
when a temperature difference arises. The electric power generated by a
thermocouple is a conversion of the heat energy that one must continuously
supply to the hot side of the thermocouple to maintain the electric potential.
The flow of heat is necessary because the current flowing through the
thermocouple tends to cause the hot side to cool down and the cold side to
heat up (the Peltier effect).

Thermocouples can be connected in series with each other to form a

thermopile, where all the hot junctions are exposed to the higher temperature
and all the cold junctions to a lower temperature. Thus, the voltages of the
individual thermocouple add up, which allows for a larger voltage and
increased power.

26
2.4.2. PRESSURE SENSORS:
In GCP Pressure sensors like Bourdon tube and Diaphragms are used.
They are listed below:

2.4.2.1. EQUIPMENT DETAILS:

Table 7 Pressure gauge details (water line):
Sensing element Bourdon tube
Process 1/2inch NPT M
connection
Accuracy +1.0% of span

Table 8 Location of pressure gauge (water line):

PI105 0-5Kg/cm² Quencher inlet water line
PI106 0-5Kg/cm² 1st Venturi inlet Water line
PI107 0-5Kg/cm² Separator inlet water line

Table 9 Pressure gauge details (gas line):

Sensing element Diaphragm
Process Flanged (40NB ANSI)
Table 10 Location of
connection pressure gauge (gas line):
Accuracy +1.6%of
PI101 0-12000mmWC Inletspan
of GCP
PI102 0-12000mmWC Inlet of 2nd Venturi
PI103 0-10000mmWC Inlet of septum valve
PI104 0-1000mmWC Outlet of GCP

27
2.4.2.2. BOURDON TUBE:

Fig2.10 Membrane-type manometer

A Bourdon gauge uses a coiled tube which as it expands due to pressure

increase causes a rotation of an arm connected to the tube.

A combination pressure and vacuum gauge (case and viewing glass

removed)

Fig2.11 Indicator Side with card and Fig2.12 Mechanical Side with Bourdon
dial tube

28
In 1849 the Bourdon tube pressure gauge was patented in France by Eugene
Bourdon.

The pressure sensing element is a closed coiled tube connected to the

chamber or pipe in which pressure is to be sensed. As the gauge pressure
increases the tube will tend to uncoil, while a reduced gauge pressure will
cause the tube to coil more tightly. This motion is transferred through a
linkage to a gear train connected to an indicating needle. The needle is
presented in front of a card face inscribed with the pressure indications
associated with particular needle deflections.

In a barometer, the Bourdon tube is sealed at both ends and the absolute
pressure of the ambient atmosphere is sensed. Differential Bourdon gauges
use two Bourdon tubes and a mechanical linkage that compares the readings.

In the following pictures the transparent cover face has been removed and
the mechanism removed from the case. This particular gauge is a
combination vacuum and pressure gauge used for automotive diagnosis:

• the left side of the face, used for measuring manifold vacuum, is
calibrated in centimeters of mercury on its inner scale and inches of
mercury on its outer scale.
• the right portion of the face is used to measure fuel pump pressure and
is calibrated in fractions of 1 kgf/cm² on its inner scale and pounds per
square inch on its outer scale.

29
2.4.2.3. DIAPHRAGM:

Fig2.13 Diaphragm
A pile of pressure capsules with corrugated diaphragms in an aneroid
barograph. A second type of aneroid gauge uses the deflection of a flexible
membrane that separates regions of different pressure. The amount of
deflection is repeatable for known pressures so the pressure can be
determined using by calibration. The deformation of a thin diaphragm is
dependent on the difference in pressure between its two faces. The reference
face can be open to atmosphere to measure gauge pressure, open to a second
port to measure differential pressure, or can be sealed against a vacuum or
other fixed reference pressure to measure absolute pressure. The
deformation can be measured using mechanical, optical or capacitive
techniques. Ceramic and metallic diaphragms are used.
Useful range: above 10-2 torr (roughly 1 Pa)

For absolute measurements, welded pressure capsules with

diaphragms on either side are often used.

Shape:

• Flat
• corrugated
• flattened tube
• capsule

30
2.4.3. FLOW METER:
In GCP the only flow meter used is Orifice meter.
2.4.3.1. EQUIPMENT DETAILS:
Table 11 Orifice plate details (water):
Application Scrubbing water to gas
Line size 150NB
Fluid Scrubbing water
Fluid state Re-circulated water with12% coal Iron Oxide dust
Temperature 55˚C
Upstream pressure 3Kg/cm²
Viscosity ˜0.6
Drain hole 1/2inch NPT with plug
Pressure taps 1inch NPTF

Table 12 Location of orifice plate (water):

