A paper on

RECENT DEVELOPMENTS IN INSTRUMENTATION IN TPS

BY SURAJIT GHOSH
DGM (C&I)
BTPS / NTPC
Control and Instrumentation has gone a vast change in the recent past. With the
advancement of electronics and development of new state of the art field instruments,
Instrumentation has achieved a new dimension in process industries. Modern day Power plants
depend heavily on Instrumentation. It is because of the fact that instrumentation has become
more reliable, accurate and more efficient. It is the brain behind modern day power plants. All
the instrumentation and all control system have gone Digital.
FIELD DEVICES
In the area of Process Transmitters, we have pressure / differential measurement
sensors mainly capacitive type and Peizo-Electric type and inductive type. The minimum
accuracy is of the order of 0.1%. The same transmitter can be used for a very large turn down
ratio of more than 30:1. Drifting is almost negligible. The stability of these transmitters has also
increased. The major change is the use of digital technology. The transmitters are
microprocessor based and have become SMART. It is because they have self-diagnostic features
and can communicate digitally about the healthiness of the transmitter and configuration details
and history of the transmitter. Even square rooting or linearization is possible in these
transmitters. One can configure and calibrate the transmitter from remote through a hand held
communicator. So there is no need to bring the transmitter to the laboratory for calibration.
There are a number of Industry standard protocols over which these transmitters can
communicate like HART, PROFIBUS, FIELDBUS etc. to a hand held communicator or a PC.
The transmitters can give an analog output of 4-20ma and superimpose digital signals over it for
communication.

In the area of Level transmitters, we have level measurement sensors mainly

differential pressure type, displacer type, ultrasonic type and guided wave radar type. The
accuracy is of the order of 0.1%. The major change is the use of digital technology. The
transmitters have become SMART and have all the features as mentioned above.

For Temperature measurement, Thermo-couples and Resistance Temperature Detectors

are used mostly. Compensating cables have to be used from Thermo-couples to Control room
for cold junction compensation. In place of that, SMART Universal Temperature transmitters
are available which can be used both for Thermocouple as well as Resistance temperature
detector with all the features as described for pressure transmitters.

For Pneumatic Control valve position control, traditionally a Current to Pneumatic (I/P)
converter is used to convert the 4-20mA from the controller and this pneumatic signal is used for
the pneumatic positioner, which is integrated with the actuator. Presently I/P converter and
Positioner are integrated in a single unit known as SMART positioners.
SMART positioners are digital valve controllers-microprocessor-based, current-topneumatic instruments with internal logic capability. They traditionally convert a current signal
to a pressure signal to operate the valve. They receive feedback of the valve travel position plus
supply and actuator pneumatic pressures, allowing them to diagnose not only themselves but
also the valve and actuator to which they are mounted. Using smart positioners as part of the
final control element permits partial-stroke, online testing of the valve and eliminates the need
for special mechanical-limiting devices.
Partial-stroke testing confirms the valve is working without disturbing the process.
Because there's no need to shutdown the process, testing can occur more frequently. Because
smart positioners hold the programming of the test procedure, partial-stroke testing happens
automatically and requires no operator attention.
Typically the partial-stroke test moves the valve 10% from its original position but can
move it up to 30% if plant safety guidelines allow. Although partial-stroke testing doesn't
eliminate the need for full-stroke testing (required to check valve seating), it does reduce the

required full-stroke testing frequency so it most likely undergoes testing during plant
turnaround.
Some smart positioners alert the operator if a valve is stuck. As the positioner begins the
partial stroke, it continually checks the valve travel to see whether it's responding properly. If it
isn't, the positioner will abort the test and alert the operator that the valve is stuck. This will
prevent the valve from slamming shut if the valve does eventually break loose.

