Control & Instrumentation

This is the main area in which IL operates. The company was set up to meet the Control &
Instrumentation requirement of Process industries of India.  The company dedicates itself to this task
with full sincerity to ensure rapid economic development of the country based on timely
commissioning of various projects and satisfactory operation/ maintenance of already commissioned
projects at a high level of efficiency, availability and plant utilization factor as far as the Control &
Instrumentation is concerned.

IL’s Process control market can be segmented in to Industrial categories such as Power generation,
especially Thermal Power Plants, Mining & Metallurgy including Iron & Steel production, Non-Ferrous
metals like Aluminum and Copper / Zinc Smelter & Refineries, Petrochemicals including Oil & Gas
Production, Chemicals including Pharmaceuticals & Water treatment plant, Cement, Paper, Fertilizers
etc.

IL has been a saga of success through hard work, vibrant ethos and high level of team spirit. A strong
turn-key capability has been established through expertise in System design, Engineering, software
development, Manufacturing, Testing, Installation, Commissioning and after sales service.  

IL can take pride of having supplied Control & Instrumentation Systems on  turn-key basis to over 200
Thermal Power stations in Power sector( almost all Electricity Boards & NTPC plants), almost all Steel
sector projects ( Bokaro, Bhilai, Rourkela, Durgapur of SAIL, Nilanchal Ispat, Vizag Steel plants etc.),
and state of the art Digital Control system and other products to Refineries, Oil & Gas, Petrochemicals
and Chemical plants ( IOCL Barauni, Guwahati, Mathura, Haldia, Panipat, NRL, BRPL, MRL,
HPCL,BPCL, IPCL Vadodara / Nagothane, ONGC Mumbai, GAIL etc.), IL has also entered in to areas
like Oil well Instrumentation, Marine Instrumentation etc. to supplement Companies growth.

Thermal Power Plants: IL is the only Indian company which has the privilege of   supplying &
executing C&I jobs on turn-key basis for thermal power units ranging from 30 MW to 500 MW through
out the country and overseas. IL has also successfully executed the speedy ‘Restoration’  of  the
several units which were damaged due to some unfortunate incidents. Thus IL has proven capability
of executing not only  new Power Projects but also in upgrading of the old C&I system with the State-
of-the-art technology. For the large projects IL has supplied DDC System of world-renowned
manufacturers like ABB, Seimens, HF Controls  and Max Controls.

Steel Plants:  IL is  the only Indian company to have the privilege of  supplying & executing the C&I
jobs on turn-key basis in almost all the steel plants. IL has done automation job for various mills like
Blast Furnace, Coke-Oven Battery, Slab/Strip/Rolling Mills, Wheel & Axle Plants, Captive Power
Plants of Steel Plants.  IL has supplied DDC system of world- renowned manufacturers to these
plants. For small systems PC based system with single loop controllers has been supplied.

Other Process Industries: IL has supplied & executed C&I jobs on turn key basis in Oil Refineries,
Cement, Paper, Fertilizer plants etc. In addition to Turn-key jobs IL has been doing retails product
sale through Marketing Division and have supplied various type of Instruments to Industry.Various
type of Instruments being supplied by IL are:

1. High performance Microprocessor based SMART Pressure & Differential Pressure

transmitters
2. High performance Microprocessor based SMART Temperature  transmitters
3. Microprocessor based Single & Multi loop Controllers  
4. Microprocessor based  multi-pen & multi-point Chart  and Chartless Recorders.
5. Microprocessor based Gas/Liquid  Analyzers and pollution monitoring instruments along with
sample handling and                               conditioning system.  
6. CMOS based Integral and Remote type  Annunciation systems  
7. Flow elements  
 8. Control Valves
9. Actuators
10. Power Cylinders
11. Control Panels, Desks & racks
12. UPS systems

We have fully automatic programmable Pick & Place M/c Model Viteese of M/s Europlacer .
The Machine is most versatile . It can place not only chip components but also components in
Trays, Tubes & Tapes .It can place components CHIPS, SOT, SOD, MELFS, MINI-MELFS,
SOIC, PLCC, QFP, PQF, BGA ...

