TRENDS IN INSTRUMENTATION

Evolution of Instrumentation and Control Technology

DCS
Manual Distributed
Control Control
System

Pneumatic
Control
(local)
Data Acquisition
System DAS

Pneumatic
Analog
Control
Electronic
(centralised)
 EVOLUTION

ELECTRONIC
MANUAL PNEUMATIC ANALOG DIGITAL ?
Pre 1940’s 1940’s-50’s 1950’s-70’s 1980’s to date

INFORMATION Pneumatic Electrical Electrical,

FLOW: Digital (Binary)

COMPUTATION: Mechanical Electronic Digital

(Bellows, Springs) Analog Computer

TRANSMISSION 0.2 to 1.0 bar 4 to 20 mA Digital standards

(3 to 15 psi) (HART, Fieldbus)
SIGNAL:
Current signal transmission -
Transmitter configurations
 Figure 1 shows a 4-wire transmitter
energized by a supply voltage at the
transmitter. The transmitter sources the
loop current to a floating receiver load.
• Figure 2 shows a 3-wire transmitter
energized by a supply voltage at the
transmitter. The transmitter sources the
loop current. Transmitter common is
connected to receiver common
• Figure 3 shows a 2-wire transmitter
energized by the loop current. The
transmitter floats and signal ground is in
the receiver.
 Current Trends
• Industry is replacing pneumatics
• Distributed control systems (DCS) is becoming
standard
• Analog is giving way to digital
• Increased processing power
• “Smart” instruments
• Tiny, cheap, low power consuming devices
• Advanced control strategies (Adaptive/self
tuning/fuzzy)
• Faster communication
• Wireless communication
 THREE LAYERS OF CONTROL

• GUI based SCADA/

HMI Systems.
• Expert systems with predictive dianostics. Supervisory
• Digital Control Systems (PLC and DCS) Control & HMI
-faster, cheaper and more common. Distributed Controls,
• Sophisticated Control PLC, Loop Controllers
• Smart sensors Sensors & Instrumentation
communicating digitally or
network capable.
• Fieldbus
• Wireless
 SHIFT TO DIGITAL
Digital electronics technology has rapidly taken over
the bulk of new electronic applications because of
its increased functionality, lower cost, improved
reliability and reduced maintenance requirements.
Use of computers started at the higher layers of
control. Control panel instruments (controllers,
display meters, recorders, etc.) have essentially
become digital electronics devices. Relay logic has
been replaced almost completely by digital logic.
Transmitters are also becoming digital and
incorporating ‘smart’ features although there is
continued preference for analog output signals (4–
20 mA).
 SHIFT TO DIGITAL
Field instruments are now being produced which communicate with
other devices utilizing total digital data transmission rather than
analog transmission. Analog transmission is limited to only one device
on a pair of wires. On the other hand, digital communications allow
several devices to share a single pair of wires. This reduces the cost
of signal wiring. Further, digital communications are bi-directional.
This allows field devices to talk to each other and allows the field
instrument to be accessed and configured from a remote location. For
example, if a user wants to re-scale an instrument he can do so by
using a software application and the digital communications path
without leaving the control room.
Most digital instruments have combined the digital data with the long
time standard of 4-20 mA dc analog signal since it has been hard to
move the end user away from the analog world. The digital instrument
communications protocols used in past have been proprietary and
they are slow. In recent years there has been a move toward more
widely accepted protocols which take the generic title “fieldbus”.
 Smart Sensor Technology Evolution

“Smart” Sensors
Ease of Configuration

Sensor A/D P network

and Connectivity

Legacy
Sensor
analog

Raw Transducer Intelligent Networked

Sensor Integration Sensor
(and Development)
EVOLUTION IN VALVES

Manual Pneumatic Electrical DCS/PLC Fieldbus Wireless

“The old way The birth of Hardwired Adds visual Reduction in More
Plant the Advancements display of capital pressure to
operators are “automated in control valve position expenditure reduce capital
required to valve” systems to the leads to expenditures
manually turn Pneumatic create the electrical adoption of and operating
valves to actuators need for feedback and fieldbus costs will
proper drive valves electrical helps reduce process introduce
position open and feedback of wiring costs control wireless field
closed valve position architectures devices
automatically provided by – and
limit switches compatible
on/off devices
 Smart Sensors (do more than what you
expect )