The advantages are that it is more accurate and precise, custom flow characterization etc.
is possible. Piezo-pneumatic technology is used for the I/P converter. Diagnostic features and
automatic configuration is available. The latest trend is that PID controller is inbuilt in the
Positioner and can communicate with HART, PROFIBUS, FIELDBUS etc. to a hand held
communicator or a PC. The position feedback is based on Hall Effect principle, which is
immune to vibration and shock and can operate at a high temperature.
There are SMART motorized actuators also which operate a valve or a damper. They
operate on a 4-20mA signal from the controller and have the similar features of a pneumatic
positioner, except that it operates either a set of power contactors of a set of Thyristers for
reversible operation, which comes as an integral part of the actuator. These valves can be
calibrated using the hand held calibrator or from the PC.

HART Communication Technology

The HART Protocol is the leading communication technology used with smart process
instrumentation today. The HART Protocol continues to grow in popularity and recognition in
the industry as a global standard for smart instrument communication. More than two-thirds of

all

smart

instruments

shipping

today

communicate

using

the

HART

Protocol.

HART is field-proven, easy to use and provides highly capable two-way digital
communication simultaneously with the 4-20mA analog signaling used by traditional
instrumentation equipment.
Unlike other digital communication technologies, the HART Protocol provides a unique
communication solution that is backward compatible with the installed base of instrumentation
in use today. This backward compatibility ensures that investments in existing cabling and
current control strategies will remain secure well into the future.
Designed to compliment traditional 4-20mA analog signaling, the HART Protocol
supports two way digital communications for process measurement and control devices.
Applications include remote process variable interrogation, cyclical access to process data,
parameter setting and diagnostics.
Structure
Specification of the HART protocol is based largely on the OSI 7-Layer Communication
Model. The HART protocol specifications directly address 3 layers in the OSI model: the
Physical, Data Link and Application Layers.
FIELDBUS
A Fieldbus is an industrial network system for real-time distributed control.
A complex automated industrial system usually needs an organized hierarchy of
controller systems to function. In this hierarchy there is usually a central computer at the top,
where an operator can monitor or program the whole system. This is typically linked to a middle
layer of programmable logic controllers (PLC) via a bus system (e.g. Ethernet). At the bottom of
the control chain is the fieldbus which links the PLCs to the components which actually do the
work such as sensors, actuators, motors, console lights, switches and contactors.
Fieldbus is a generic-term which describes a new industrial digital communications
network intended to replace the existing 420mA analogue signal standard. The network is a
digital, bi-directional, multidrop, serial-bus, communications network used to link isolated field
devices, such as controllers, transducers, actuators and sensors. Each field device has low cost
computing power installed in it, making each device a smart device. Each device is able to
execute simple functions on its own such as diagnostic, control, and maintenance functions as
well as providing bi-directional communication capabilities. With these devices not only is the
engineer able to access the field devices, but they are also able to communicate with other field
devices.
In essence fieldbus will replace centralised control networks with distributed-control
networks. Therefore fieldbus is much more than a replacement for the 420mA analogue
standard. The fieldbus technology promises to improve quality, reduce costs and boost
efficiency. These promises made by the fieldbus technology are derived partly from the fact that
information that a field device is required to transmit or receive can be transmitted digitally.
This is a great deal more accurate than transmitting using analogue methods which were used
previously. Each field device is also a smart device and can carry out its own control,
maintenance and diagnostic functions. As a result it can report if there is a failure of the device
or manual calibration is required. This increases the efficiency of the system and reduces the
amount of maintenance required.