Salient Features :-

1. Speed of M/c:- It can place 20000 component/hour

2. Feeder Capacity:-198 feeders of 8mm Max Size
3. Tape Feeders Size:- 8mm to 72mm
4. Tray feeder:- 10 Position, Programmable waffle tray of QFP & BGA/CSP
components, two Feeders one for each head
5. Component Size:-0204 to 50 mm sq
6. Head:-Two head with 8 nozzles each
7. Tool Bank:- Tool Magazine has capacity of 48 tools. There are two magazine of 48
nozzles one for each head.
8. Software:-The Software is Window NT Base Operating system .This software is used
for programming of the M/c for Placement of Particular component at particular
location on the PCB. This Program can be used ON-LINE as well as OFF-LINE
 CNC Centre

To keep pace with time and to meet the changing technological demand of the manufactured /
machined components, CNC Centre was established in 1988. Following three machines are
installed in CNC Centre.

1)         CNC CHUKER                                                            HMT.STC.25

2)         CNC VERTICAL MACHINING CENTRE                PAL.VA.35

3)         CNC 3-D MEASURING MACHINE                          CARL ZEISS UC550 

These machines have given us assured production with negotiable process rejections. These
machines enabled IL to indigenise various product ranges speedily. It would be much faster
to execute on-time order at minimum cost. For quick inspection of first work piece produced
by CNC machines & for random sampling of production runs, IL have CNC-3D Co-ordinate
measuring machine in CNC Centre. CNC-3D Co-ordinate measuring machine is an advance,
multipurpose quality control system used to help the inspection to keep pace with modern
requirements. It replaces long, complex and inefficient conventional inspection methods with
simple procedures that are much faster as well as accurate. It reduces or eliminates CNC
down time, cuts down scrap and rework. A CMM can check the dimensional and geometric
accuracy of every item from big complex mechanical parts to flexible rubber, plastic moulded
parts. It measures virtually any part at any stage of production with exact precision and
substantial time savings.
Power Electronics & Energy Conservation Devices
Being in Control & Instrumentation field for several years, it was natural for IL to diversify in
related areas of Power Electronics. As a turn-key supplier of C&I system ,IL used to procure and
supply UPS system, so efforts were made to enter as manufacturer in this Area. After UPS
production was established , energy saving items like Solar Dusk to Dawn Switching  System
(SDDS) was developed. Electronic Energy meter is also developed and is under BS certification
before Commercial launch.

Instrumentation Limited is manufacturing Uninterrupted Power Supply (UPS) systems for the last
15 years.  UPS works are ISO-9001 certified by the renowed certification agency DNV.  These
UPS Systems are designed with IGBT in Pulse Width Modulation (PWM) technique and Digital
Control Technology suitable for wise range of power requirement both for Single and Three
Phases.  These are highly efficient, reliable, low acoustic noise level with excellent economy in
installation and operating costs.  The products find wide application from industries to banks,
hospitals, insurance sector, computer installations etc. UPS systems manufactured by IL are
classified in two categories namely Mini UPS and CVCF UPS.

       i)      Mini UPS :  These UPS incorporate IGBT based PWM design for optimum efficiency for
AC/DC conversion and suitable for non-linear loads with built-in Electronic Current Limiting
features.  These UPS are backed up by maintenance free high quality batteries.  The rated
capacity available are from 1 KVA to 10 KVA for single phase requirement.

      ii)   Constant Voltage Constant Frequency (CVCF) UPS.  These UPS are available in wide
range from 10 KVA to 600 KVA both for single phase and three phase requirement. Use of
IPM   ensures higher reliability and excellent performance.  It guarantees high efficiency of
the order of 95% and above and an AC/AC overall conversion efficiency of better than 89%
thus rendering substantial reduction in running costs.  Being IPM based, UPS, special circuits
like commutation circuit are not required and therefore, these UPS are compact and light
weight and has a low acoustic noise level. Use of floating battery system caters for no
interruptions or fluctuations when commercial power supply fails.  These UPS are stable
against abrupt variations in the load due to their Pulse Width Modulation feature.

Our UPS products are approved by all major testing houses and technical consultants like  ETDC,
Sameer, PDIL, EIL, DCL, Desein etc.