Pressur Range Location Flow Normal Line ID/
e Thickness
100NB 0-60m³/hr Quencher inlet 0-50m³/hr 105.3mm/
Water line 4.5mm
150NB 0-130m³/hr 1st Venturi inlet 0-125m³/hr 155.4mm/
Water line 4.85mm
200NB 0-150m³/hr Separator inlet 0-140m³/hr 206.3mm/
Water line 6.35mm

31
Table 13 Orifice Plate details (Gas):
Application Gas cleaning plant outlet
Dust size 1400mm,ID 1mm Thick plate
Fluid Blast furnace gas with minute moisture & dust
Gas composition CO:16.15%

N2:55.19%

CO2:56.70%

H2O+HC:1.24%
Flow max/min 108000Nm³/hr,104000Nm³/hr
Temperature 45˚C
Specific gravity 0.96
Upstream pressure 800mmWC at 104000Nm³/hr
Orifice plate Concentric type
Thickness 6.35mm
Drain hole 1/2inch NPT
Pressure taps 1 inch NPT, On-Duct
Calibration Range 108000m³/hr
Location GCP Outlet

32
2.4.3.2. ORIFICE PLATE:

Fig2.14
Flat-plate, sharp-edge orifice

An orifice plate is a device used to measure the rate of fluid flow. It

uses the same principle as a Venturi nozzle, namely Bernoulli’s principle
which says that there is a relationship between the pressure of the fluid and
the velocity of the fluid. When the velocity increases, the pressure decreases
and vice versa.

Fig2.15

33
 An orifice plate is basically a thin plate with a hole in the middle. It is
usually placed in a pipe in which fluid flows. As fluid flows through the
pipe, it has a certain velocity and a certain pressure. When the fluid reaches
the orifice plate, with the hole in the middle, the fluid is forced to converge
to go through the small hole; the point of maximum convergence actually
occurs shortly downstream of the physical orifice, at the so-called vena
contracta point (see drawing to the right). As it does so, the velocity and the
pressure changes. Beyond the vena contracta, the fluid expands and the
velocity and pressure change once again. By measuring the difference in
fluid pressure between the normal pipe section and at the vena contracta, the
volumetric and mass flow rates can be obtained from Bernoulli's equation.

34
2.4.4. POSITION SENSORS:

2.4.4.1. Inductive sensor

Fig2.16 Inductive sensor

An inductive sensor is an electronic proximity sensor, which detects
metallic objects without touching them. The sensor consists of an induction
loop. Electric current generates a magnetic field, which collapses generating
a current that falls asymptotically toward zero from its initial level when the
input electricity ceases. The inductance of the loop changes according to the
material inside it and since metals are much more effective inductors than
other materials the presence of metal increases the current flowing through
the loop. This change can be detected by sensing circuitry, which can signal
to some other device whenever metal is detected.Common applications of
inductive sensors include metal detectors, traffic lights, car washes, and a
host of automated industrial processes. Because the sensor does not require
physical contact it is particularly useful for applications where access
presents challenges or where dirt is prevalent. The sensing range is rarely
greater than 6cm, however, and it has no directionality.
35
2.4.4.2. Linear variable differential transformer

Fig2.17 LVDT

Cut away view of an LVDT. Current is driven through the primary coil
at A, causing an induction current to be generated through the secondary
coils at B.
L:inear variable differential transformer (LVDT) is a type of electrical
transformer used for measuring linear displacement. The transformer has
three solenoid coils placed end-to-end around a tube. The centre coil is the
primary, and the two outer coils are the secondary. A cylindrical
ferromagnetic core, attached to the object whose position is to be measured,
slides along the axis of the tube. An alternating current is driven through the
primary, causing a voltage to be induced in each secondary proportional to
its mutual inductance with the primary. The frequency is usually in the range
1 to 10 kHz.
As the core moves, these mutual inductances change, causing the
voltages induced in the secondary to change. The coils are connected in
reverse series, so that the output voltage is the difference (hence
"differential") between the two secondary voltages.
36
 When the core is in its central position, equidistant between the two
secondary, equal but opposite voltages are induced in these two coils, so the
output voltage is zero.
When the core is displaced in one direction, the voltage in one coil
increases as the other decreases, causing the output voltage to increase from
zero to a maximum. This voltage is in phase with the primary voltage. When
the core moves in the other direction, the output voltage also increases from
zero to a maximum, but its phase is opposite to that of the primary. The
magnitude of the output voltage is proportional to the distance moved by the
core (up to its limit of travel), which is why the device is described as
"linear". The phase of the voltage indicates the direction of the displacement.
Because the sliding core does not touch the inside of the tube, it can move
without friction, making the LVDT a highly reliable device. The absence of
any sliding or rotating contacts allows the LVDT to be completely sealed
against the environment.
LVDTs are commonly used for position feedback in servomechanisms,
and for automated measurement in machine tools and many other industrial
and scientific applications