Fieldbus devices are more flexible than older devices due to the inclusion of a CPU. One
fieldbus device could be used to replace a number of devices using the 420mA analogue
standard. Other major cost savings from using fieldbus are due to wiring and installation - the 4
20mA analogue signal standard requires each device to have is own set of wires and its own
connection point. Fieldbus eliminates this need so only a single twisted pair wiring scheme is
required.
Ongoing Standard:The decision to provide an international standard saw the Instrument Society of America
(ISA), the International Electrotechnical Commission (IEC), Profibus (German national
standard) and FIP (French national standard), form the IEC/ISA SP50 Fieldbus committee. The
standard to be developed must integrate the enormous range of control instruments, provide
them with interfaces to operate various devices simultaneously, and set a communication
protocol to support them all. This daunting task was perceived by many to be moving too slow, a
problem compounded by companies world wide pushing to have their own product ideas
standardised. With the diversity in products and methods of implementation, there was no one
direct solution for the standard to be set to. In 1992, two groups, each consisting many major
companies world wide, emerged to lead the market in a fieldbus solution. The ISP (Interoperable
Systems Project) and WorldFIP (Factory Instrumentation Protocol) both share differing views
on the implementation of fieldbus, but they claim they will alter their products to conform to the
ISAs SP50 standard when it is formalised.
The SP50 committee decided to concentrate on four layers for the fieldbus solution:
1. Physical Layer: This defines the media that communication occurs over and could be
viewed as the 4 - 20mA standard replacement.
2. Data Link Layer: This monitors the communications taking place among the various
devices and detects errrors.
3. Application Layer: This formats the data into messages which all devices connected to
the network can understand and provides the services for process control, supplying them
to the user layer.
4. User Layer: This connects the individual plant areas and provides an environment for
applications. It is implimented using high level control functions.
The fieldbus has a multitude of advantages that the end users will benefit from. The
major advantage of the fieldbus, and the one that is most attractive to the end user is its
reduction in capital costs. The savings attained by the user stem from three main areas, initial
savings, maintenance savings, and savings due to improved systems performance.
WIRELESS TRANSMITTERS:The hottest thing in smart instrumentation is wireless transmitters. Presently use of wired
transmitters is for control purposesthey take a signal, and the computer makes a decision
based on that signal. Use of wireless transmitters is only for monitoring applications
Why wireless?
The first is to measure where you've never measured before. The second is to provide an
alternative to wires. So far, any solution you implement for measurement for sensing or
measuring has to have wires; whether fieldbus, or HART, or 420 mA, you'll have wires, he
said. The third scenario is the replacement of mechanical instrumentsgauges and transmitters.

We have integrated device containing the sensor, the signal conditioning device, the transceiver,
the battery, the antennas, the displays, and buttons in one unit.
The wireless technology used is the IEEE 802.15.1 standard Bluetooth version 1.2, which
operates in the 2.4 GHz ISM band. It uses FHSS technique. Frequency-hopping spread
spectrum (FHSS) is a method of transmitting radio signals by rapidly switching a carrier among
many frequency channels, using a pseudorandom sequence known to both transmitter and
receiver. WirelessHART communication uses Time Division Multiple Access (TDMA)
technology to arbitrate and coordinate communications between network devices. The TDMA
Data-Link Layer establishes links specifying the timeslot and frequency to be used for
communication between devices.

Wireless Vibration Transmitter

CONTROL SYSTEM
Programmable Logic Control:-

In most of the Offsite areas all relay based logic systems have given way to Programmable
Logic Control (PLC) based systems. In earlier days when PLC was introduced, it was mostly
used for Open Loop Control using ladder network which used combinational as well as
sequential logic (basically for low end use). With the advancement of microprocessors, the
processing power has increased and capacity of I/O and processing capacity has increased.
Nowadays it can be used for Closed Loop Control also. In otherwords the higher end version of
PLC is DDCMIS.

In the area of control system, there has been a major upgradation in DDCMIS
(Distributed Digital Control and Management Information System). Hardware wise, there has
been a drastic change because of the development of high speed micro-processors along with its
associated memory and input / output devices. The computation power has increased a lot. More
and more processing can be carried out in lesser time. Hence more intelligence is provided by
the system manufacturers. Diagnostic features are built into the system to monitor the
healthiness of the modules and reporting the same. Since reliability of hardware has increased
because of manufacturing technology of ICs, and also cost has reduced, digital electronics are
used almost everywhere. More density of electronic components can be accomodated in the
functional modules (cards) due to Surface mounted Devices (SMD). The control system operates
on 24V Dc power supplies, which is a low voltage and very safe. Distributed Digital Control is
process control and Management Information System is operator interface between the field
devices and the human being. MIS is the combination of the Data Acquisition system and
Operating System (OS). All operation is being carried out through the help of CRT and mouse
(workstation) and through Large Video Screens which provide dynamic multi-media
visualization and control. Sequence of Events recording (resolution 1msec) is also integrated in
the same system. The use of conventional Push Button stations has been reduced to a minimum.
Hardwiring has reduced and more stress is on communicstion and software.
Different manufacturers have different Hardware Architecture. Some have Fieldbus at
the field I/O level or conventional 4-20ma with HART protocol at field I/O level, their
proprietory bus at the control level and ethernet architecture at the OS level. In some system, the
operator stations directly communicate to the Process controllers via LAN and in other cases,
operator stations communicate to the process controllers via a central server. All controllers are
of modular concept. The same platform is used for Open loop control, Closed loop control,
Calculation and monitoring using function modules and signal modules.
Redundancy can be introduced at all levels. Dual redundant field sensors or tripple
redundant fiels sensors along with redundant processors are provided for all critical applications.
Redundancy can be provided at all processor levels and all bus communications. Power supplies
are also redundant. Hence availability and reliability of the system has increased. Processor
Master Slave configuration is available.