State-of-the-art manufacturing facility with dust control PCB assembly and anti static precautions,
skilled and qualified professional, quality tests at all stages of manufacturing, full and exhaustive
testing facilities  of all parameters ensures product of best quality.

Components used are industrial grade, very good quality connectors, push buttons, and wires are
used and soldering is done through wave soldering machine.  UPS systems are designed for tough
Indian environmental conditions ,  after considering problems being faced by users from other UPS
systems.

Sales, Service Centre and Dealer network are spread all over the country, thus making it possible to
supply & maintain UPS in any part of India.

DGS&D rate contract: 1 & 2 KVA Online UPS with 20 Minutes Battery back up are also available on
DGS&D rate contract.

SPV DUSK DAWN SWITCHING SYSTEM (SDDS)

Solar Photo Voltaic Dusk Dawn switching System is an energy saving device used for automatic
operation of street lighting system making proper use of power and increasing the life of pole-lamps
for an optimum period. The system is highly reliable and  efficient for years of  flaw-less operation.

The operation is based on sensing the ambient light level which actuates the relay to switch on the
street light in the evening and switch off in the morning. The sensor is hermetically sealed, weather
proof and maintenance free, thereby ensuring reliability even in adverse atmospheric conditions.  No
separate operative time settings for summer or winter are required due to use of Solar Photo Voltaic
Sensor. In built protection against Line to Line, Line to Earth and Line to Neutral is provided. The
SDDC are available in different ratings from 30 Amperes per phase to 100 Amperes per phase
depending upon load requirement. 

Instrumentation and Control in Power Plants

The instruments are used in power plants for a number of reasons as to operate the power
plant most efficiently. Instruments furnish accurate information for guidance to safe,
continuous and proper plant operation. The information given by the recording units from the
control room helps to direct its operation so as to achieve the best performance possible and
furnish data for calculation so that results may to compared from time to time. These may be
used to check on the internal condition of equipment and indicate when and where
maintenance or repair is needed.

This also helps to an operating crew to detect appreciable deviation from normal. The
functions of instruments to be performed are listed below:

(I) Operating guidance. (2) Performance calculations. (3) Maintenance and repair guidance.
(4) Economical supervision, and (5) Cost allocation.

The instruments used in modem power plants include the pressure and temperature
measurements of steam and water, the flow measurement, CO2 indicator, air flow recorder,
draft gauge, vacuum gauge, flue gas thermometer, fuel meter, watt hour meter and many
others. The installation of recording type instruments to aid operating supervision will depend
on the extent to which it is necessary for the superintendent to have a check record on the
work of his staff.

With the introduction of modern type of steam power plants there is tendency towards remote
control of power plant equipment. The use of computer has opened a new era for the
successful control and operation of power plants.
 Thermal Power Plants

Thermal Power Plants The development of power in any country depends upon the
available resources in that country. The hydel power totally depends upon the natural sites
available and hydrological cycle in that country. New sites cannot be humanly created for
hydel power plants. The development of nuclear power in a country requires advanced
technological developments and fuel resources.

This source of power generation is not much desirable for the developing countries as it is
dependent on high technology and they are highly capital based systems. Many times, hydel
power suffers if draught comes even once during a decade and the complete progress of the
nation stops. The calamity of rain draught on power industry has been experienced by many
states in this country. To overcome this difficulty, it is absolutely necessary to develop
thermal plants in the country which are very much suitable for base load plants.

Hydel power plants arc much better for peak load requirements; therefore the development of
the thermal plants becomes a necessity for economic generations of the power. The
development of all three sources should be made simultaneously if possible to assure sound
supply of power in the country. The mix of three depends upon the availability in the
particular area but it is always economical and desirable to develop all sources of power for
steady and sure progress of the country

Fuel Properties and Storage

Coal is the oldest fuel and still used on large Scale throughout the world for power
generation. It is a fuel which brought about an industrial revolution and made a dramatic
charge in the life style of people. It sustained most of our combustion activity until oil was
struck and even now continues to be a major source of energy. After the first and second
shocks of oil prices, the power industry in the western countries moved from oil to coal.

Mankind has realised that the future lies in establishing an energy economy at the earliest
possible time, based on sun, wind, ocean tides and thermal gradients, biomass etc. All effects
are going on throughout the world to develop such non conventional ever lasting sources of
energy. But it will take time, a couple of decades or more, to develop these sources and in the
present condition of soaring oil prices, the coal is going to play a vital role in the power
generation industry at least for 20 to 30 years.