Signal
TXDR ADC MPU Comm.
Conditioning

Sensors with onboard microprocesssors that offer communication

capability, self-monitoring and compensating capabilities and number
of diagnostic capabilities..
Examples:
• Smart pH sensors determine when it is necessary to trigger a wash
cycle due to buildup on the electrode surface.
• Smart flow meters use statistical techniques to check for plugging of
the lines to the DP cell.
• Smart temperature sensors use redundant sensors to identify drift and
estimate expected life before failure.
 Smart Transmitter
The primary characteristic of a smart transmitter is having a
digital output. However, “smart” refers to more than one
characteristic. To be smart,device must have the following
three features:
- Microprocessor based
- Digital output
- Capable of remote two-way communication
The above are defining characteristics for any field device to
be smart.
The following are additional characteristics that smart
transmitters typically have:
- Higher accuracy than analog transmitters
- Remotely programmable
- Capable of accepting more than one type of sensor
Smart transmitters, have potential advantages of
additional diagnostic capability, internal compensation
for higher accuracy, remote engineering range change
capability via a handheld unit and digital
communications that may be used to provide secondary
variables.
 HART® ( Highway Addressable Remote Transducer) protocol

Transmitter 4 - 20 mA+ Hart

1,4bar
Set Point

I/P
4 - 20 mA+ Hart
3 - 15 Psi

HART protocol provides a single pair of wire to each field device and powers the
device over the 4 to 20 mA signal current. HART is a hybrid protocol of analog and
digital communication developed to define the communication between intelligent
field devices and a control system using superimposed digital information on the
conventional 4-20 mA analog signal. The HART protocol permits the process variable
to continue to be transmitted by the 4-20mA analog signal and additional information
pertaining to other parameters, device configuration, calibration, and device
diagnostics to be transmitted digitally at the same time.
mA
20

4
 HART - Principle
HART was developed by Fisher-Rosemount to retrofit 4-to-20mA current loop
transducers with digital data communication. HART modulates the 4-20mA current with
a low-level frequency-shift-keyed (FSK) sine-wave signal, without affecting the average
analogue signal.

HART uses low

frequencies (1200Hz
and 2200 Hz) to deal
with poor cabling.
Practically all 4..20mA
devices come equipped
with HART today.
It has limited digital
capability and does
not support a true
multi drop capability.
Conventional
Transmitter

HART
Transmitter
 Fieldbus
DCS vs. Fieldbus System

Workstation Workstation

Controller Fieldbus eliminates

FIELDBUS
the need for I/O
Other field devices
A/D
DPharp eliminates
the need for A/D
4-20 mA

Fieldbus Interface Fieldbus Interface

D/A
Microprocessor Microprocessor
Microprocessor
A/D
A/D Sensor
A/D
Digital
A/D
A/D Today’s Analog
Sensor Sensor Sensor
Scheme
Sensor Scheme Scheme
Sensor
 Fieldbus Architecture

Plant-Wide Network

Local Local
Area
Network
................. Area
Network

Smart Smart Control Smart Smart Control

Sensors Valves and Sensors Valves and
Controllers Controllers

Fieldbus Network Fieldbus Network

a
 Fieldbus Technology
• Based upon smart valves, smart sensors and controllers
installed in the field.
• Uses data highway to replace wires from sensor to DCS
and to the control valves.
• Less expensive installations and better reliability.
• Can mix different sources (vendors) of sensors,
transmitters, and control valves.
• Now commercially available and should begin to replace
DCSs.

What Does Fieldbus Enable?