Open Loop Control:-

Group
Control
Sub-Group
Control
Drive Level Control

Process Interface

Drive Control function - All required process variables, manipulated variables, protection
signals, maual and automatic commands are routed to open loop modules. Transmitters
associated with the feeder, e.g. travel limit switches, are also suppied, detected and monitored by
the open loop control modules. Several drives functions as well as associated protection and
release interlocking circuits may be present on a module.
Subgroup Control function (SGC) - In the operating mode section, the manual, automatic and
protection commands for determining the mode application to the sequence control are linked
and the effective mode provided for further functions. In the program section, the manual,
automatic and protection commands as well as plant feedbacks and the effective mode are linked
to generate the program (standstill / operation) applicable to the sequence control and the
effective program is provided for further control. The interaction between the command block
and the step blocks is coordinated for the operating mode section and for the program section in
the organization section. The sequence control has different steps and each step has different
criteria to be fulfilled. Each step has a waiting period and a monitoring perion. Each step has a
command section. An example of SGC is Automatic Turbine Runup / Rundown System
(ATRS) which co-ordinates the Automatic startup / shutdown sequence, loading of the turbine
as per the stress margins available, automatic synchronization and loading of the turbine and
Unloading and shutdown of the turbine.
Group Control function The command section is the interface to the higher level open-loop
control and is used for operation and monitoring of the group control. The operating modes
(group control in manual mode or automatic mode) and the program (start-up / shut-down) are
determined in the command section. It is determined by preselection which sug group is selected
as the start for placing of the automatic control commands. One or several units can be
preselected. The preselected units are the plant units, i.e. they are started-up first and put out of
operation last, if necessary. The statuses of the group control and the lower level sub group
controls are monitored, fault signal are generated for alarm purpose and display.
Closed Loop Control:-

Standard features like PID and their varients, cascade control, feed forward control
(conventional controls) are used. In addition to the above , Predictive Control, Fuzzy logic
Control, State Feedback Control and Unit Co-ordination control including load prediction are
also used for Combustion control, Furnace draft control, Drum level control, Super heater and
Reheater control etc.
Predictive Control In process control, the control variables are often very slow in reacting to
the control element changes. To provide stable primary and secondary control, the principle
factors affecting the process are measured and along with the set point are used in computing the
the corrent process conditions. In this manner, whenever a disturbance occurs, corrective action
starts immediately to cancel the disturbance before it affects the controlled variable.
Fuzzy Logic Control It is required when conventional control does not provide satisfactory
result, process measurement are not directly possible and all the process facts cannot be reduced
to values 0 or 1 as required by any system. In Fuzzy logic, undefined quantities are interlinked
as input variables according to IF-THEN rules. In this logic, the experience and knowledge is
combined with open loop control strategies. Interdependencies in the process and disturbance in
variables are integrated into Fuzzy logic control design. Fuzzy logic controls are primarily used
for non linear processes which cannot be represented in mathematical models. Fuzzy logic is
used in Soot Blowing control.
State Feedback Control The function of the state feedback controller is to optimize closed loop
control for higher order systems. This is a model supported control algorithm. The state
feedback controller is much better compared to conventional controllers as it reacts faster to the
disturbances located at the beginning of the the process. A number of first order delay elements
are set up and their outputs are connected to the controller as intermadiate variables of the
process. These intermediate output variables are compared to the process output variable. Thus
the model is continuously matched to the process. Therfore, in this type of control, not only the
output variables but also the intermediate statuses of the process are used for the closed loop
control. Thus systems with short delay time are sreated which can be corrected faster. This type
of control is primarily used for sluggish controls.