LVDT Working Principle

The LVDT, Linear Variable Differential Transformer is a well
established transducer design which has been used throughout many decades
for the accurate measurement of displacement and within closed loops for
the control of positioning. In its simplest form, the design consists of a
cylindrical array of primary and secondary windings with a separate
cylindrical core which passes through the centre.
37
 Fig2.18 Working of LVDT
The LVDT, Linear Variable Differential Transformer is a well established
transducer design which has been used throughout many decades for the
accurate measurement of displacement and within closed loops for the
control of positioning. In its simplest form, the design consists of a
cylindrical array of a primary and secondary windings with a separate
cylindrical core which passes through the centre. (Fig A)The primary
windings (P) are energized with a constant amplitude A.C. supply at a
frequency of 1 to 10 kHz. This produces an alternating magnetic field in the
centre of the transducer which induces a signal into the secondary windings
(S & S) depending on the position of the core.
38
 Movement of the core within this area causes the secondary signal to
change (Fig B). As the two secondary windings are positioned and
connected in a set arrangement (push-pull mode), when the core is
positioned at the centre, a zero signal is derived. Movement of the core from
this point in either direction causes the signal to increase (Fig C). As the
windings are wound in a particular precise manner, the signal output has a
linear relationship with the actual mechanical movement of the core. The
secondary output signal is then processed by a phase-sensitive demodulator
which is switched at the same frequency as the primary energizing supply.
This results in a final output which, after rectification and filtering, gives
D.C. or 4-20mA output proportional to the core movement and also
indicates its direction, positive or negative from the central zero point (Fig
D).
The distinct advantage of using an LVDT displacement transducer is
that the moving core does not make contact with other electrical components
of the assembly, as with resistive types, as so offers high reliability and long
life. Further, the core can be so aligned that an air gap exists around it, ideal
for applications where minimum mechanical friction is required. The LVDT
design lends itself for easy modification to fulfill a whole range of different
applications in both research & industry.

2.4.4.3. Hall Effect sensor

A Hall Effect sensor is a transducer that varies its output voltage in
response to changes in magnetic field. Hall sensors are used for proximity
switching, positioning, speed detection, and current sensing applications.
In its simplest form, the sensor operates as an analogue transducer, directly
returning a voltage. With a known magnetic field, its distance from the Hall
plate can be determined.

39
Using groups of sensors, the relative position of the magnet can be deduced.

Fig2.19 Hall effect sensor

The magnetic piston (1) in this pneumatic cylinder will cause the Hall effect
sensors (2 and 3) mounted on its outer wall to activate when it is fully
retracted or extended.
A Hall Effect sensor is a transducer that varies its output voltage in
response to changes in magnetic field. Hall sensors are used for proximity
switching, positioning, speed detection, and current sensing applications.
In its simplest form, the sensor operates as an analogue transducer, directly
returning a voltage. With a known magnetic field, its distance from the Hall
plate can be determined. Using groups of sensors, the relative position of the
magnet can be deduced. Electricity carried through a conductor will produce
a magnetic field that varies with current, and a Hall sensor can be used to
measure the current without interrupting the circuit.
40
 Typically, the sensor is integrated with a wound core or permanent
magnet that surrounds the conductor to be measured.
Frequently, a Hall sensor is combined with circuitry that allows the
device to act in a digital (on/off) mode, and may be called a switch in this
configuration. Commonly seen in industrial applications such as the pictured
pneumatic cylinder, they are also used in consumer equipment; for example
some computer printers use them to detect missing paper and open covers.
When high reliability is required, they are used in keyboards.
Fig2.20

Fig2.20 Hall effect sensor

Hall sensors are commonly used to time the speed of wheels and
shafts, such as for internal combustion engine ignition timing or
tachometers.
They are used in Brushless DC electric motors to detect the position of
the permanent magnet. In the pictured wheel carrying two equally spaced
magnets, the voltage from the sensor will peak twice for each revolution.
This arrangement is commonly used to regulate the speed of disc drives.