Keeping this in mind, all oil based power plants are shifting to coal based plants in USA and
Europe. In India, coal is the only source of power generation, and it will play more important
role in coming years.

Coal Handling and Storage

Coal handling and storage systems are experiencing many changes as coal gradually moves
into its expected dominant role as a fuel. The predicted growth in coal fired plants is 90% in
the next five years, as 250 new power stations are expected by 2000 only in USA
Continuously increasing power demand even in developing countries cans for setting up of
higher capacity power stations. Rise in capacity of plant posses problems in coal handling
systems.
A good coal handling plant must perform two duties as unloading the coal from railways
wagons as fast as possible and then transferring the unloaded coal either to coal bunkers or in
the stock pile for storage and then feeding the coal from the stock: pile to the bunkers when
railway wagons are not available. To day, most of the world's coal production is still
consumed in the countries where it is mined. Only about 10% of the total production are
traded internationally. Coal used for power plants accounts for only 30% of the total coal
traded internationally, and much of this goes only short distances, such as from poland to
USSR and Western Europe and from USA to Canada. In contrast,.65% of the world's oil is
traded internationally The future of the world coal trade will require construction of greatly
enlarged transportation system and this in turn will involve massive investment and long lead
times.

Much progress has been already made by improving operating procedures and by scaling up
conventional equipment. Even with present technology, there are still considerable
opportunities for increasing the capacity of the present infrastructure as by improving existing
ports to take larger ships and adding more large ships to the dry bulk fleet

Burning of Fuels

Coal Burning Methods The efficient combustion of fuel in the combustion chamber and
efficient transfer of heat energy to the water for steam generation are essential for the
economical Working of power plant.

The two commonly methods used for burning coal are stoker firing and pulverised fuel firing.
The stroker firing method is used for solid fuel and pulverised firing, method is used for
pulverised coal. The selection of firing method adopted for a particular power plant depends
upon so many factors

Ash Handling and Dust Collection

The disposal of ashes from a large capacity power station is of some importance as it is 10 to
20% of the coal used. A 200 MW capacity power plant using Indian coals produces as large
as 60,000 tons of ash per annum. This quantity of ash is equivalent to a height of 1.5 metres
covering four hectares area. This shows that a power plant of 200 MW capacity requires 160
hectares area during its life time if the ashes produced are dumped at the site of the plant.

The ashes should be discharged and dumped at a sufficient distance from the power plant
because of following reasons

(1) The ash is dusty, therefore irritating and annoying to handle.

(2) It is sufficiently hot when it comes out of the boiler furnaces.

(3) It produces poisonous gases and corrosive acids when mixed with water.

The ash handling is a difficult problem and sufficient attention should be given to design the
ash handling plant. The difficulties encountered in the ash-handling plant layout are listed
below:
(I) It forms clinkers by fusing together in large lumps which must be broken before given to
any reasonably sized conveying equipment.

(2) The ash produced is abrasive and will wear out the conveyor parts on contact with it
therefore special conveyors must be designed to handle the ashes.

(3) The ashes must be cooled before carrying from the furnace collecting hoppers as it is very
difficult to carry hot ashes.

igh Pressure Boilers

The demand for the higher power outputs from the boiler and associated plant is increased in
the last ten years. It is a common practice to use high pressure and temperature steam in
power plants to increase: the efficiency of the plant and to reduce the cost of electricity
production. In the last to years, the operating pressures and temperatures of boilers have
risen, and this has been possible because of developments of materials. For the given steam
conditions and boiler size, there is not much variation in efficiency between different types
and the widest scope left to the designer only in increasing plant economy by making use of
high temperature flue gases.

When steam is needed at pressures 30 kg/cm2, and individual boilers are required to raise less
than about 30 tons of steam per hour, shell boilers arc considerably cheaper than water tube
boiler and are equally satisfactory it. all other respects. Above these limit shell boilers
(generally factory built) are difficult to transport if not impossible. There arc no such limits to
water tube boilers. These can be site erected from easily transportable parts, and moreover the
pressure parts are of small, diameter and therefore can be thinner. The geometry can be
varied to suit a wide range of situations, and furnace is not limited to cylindrical form.