Set Point

State Feed
back
Controller

Controller

Process

Feedback

Unit Co-ordination control including load prediction The unit co-ordination control is
provided with sufficient fuzziness and suplemented by the prediction of the load reserves. Its
application is very useful for power plant automation. The unit can be controlled in co-ordinated
master control (CMC) mode. The unit demand is transferred to turbine control system as set
point for electrical load generation. The same setpoint is used as a feed forward signal to the
boiler firing rate control. A correcting signal is added to or subtracted from the feed forward
signal to maintain steam pressure at its setpoint. On frequency related load load variations, the

setpoint is modified only if the frequency deviation is more than the recommended limits.
Provision for plant runback / runup depending on unit capability are also present. This results in
a simple and stable control system. Primary controllability is ensured by model based steam
generator control (control variable : thermal output) and turbine control ( control variable :
throttle steam pressure setpount).

Unit
Demand

Limits

Unit Set
point

Unit Capability

Turbine Load
Set Point

Boiler Load
Set Point

Management Information System:-

Various displays on the OWS/LVS include P&ID displays or mimic, bar chart displays, X-Y &
X-T plot (trend) displays, operator guidance message displays, group displays, plant startup/shutdown message displays, alarm facia displays, system status displays etc.
Basic Calculation - All the algebraic / logical calculations related to analog points (e.g., sum /
difference / average / maximum / minimum / integration, selection of one analog point out of
two. based on status of digital point, duration for which an analog point is above/below a
threshold, digital point (e.g., AND/OR/COMPARE etc.), transformations, like running average,
periodic average, weighted average, hourly/daily max./min. (or for a specified duration) & time
of max/min., flow calculations, time projection or rate of change calculations, duration in alarm
(or duration in a band), number of transgression of a point in a band etc are available.
Performance Calculation - Boiler efficiency , Gross turbine-generator heat rate , Gross unit heat
rate , Net unit heat rate, H.P. turbine enthalpy drop efficiency, I.P. Turbine enthalpy drop
efficiency , L.P. turbine enthalpy drop efficiency(using dry exhaust) , Feed water heater
performance terminal temperature difference , Feed water heater performance drain cooler

approach , Condenser performance, Deaerator performance , Economizer performance , BFP

performance , Air Pre-heater performance, Fan efficiency, Unit availability calculations.
Merit Order Rating Calculation for most efficient multi-unit operation.
The system generates three basic types of reports/logs i.e., Event activated, Time activated and
Operator demand log & summaries. Historical storage and retrieval of process system data is
also available.
As the sequence of events FSSS operation on record as demanding, and may be combined to
complete the multi-system function, so SOEs with a time stamp of digital input devices and
related functions must be available.
WIRELESS TECHNOLOGY:The next technological revolution that will impact plant performance is wireless a
technology that will have further implications on reliability and availability. A wireless solution
cost-effectively extends the full benefits of a digital bus-based plant architecture to locations that
were previously inaccessible. Going wireless can eliminate the need for drilling through
concrete decks, installing conduit and cable trays and pulling wires.
Even more importantly, data from wireless devices can be seamlessly integrated into the
control system, offering insight into additional plant and process data for control and asset
optimisation. This translates into further operational efficiencies and performance
improvements.
Wireless devices employ self-organising mesh networks in which each device can act as
a router for other nearby devices, passing messages along until they reach their destination. If
there is an obstruction, transmissions are simply re-routed along the mesh network until a clear
path to the gateway is found.
As conditions change or new obstacles are encountered in the plant, such as temporary
scaffolding, new equipment or a parked construction trailer, these wireless networks simply
reorganise and find a way to deliver the data. All of this happens automatically, without any
involvement from the user.