41
2.4.5. TRANSMITTER DETAILS:

Table 14 Pressure/Flow/Differential Pressure Transmitter details:

Application For pressure, flow & differential pressure at

Inlet or outlet
Duty Continuous
Humidity 45˚C(max) 99%RH(max)
Accuracy 0.1% of FSD
Over pressure range 150% of rated pressure
Instrument connection 1/2inchNPTF
Process fluid Mini Blast Furnace outlet gas
Composition:
CO2=16.15%
N2=55.19%
CO=26.70%
H2O+HC=1.24%
Gas is 100% saturated Yes
Maximum flow 108000Nm³/Hr
Maximum pressure 12000mmWC
Dust Granulometer 10-250,80%
Dust content 15gm/Nm³
Power supply 240V DC,2 wire from PLC
Output 4-20mA

42
Table 15 Location of pressure/flow/differential pressure transmitters:
PT101 Diaphragm seal Quencher inlet 0-12000mmWC
pressure transmitter
PT102 Diaphragm seal Secondary Venturi 0-12000mmWC
pressure transmitter inlet
PT103 Diaphragm seal Septum valve inlet 0-10000mmWC
pressure transmitter
PT104 Diaphragm seal GCP outlet 0-2000mmWC
pressure transmitter
DPT101 Diaphragm seal Across Quencher 0-12000mmWC
Differential pressure inlet & Separator
transmitter outlet
DPT102 Diaphragm seal Across 1st Venturi 0-12000mmWC
Differential pressure inlet & outlet
transmitter
FT101 Water flow transmitter Quencher inlet 0-50m³/hr
water line
FT102 Water flow transmitter 1st Venturi inlet 0-125m³/hr
water line
FT103 Water flow transmitter Separator inlet 0-140³/hr
water line
FT104 Gas flow transmitter GCP outlet gas line 0-125m³/hr

43
2.5. VALVE DETAILS:
The GCP is using gate valves and isolation valves for the regulation of
BF gas moving inside pipelines.
2.5.1. GATE VALVES:

Fig2.21 Gate valve

A Gate Valve, or Sluice Valve, as it is sometimes known, is a valve that
opens by lifting a round or rectangular gate/wedge out of the path of the
fluid. The distinct feature of a gate valve is the sealing surfaces between the
gate and seats are planar. The gate faces can form a wedge shape or they can
be parallel. Gate valves are sometimes used for regulating flow, but many
are not suited for that purpose, having been designed to be fully opened or
closed. When fully open, the typical gate valve has no obstruction in the
flow path, resulting in very low friction loss. Gate valves are characterized
as having either a rising or a non rising stem. Rising stems provide a visual
indication of valve position. Non rising stems are used where vertical space
is limited or underground. Bonnets provide leak proof closure for the valve
body. Gate valves may have a screw-in, union, or bolted bonnet. Screw-in
bonnet is the simplest, offering a durable, pressure-tight seal. Union bonnet
is suitable for applications requiring frequent inspection and cleaning. It also
gives the body added strength. Bolted bonnet is used for larger valves and
higher pressure applications.
44
 Another type of bonnet construction in a gate valve is pressure seal
bonnet. This construction is adopted for valves for high pressure service,
typically in excess of 15 Mpa (2250 psi). The unique feature about the
pressure seal bonnet is that the body - bonnet joints seals improves as the
internal pressure in the valve increases, compared to other constructions
where the increase in internal pressure tends to create leaks in the body-
bonnet joint.
Gate valves normally have flanged ends which are drilled according to
pipeline compatible flange dimensional standards. Cast iron, cast carbon
steel, gun metal, stainless steel, alloy steels, and forged steels are different
materials from which gate valves are constructed.
Maintenance
To avoid failure, it is a very good practice to use the valve three or four
times a year. From its normal position of nearly full-open: wind it fully
closed, then fully open, then half a turn closed. Make sure the system that
the pipes are connected to doesn't require water flow whilst you do this.

2.5.2. ISOLATION VALVES:

A valve intended for use only in the closed or fully open position.
Isolation valves are used for diverting process media, facilitating
maintenance, equipment removal and Isolation valves are a key component
in any fluid system as they are used to stop the flow of fluid into a particular
area of the system. They are also sometimes used to manually control the
flow of the fluid.

45
 Ball valves and butterfly valves are the two most important rotary
valves or Isolation Valves associated with steam applications.

2.5.2.1. Ball Valves:

A ball valve is a valve that opens by turning a handle attached to a ball

inside the valve. The ball has a hole, or port, through the middle so that
when the port is in line with both ends of the valve, flow will occur. When
the valve is closed, the hole is perpendicular to the ends of the valve, and
flow is blocked. The handle position lets you "see" the valve's position.

Ball valves are durable and usually work to achieve perfect shutoff
even after years of disuse. They are therefore an excellent choice for shutoff
applications (and are often preferred to globe valves and gate valves for this
purpose). They do not offer the fine control that may be necessary in
throttling applications but are sometimes used for this purpose.

The body of ball valves may be made of metal, ceramic, or plastic. The ball
may be chrome plated to make it more durable

Fig2.22 T and L Type ball valves

46
2.5.2.2. Butterfly Valve:

A butterfly valve is a type of flow control device, typically used to

regulate a fluid flowing through a section of pipe. The valve is similar in
operation to a ball valve. A flat circular plate is positioned in the center of
the pipe. The plate has a rod through it connected to an actuator on the
outside of the valve. Rotating the actuator turns the plate either parallel or
perpendicular to the flow. Unlike a ball valve, the plate is always present
within the flow, therefore a pressure drop is always induced in the flow
regardless of valve position.