Therefore, water tube boilers are generally preferred for high pressure and high output,
whereas shell boilers for low pressure and low output. The modern high pressure boilers used
for power generations are for steam capacities 30 to 650 ton3/hr and above with a pressure:
up to 160 kgf/cm2 and maximum steam temperature of about 540 Degree Celsius

One of the largest boiler plants in the world is in U.K. used to the Central Electricity
Generating Board. This boiler was designed for 1700 tons of steam generation per hour at a
pressure of 160 kg/ cm2 and a temperature of 560 Degree Celsius with one reheat to 560°C
burning 220 tons of coal per hour

Power Plant Boiler Accessories

An huge quantity of fuel is used in thermal power plant and very large quantity of heat is
carried by the exhaust gases. The heat carried by the exhaust gases per hour from 100MW
plant is of the order of 75 x 106 Kcal as 25% heat remains in the exhaust gases. This loss can
be halved by installing economizers in the flue gases. In the present age of costly fuel, it has
become necessary to conserve the fuel by utilizing the wasted energy to the atmosphere. This
is done in all modern power plants by incorporating economiser and air pre heater. By
increasing the temperature of feed water passing through the economiser using waste heat of
gas, the quantity of heat given per kg of steam generated in the boiler is reduced. Similarly
the temperature of the air is also increased by passing through the air pre heater using
remaining waste energy of the gases. The preheated air increases the combustion efficiency in
the furnace and reduces the fuel loss. In both equipments the quantity of fuel is reduced the
extracting the heat from the exhaust gases

Condensers in Power Plants

The generation of electrical energy in steam power plants is relatively in efficient process. In
modern fossil fuel plant, approximately 1200 kcal are rejected to the circulating water for
each kw-hr of energy produced. With the nuclear power plant, it is 50% greater than that for a
fossil fueled plant. This means that more than 10% of heat from the fuel burned in modern
fossil fueled plant and that about 2/3rd of the heat generated in nuclear plant is rejected to the
cooling water system. Therefore, the quantity of water required for a thermal power plant of
400 MW O:1pacity requires nearly 50 to 100 thousand tons of water per hour. This thirst for
cooling water makes water availability a paramount factor in choosing the plant site.
Therefore the plant must be sited near the sources for large quantities of water like ocean,
bays, rivers and lakes. The planner would have much more flexibility in power plant siting if
the availability of cooling water were not a major consideration

The use of Condensers in the power plant improves the efficiency of the power plant by
decreasing the exhaust pressure of the steam below atmosphere. Another advantage of the
condenser is that the steam condensed may be recovered to provide a source of good pure
feed water to the boiler and reduces the water softening plant capacity to a considerable
extent

Power Plant Pollution and it's Control

The purpose of this topic is to introduce the readers with the sources polluting the
atmosphere. The electric power demand is continuously increasing and it is expected that the
demand would be doubled after every 7 to 10 years and the pollution of the environment
would be rapid in the coming years.

The electric utilities are currently faced with simultaneous demand for increased power, and
the demand for the elimination of all the objections attributed to hydro-electric power, fossil
fuels and nuclear energy. The main pollutants from the thermal plants are dust and
objectionable gases like CO, CO., SO2, NO2 and many others. The ash is also a problem as it
also emits heat to the atmosphere as well as small diameter pollutants carried by the air.

The pollution from the thermal plant is also large quantity of heat discharged to the
atmospheric air and water used for condensing the steam. The pollution from the nuclear
power plants is radio-active waste in form of gases, liquids and solids whose radio active
property may retain number of years. The dumping and leakages of these wastes are the
major problems in nuclear power plants.

The pollution problem is mainly faced by the developed countries like U.S.A., U.K., Japan
and France and positive steps are already taken by the Governments to reduce the pollution
effects. An increased concentration of man's activity in to any area is another cause of air
pollution. In USA, 50% of the total emissions are released over leas than 1.5% of the
country's area. No. doubt, presently the percentage pollution by electric plants is considerably
less (15% of total) but it is estimated that the source of pollution will increase rapidly as the
power demand increase is very very rapid.