• A digital plant architecture that uses the power of field
intelligence to improve plant performance.
Indicators

With the advent of Good for indicating discrete state

electronics and
LED/LCDs the analog
indicating meters have
been replaced with
digital technology.
Good for qualitative
Sometimes a digital
reading
indicator is used to Good for quick
simulate an analog quantitative reading
scale. Digital indicators
with an
electroluminescent
display have become
common.
 Recorders
Recorders are data acquisition tools used for trend displays. Recorders can present
parametric information about rate of change, direction of change and approach to
limits and also provide historical data over time for analysis/diagnostics to generate a
plot, graph or other visualization of data versus time. Chart recorders typically output
data in one of four common formats. These include circular, x-y plotter, strip chart, or
paperless. Circular charts rotate uniformly while variable is plotted radially.
Advantages include relatively compact size and simplicity of operation. Revolution
time may span from minutes to hours(8/12/24). In an X-Y plotter two selectable
variables are plotted against each other in rectilinear coordinates. The paper source is
often a standard size sheet, but can also be a roll or drum. Plotted variables may
include mathematical functions of data input. Strip charts plot variables with regard to
time, as the paper strip advances uniformly through the plotter. Strip frequently comes
from a roll. In a paperless or video graphing system the plot is displayed on video
screen. Scaling and mathematical functions are possible. It is possible to produce
multiple plots simultaneously.
 Paperless or videographic recorders

A paperless recorder resembles a traditional paper chart recorder,

however, instead of recording a with pen and paper, it displays the value
on a display screen and also records the measured values to memory.
The following are some of the advantages of using paperless recorders -
1. Traditional chart recorders have wear, paper jams with moving
pens and charts. Paperless recorders are comparatively
maintenance-free, with no pens, paper drives, or motor
mechanisms and eliminate paper handling.
2. Most paperless recorders allow several selectable display modes
for viewing trends and data from a variety of perspectives with
extended mathematical capabilities (such as minimum, maximum,
average).
3. Data can be exported to other applications.
4. Most designs can record several recording periods of data, rather
than the 8/12/24 hours only. Long term data storage is possible
depending on memory capacity.
5. Many paperless recorders are available with 6/ 8/12/18 recording
 Typical Paperless Recorder
Features: Paperless recorder displays up to 18
channels of data on a brilliant 5.7" TFT color LCD. A
wide variety of display modes allows users to view
data as trends (horizontally or vertically), bar
graphs, analog meters, digital/numeric output,
totalized output, event summaries, and more.
Switch between display modes quickly and easily
with the front key panel.

Typical specifications -
•Long Term Data Storage: Up to 1.5 years in
Compact Flash (with the optional 256MB
Compact Flash card
• Saved Data playback: Saved data in Memory card
can be easily called out and played back on display
• Math and totalization: These functions are
available as standard.
•18-point recording: 12 types of thermocouples, 5
types of RTDs and a voltage/current input are
available
 Typical Paperless Recorder
A paperless recorder that displays, records and transmits.
Flexible multi-coloured display modes mean that the
process variables can be displayed as multi-channel
digital numeric displays, in bar graph format or as curves
similar to those of standard strip chart recorders. The
integrated alarm and set point management system
enables up to 14 freely programmable set points
(min/max) to be allocated to any input channel and when
active can be displayed on screen and transmitted using
up to four available relays.

Safe and secure measurement storage is guaranteed

by the internal digital memory (upto 512MB
CompactFlash card) where no data loss occurs, even if
there is a power failure. Offering 100 ms scan rate, Sirec display recorder units
recorder includes USB port, Ethernet, RS485/RS232, (D200, D400 shown)
and embedded web server for remote monitoring from provide full color data
anywhere. display, logging,
communicating, and
archiving.
 Graphic User Interface
(GUI)
GUI is an interface for issuing
commands to a computer utilizing
a pointing device, such as a mouse,
that manipulates and activates
graphical images on a monitor.
GUI uses windows, icons and
menus and which can be
manipulated by a mouse (and often
to a limited extent by a keyboard
as well). GUIs stand in sharp
contrast to command line
interfaces (CLIs), which use only
text and are accessed solely by a
keyboard.
Large displays –
Video walls
There is a trend to use
back-projected dynamic
displays on large (67”
diagonal size) video
screens. The displays can
be viewed from distance
and help in better co-
ordination among the
control room staff. The
technology to make large
displays is however ever
changing.