A butterfly valve is from a family of valves called quarter-turn valves.

The "butterfly" is a metal disc mounted on a rod. When the valve is closed,
the disc is turned so that it completely blocks off the passageway. When the
valve is fully open, the disc is rotated a quarter turn so that it allows an
almost unrestricted passage of the process fluid. The valve may also be
opened incrementally to regulate flow.

There are different kinds of butterfly valves, each adapted for different
pressures and different usage. The resilient butterfly valve, which uses the
flexibility of rubber, has the lowest pressure rating. The high performance
butterfly valve, used in slightly higher-pressure systems, features a slight
offset in the way the disc is positioned, which increases the valve's sealing
ability and decreases its tendency to wear. The valve best suited for high-
pressure systems is the tricentric butterfly valve, which makes use of a metal
seat, and is therefore able to withstand a greater amount of pressure.

47
2.6. ACTUATOR DETAILS:

Actuators are used for the automation of industrial valves and can be
found in all kinds of technical process plants: they are used in wastewater
treatment plants, power plants and even refineries. This is where they play a
major part in automating process control. The valves to be automated vary
both in design and dimension. The diameters of the valves range from a few
inches to a few metres. Depending on their type of supply, the actuators may
be classified as pneumatic, hydraulic and electric actuators.

Fig2.23 Industrial Electric Actuator

48
Classification of the actuators according to their movement

Travel means the distance of the closing element within the valve has to
cover to completely open or close that valve. Typical closing elements
include butterfly, globe or gate valve discs. These three closing elements
stand for the three basic movements required for covering the travel. The
butterfly valve disc is operated by a 90° swivel movement from end position
OPEN to CLOSED, the globe valve disc is operated by a rather short linear
movement (stroke) while the gate valve disc movement covers the full
diameter of the valve. Each movement type requires a specific actuator type.

Fig2.24 Electric multi-turn actuator on a gate valve

Multi-turn actuators

Multi-turn actuators are required for the automation of multi-turn

valves. One of the major representatives of this type is the gate valve. The
basic requirements on multi-turn actuators are described as follows:

49
 "A multi-turn actuator is an actuator which transmits to the valve a
torque for at least one full revolution. It is capable of withstanding thrust."A
valve stem is mounted to the gate valve disc. The multi-turn actuator moves
the gate valve disc from OPEN to CLOSED and vice versa via a stem nut.
To cover the complete valve travel, the so-called valve stroke, the actuator
has to perform – depending on the valve – a few or several hundred
rotations. Due to their design, the stroke of electric actuators, contrary to that
of their pneumatic counterparts, has no limits. Therefore, gate valves are
exclusively automated by means of electric multi-turn actuators.

The multi-turn actuator has to be able to withstand the weight of the

gate valve disc by means of the valve attachment, the interface to the valve.
This is expressed in the second sentence of the definition.

Gate valves may have a diameter of approx. 4 inches to several meters.

The torque requirement for multi-turn solutions ranges from approx. 10 N m
to 30,000 N m.

Fig2.25Electric part-turn actuator on a butterfly valve

50
Part-turn actuators

Part-turn actuators are required for the automation of part-turn valves.

Major representatives of this type are butterfly valves and ball valves. The
basic requirements on part-turn actuators are described as follows:

"A part-turn actuator is an actuator which transmits a torque to the

valve for less than one full revolution. It need not be capable of withstanding
thrust."

Less than one full revolution usually means a swivel movement of 90°;
however, there are some valve types requiring a different swing angle, such
as two-way valves. The closing elements in part-turn actuators are always
supported by the valve housing, i.e. the weight of the closing element does
not act upon the part-turn actuator. This is expressed in the second sentence
of the definition. Part-turn valves diameters range from a few inches to
several meters. The torque requirement for operating the closing element has
a comparable range from approximately 10 N m to several 100,000 N m.
Electric actuators are unrivalled for large-diameter valves with high torque
requirements.

Linear actuators

Currently there is no international standard describing linear actuators

or linear thrust units. A typical representative of the valves to be automated
is the control valve. Just like the plug in the bathtub is pressed into the drain,
the plug is pressed into the plug seat by a stroke movement.

51
 The pressure of the medium acts upon the plug while the thrust unit has
to provide the same amount of thrust to be able to hold and move the plug
against this pressure. Most of the linear actuators used are pneumatic
diaphragm actuators. They are characterized by a simple design principle
and are therefore cost-effective. A compressed air supply is a prerequisite
for their use. In case this is not possible, the use of thrust units is
recommended which can easily be supplied with power.

Motor

Robust asynchronous 3-phase AC motors are mostly used as electric motors,

for some applications also 1-phase AC or DC motors are used. The motors are
specially adapted for valve automation requirements. Due to their design, they
provide higher torques from standstill than comparable conventional motors. This
feature is required to be able to unseat sticky valves. Electric actuators are used
under extreme ambient conditions. Fan motors do not provide sufficient enclosure
protection and can therefore not be used. Actuators can generally not be used for
continuous operation since the motors have to cool down after a certain operating
time. This suits the application since valves are not continuously operated.

Limit and torque sensors

The limit switching measures the travel and signals when an end position
has been reached, the torque switching measures the torque present in the
valve. When exceeding a set limit, this is signaled in the same
way.Actuators are often equipped with a remote position transmitter which
indicates the valve position as continuous current or voltage signal.

52
Gearing

Often a worm gearing is used to reduce the high output speed of the
electric motor. This enables a high reduction ratio within the gear stage,
leading to a low efficiency which is desired for the actuators. The gearing is
therefore self-locking i.e. it prevents accidental and undesired changes of the
valve position by acting upon the valve’s closing element. This is of major
importance for multi-turn actuators which are axially loaded with the weight
of the gate valve disc.

Valve attachment

The valve attachment consists of two elements.

First: The flange used to firmly connect the actuator to the counterpart on
the valve side. The higher the torque to be transmitted, the larger the flange
required.

Second: The output drive type used to transmit the torque or the thrust from
the actuator to the valve shaft. Just like there is a multitude of valves there is
also a multitude of valve attachments.

Manual operation

In their basic version most electric actuators are equipped with a hand
wheel for operating the actuators during commissioning or power failure.
The hand wheel does not move during motor operation.

53
Actuator controls

Both actuator signals and operation commands of the DCS are

processed within the actuator controls. This task can in principle be assumed
by external controls, e.g. a PLC. Modern actuators include integral controls
which process signals locally without any delay. The controls also include
the switchgear required to control the electric motor. This can either be
reversing contactors or thyristors which, being an electric component, are
not subject to mechanic wear. Controls use the switchgear to switch the
electric motor on or off depending on the signals or commands present.
Another task of the actuator controls is to provide the DCS with feedback
signals, e.g. when reaching a valve end position.

Electrical connection

The supply cables of the motor and the signal cables for transmitting
the commands to the actuator and sending feedback signals on the actuator
status are connected to the electrical connection. The electrical connection is
ideally designed as plug/socket connector. For maintenance purposes, the
wiring can easily be disconnected and reconnected.

54
2.7. PROGRAMMING INSTRUMENTS:

The GCP can be programmed digitally using PLC. Here the PLC used is
Siemens S7 300. Three operations of GCP can be done using PID. The
details about PLC and PID controller are shown in the following.

2.7.1. PLC DETAILS:

A programmable logic controller (PLC) or programmable controller is a

digital computer used for automation of industrial processes, such as control
of machinery on factory assembly lines. Unlike general-purpose computers,
the PLC is designed for multiple inputs and output arrangements, extended
temperature ranges, immunity to electrical noise, and resistance to vibration
and impact. Programs to control machine operation are typically stored in
battery-backed or non-volatile memory. A PLC is an example of a real time
system since output results must be produced in response to input conditions
within a bounded time, otherwise unintended operation will result.

Features

Fig2.26 PLC
55
 Control panel with PLC (grey elements in the center). The unit consists
of separate elements, from left to right; power supply, controller, relay units
for in- and output. The main difference from other computers is that PLCs
are armored for severe condition (dust, moisture, heat, cold, etc) and have
the facility for extensive input/output (I/O) arrangements. These connect the
PLC to sensors and actuators. PLCs read limit switches, analog process
variables (such as temperature and pressure), and the positions of complex
positioning systems. Some even use machine vision. On the actuator side,
PLCs operate electric motors, pneumatic or hydraulic cylinders, magnetic
relays or solenoids, or analog outputs. The input/output arrangements may
be built into a simple PLC, or the PLC may have external I/O modules
attached to a computer network that plugs into the PLC.

PLCs were invented as replacements for automated systems that would

use hundreds or thousands of relays, cam timers, and drum sequencers.
Often, a single PLC can be programmed to replace thousands of relays.
Programmable controllers were initially adopted by the automotive
manufacturing industry, where software revision replaced the re-wiring of
hard-wired control panels when production models changed.

Many of the earliest PLCs expressed all decision making logic in

simple ladder logic which appeared similar to electrical schematic diagrams.
The electricians were quite able to trace out circuit problems with schematic
diagrams using ladder logic. This program notation was chosen to reduce
training demands for the existing technicians. Other early PLCs used a form
of instruction list programming, based on a stack-based logic solver.

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The functionality of the PLC has evolved over the years to include
sequential relay control, motion control, process control, distributed control
systems and networking. The data handling, storage, processing power and
communication capabilities of some modern PLCs are approximately
equivalent to desktop computers. PLC-like programming combined with
remote I/O hardware, allow a general-purpose desktop computer to overlap
some PLCs in certain applications.

Fig2.27 Block of PLC

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How the PLC operates

The PLC is a purpose-built machine control computer designed to

read digital and analog inputs from various sensors, execute a user defined
logic program, and write the resulting digital and analog output values to
various end effectors.

Scan cycle

Exact details vary between manufacturers, but most PLCs follow a

'scan-cycle' format.

Overhead
Overhead includes testing I/O module integrity, verifying the user
program logic hasn't changed, that the computer itself hasn't locked up (via a
watchdog timer), and any necessary communications. Communications may
include traffic over the PLC programmer port, remote I/O racks, and other
external devices such as HMIs (Human Machine Interfaces).
Input scan
A 'snapshot' of the digital and analog values present at the input
cards is saved to an input memory table.
Logic execution
The user program is scanned element by element, then rung by rung
until the end of the program, and resulting values written to an output
memory table.

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Output scan
Values from the resulting output memory table are written to the
output modules. Once the output scan is complete the process repeats itself
until the PLC is powered down.
The time it takes to complete a scan cycle is, appropriately enough,
the "scan cycle time", and ranges from hundreds of milliseconds (on older
PLCs, and/or PLCs with very complex programs) to only a few milliseconds
on newer PLCs, and/or PLCs executing short, simple

2.7.2. SIEMENS S7 300 PLC:

S7 Modules:
An S7-300 consists of several modules. The following diagram illustrates a
possible configuration:

Fig2.28 S7 Modules

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Table 16 S7 Modules:

Module Arrangements:

Fig2.29 S7 Module arrangements

Table 17 Arrangement of modules:

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Table 18 Components of S7 PLC

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62
2.7.3. PID CONTROLLER:
A proportional–integral–derivative controller (PID controller) is a
generic control loop feedback mechanism widely used in industrial control
systems. A PID controller attempts to correct the error between a measured
process variable and a desired set point by calculating and then outputting a
corrective action that can adjust the process accordingly.
The PID controller calculation involves three separate parameters; the
Proportional, the Integral and Derivative values. The Proportional value
determines the reaction to the current error, the Integral determines the
reaction based on the sum of recent errors and the Derivative determines the
reaction to the rate at which the error has been changing. The weighted sum
of these three actions is used to adjust the process via a control element such
as the position of a control valve or the power supply of a heating
element.By "tuning" the three constants in the PID controller algorithm the
PID can provide control action designed for specific process requirements.
The response of the controller can be described in terms of the
responsiveness of the controller to an error, the degree to which the
controller overshoots the setpoint and the degree of system oscillation. Note
that the use of the PID algorithm for control does not guarantee optimal
control of the system. Some applications may require using only one or two
modes to provide the appropriate system control. This is achieved by setting
the gain of undesired control outputs to zero. A PID controller will be called
a PI, PD, P or I controller in the absence of the respective control actions. PI
controllers are particularly common, since derivative action is very sensitive
to measurement noise, and the absence of an integral value prevents the
system from reaching its target value due to the control action.
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Fig2.30 Block diagram of PID controller
The PID control scheme is named after its three correcting terms, whose sum
constitutes the manipulated variable (MV). Hence:

where Pout, Iout, and Dout are the contributions to the output from the PID
controller from each of the three terms, as defined below

Proportional term

The proportional term makes a change to the output that is

proportional to the current error value. The proportional response can be
adjusted by multiplying the error by a constant Kp, called the proportional
gain.

Where

• Pout: Proportional output

• Kp: Proportional Gain, a tuning parameter
• e: Error = SP − PV
• t: Time or instantaneous time (the present)

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Integral term

Where

• Iout: Integral output

• Ki: Integral Gain, a tuning parameter
• e: Error = SP − PV
• τ: Time in the past contributing to the integral response

Derivative term

Where

• Dout: Derivative output

• Kd: Derivative Gain, a tuning parameter
• e: Error = SP − PV
• t: Time or instantaneous time (the present)

Output of PID controller:

The output from the three terms, the proportional, the integral and the
derivative terms are summed to calculate the output of the PID controller.
Defining u(t) as the controller output, the final form of the PID algorithm is:

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2.8. SOFTWARE PROGRAMMING DETAILS:
2.8.1. SEQUENCE OF OPERATIONS:
Operations done in Quencher & Venturi inlet and Seal pot:
1. After passing dust catcher the hot gas was sensed by temperature sensor
or flow sensor. By sensing it the water pump is operated so that water is
sprayed inside the quencher.
2. The gas from quencher is again sensed by the temperature sensor or flow
sensor and water pump is operated according to it.
3. The seal pot is used to seal the CO leakage while releasing slag. When
two Position sensors are ON, the outlet valve should be open. When two
sensors are OFF, Pump should be operated.
Operations done by PID controller:
4.Venturi1 inlet and outlet pressure difference is measured using
DPT1.Using that signal the Venturi throat is adjusted to control the pressure
in the pipe. This can be done by PID controller.
5. Venturi2 throat is adjusted by using the DPT2 signal. This can be done by
PID controller.
6. Septum valve contains 4 butterfly valves. Of that 3 valves are operated
from the central control panel using PLC and electrical actuator for ON/OFF
duty.
The remaining 1 valve is used for regulating purpose. It is also operated
by PLC and electrical actuator.All the butterfly valves of the septum valve
are provided with 2 wire position transmitter to provide continuous feedback
of individual butterfly valve to PLC/Control panel When the set pressure is
beyond the range of regulating valve, the valve is fully open (60 to 70ºopen)
or fully closed (0º).
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 The end limit switches of the valve will operated in this condition and
give signal/indication that the set pressure is beyond range if regulating
valve. In such case the ON/OFF valves are required to operated to bring the
set pressure with in the range of regulating valve. If the regulating valve is
fully closed & still BF top pressure is less than desired/set top pressure, 2/3
ON/OFF valves are required to be closed partially till the desired/set top
pressure is achieved and regulating valve position is between 30º and 35º to
have control range open both upper & lower side. Similarly if BF top
pressure is more then valve is fully open(60 to 70ºopen), 2 or 3ON/OFF
valves are required to be open gradually till the desired/set BF top pressure
is achieved & regulating valve position is between 30 to 35º to have control
range on upper & lower side.

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2.8.2. PROGRAM:

68
69
2.9. ADVANTAGES OF GCP:

• The GCP controls air pollution caused by dust from the BF gas in the
atmosphere.

• It reduces the temperature at the BF gas that are unused there by

reducing the global warming.

• The process in which the CO gas is recycled, makes the blast furnace
to work at high efficiency.

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 CHAPTER 3
3.1. CONCLUSION:
Summary of work done:
The BF gas was directly exposed to the atmosphere in previously. It
will cause severe effects to the environment. To overcome this, Gas cleaning
plant is used to clear the dust in the BF gas and also it reduces the
temperature of the wasted BF gas. The GCP can be operated automatically
using Siemens S7 300 PLC.
The gas can be collected from the blast furnace and treated with water
for more than three times automatically to achieve the goal of the project.

Suggestion of future work:

The project should be extended such that even a small amount of CO
gas should not be sent to the atmosphere by using the gas analyzers.

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 APPENDIX

IMPLEMENTATION OF LOGIC GATES IN LADDER DIAGRAM

OR logic

The lamp will come on if either contact A or contact B is actuated,

because all it takes for the lamp to be energized is to have at least one path
for current from wire L1 to wire 1. A simple OR logic function, implemented
with nothing more than contacts and a lamp.

AND logic:

The AND logic functions can be mimicked by wiring the two contacts in
series instead of parallel:

Now, the lamp energizes only if contact A and contact B are

simultaneously actuated. A path exists for current from wire L1 to the lamp
(wire 2) if and only if both switch contacts are closed.

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NOT Logic:

The logical inversion, or NOT, function can be performed on a contact

input simply by using a normally-closed contact instead of a normally-open
contact:

Now, the lamp energizes if the contact is not actuated, and de-energizes
when the contact is actuated.

A pattern quickly reveals itself when ladder circuits are compared with
their logic gate counterparts:

• Parallel contacts are equivalent to an OR gate.

• Series contacts are equivalent to an AND gate.
• Normally-closed contacts are equivalent to a NOT gate (inverter).

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 The following are the functions of combinational circuits

NAND Logic:

NOR Logic:

Exclusive OR Gate:

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REFERENCES:

1. Bolton, W. (2005) ‘Mechatronics’, Pearson Education, Ltd, pp 460-482.

2. Jain, R.K. (1999) ‘Mechanical and Industrial Measurements’, Khanna Publishers,

New Delhi.

3. Patranabis, D. (1996) ‘Principles of Industrial Instrumentation’, Tata McGraw Hill

Publishing Company Ltd.

4. Sawhney, A.K. (2004) ‘A course in Electrical & Electronic Measurement

and Instrumentation’, Dhanpat Rai and Co (P) Ltd.

5. Stephanopoulis, G. (1990) ‘Chemical Process Control’, Prentice Hall of

India, New Delhi,

6. www.wikipedia.com.html

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