Instrumentation questions and answers

Q: what is instrumentation ?
A: To measure, monitor and control the process variable is called
instrumentation.
Q: what are the main parameters in industrial instrumentation.
A: 1. Flow 2. Pressure. 3. Temperature.
4. Level. 5. Quality.
Q: Define range.
A: Distance between zero and span is called range.
Q: Define zero.
A: Minimum value of the range is called zero.
Q: Define span.
A: Maximum value of the range is called span.
Q: Define pressure.
A: Force acting per unit area is called pressure.
P== F/A
Q: What are the types of pressure measurement ?
A: There are three types of pressure measurement.
1. Gage pressure 2. Absolute pressure 3. Vacuum
Q: What is the main part of pressure guage ?
A: Bourdon tube.
Q: What are the units of pressure measurement ?
A: kg/cm², bar, psi, kpa, mm of water column.
Q: Explain working a pneumatic relay in pressure transmitter.
A: 1. The supply pressure 20 psi is passing through a resister to the nozzle. The
pressure pressing to the flapper. The back pressure appear on the diaphragm.
2. The relay assembly having 20 psi supply, and 3 to 15 psi out put. This output
is controlled by diaphragm which is getting back pressure signal from the nozzle.
Q: What is absolute pressure ?
A: It is total pressure in the system.
Absolute pressure ==== Guage pressure +atmospheric pressure.
Q: What is guage pressure ?
A: Guage pressure ===== Absolute pressure – atmospheric pressure.
Q: What is perfect vacuum ?
A: 760 mmhg.
Q:1 bar is equal to------psi ?
A: 14.5
Q: What are types of pressure measuring methods electronics
transmitter ?
A: 1.Resistance type, 2. Inductance type, 3. Capacitance type
Q: An electronic pressure transmitter range 0-60 psi. What will be the
output at 24 psi ?
A: 10.4 ma.
Q:A pneumatic transmitter 8.3 psi. What will be its input ?
A: 44.16 input.
Q: What are main manometer liquids ?
A: Alcohol, mercury.
Q: What is the specific gravity of mercury ?
A: 13.6 gr/cc.
Q: Expand mmwc.
A: millimeter of water column.
Q: Define specific gravity.
A: The specific gravity of a liquid is the ratio of its density compared with the
density of water at 4 degree celcious.
Q: Define density.
A: The density of a material is its weight per unit of volume.
Q: Expand mwp.
A: Maximum working pressure.
Q: What is purpose of a DP transmitter using across the filter ?
A: It is used to see whether in side filter is there more dust or not. If there dust is
more the DP will be more and then it is the time to clean the filter.
Q: Explain calibration procedure of DP transmitter.
A: The following steps are to be taken :
1. Adjust zero of the transmitter.
2. Static pressure test : give equal pressure on both side of the transmitter.
Zero should not shift. If it is shifting carry out static alignment.
3. Vacuum test : apply equal vacuum on both side. The zero should not shift.
4. Calibration procedure : give 20 psi air supply to the transmitter,
Vent LP side to atmosphere,
Connect standard test gage in output side of transmitter. Adjust zero.
5. Apply required pressure to high pressure side of the transmitter and adjust
span.
6. Adjust zero again if necessary.
Q: Explain two procedure to check the zero of a flow transmitter in on
line without venting or draining.
A: 1. Isolate both isolation valve and open equalizer.
2. Isolate one isolation valve and open equalizer.
Q: A DP flow transmitter 0—100"w/0—100 bpd. What will be the flow
at 30 percent input?
A: 9BPD
Q: Response time of the t/c is-------- than the RTD.
A: Slower.
Q: The non linearity of RTD is --------than T/C.
A: Better.
Q: What is the purpose of siphon using with pressure guage?
A: To avoid, effect bourdon tube by steam.
Q: Explain BOAYANCY principle.
A: When an object is immersed in a liquid fully or partially, the apparent loss of
weight of the object will be equal to displaced liquid.
Q: Explain purge type level measurement.
A: This method is also known as bubbler method of level measurement. A pipe
is installed vertically with its open end at the zero level. The other end of the pipe
is connected to a regulated air supply and to a pressure gauge or to Pressure
transmitter. To make a level measurement the air supply is adjusted so that
pressure is slightly higher than the pressure due to the height of the liquid. This is
accomplished by regulating the air pressure until bubbles can be seen slowly
leaving the open end of the pipe. The gage then measures the air pressure needed
to over come the pressure of the liquid.
/\ P = H X D
USE : On for corrosive liquids where the transmitter cannot be directly connected
to process e.g... Acids, Some organic liquids.
Q: Name two types flame sensing measurement.
A: 1. Pyrometer 2. Ultra violate scanner
Q: 45 degree celcious is equal to--------- degree farenheit.
A: 113 degree Fahrenheit.
Q: Two control valves operated in split range having 4-12 ma direct
and 12-20ma reverse operating range, at 14 ma signal both valve be ----
--- % opening.
A: 75%.
Q: 40 degree celcious corresponds to ------- degree farenheit ?
A: 104 degree Fahrenheit.
Q: Generally for a temperature control------- action will be suitable.
A: Derivative action.
Q: Name two factors to be considered in actuator sizing.
A: Line pressure and temperature.
Q: How can a control valve be made quick opening ?
A: The positioner contains different types of cam in it. By selection of the proper
cam in it and changing the plug of the valve we can made the control valve quick
opening.
Q: For gland packing of a high pressure and temperature control valve
which material to be used ?
A: Graphite.
Q: What is generally material of construction of control valve
diaphragm ?
A: Rubber.
Q: What is generally material of construction of control valve body ?
A: Mild steel.
Q: In which instrument peak detection is used ?
A: Oscilloscope.
Q: Write advantage of circuit braker over fuse ?
A: It prevent to damage expensive wiring and the risk of fire.
Q: What is virus in computer ?
A: It is a command to hazardous the computer program.
Q: Where is SR flip flop used in industrial instrumentation ?
A: PLC.
Q: Where is opto coupler used in industrial instrumentation ?
A : PLC.
Q: Where is 250 ohms precision resistance used in industrial
instrumentation ?
A: Recorder, controller.
Q: Name any operating system that you know.
A: Windows.
Q: Name any application packages that you know.
A: Microsoft word.
Q: What is harmonics in an ups out put ?
A: Harmonics is in other word called as static switch. The harmonics is permit
current flow in one direction only.
Q: What is multiplexer ?
A: Many input and one output is called multiplexer.
Q: What is full form of HRC fuse ?
A: High rupturing cartridge fuse.
Q: What is difference between toxic gas and explosive gas ?
A: Toxic gas---- It is harmful in breath.
Explosive gas----- It is flammable gas, it can catch fire.
Q: What precaution should you take while flushing a transmitter ?
A: 1. Inform operator 2. Keep ready water hose 3. Wear gloves and goggles
4. Wear gas mask if necessary.
Q: What are the different types of orifice plate in use ?
A: 1. concentric. 2.essentric.
3. segmental. 4. quadrant.
Q: Orifice equation is based on---------- .
A: Flow characteristics.
Q: Why three wire RTD is preferred ?
A: It has more accuracy than the two wire RTD system because of lead line
compensation.
Q: Name three types of RTD .
A: 1. Platinum 2. Nickel 3. copper
Q: Name any one method for measuring density ?
A: Resonance frequency.
Q: The radio metric type analyzer is used for measurement of------.
A: Hydrocarbon.
Q: What is redundant system ?
A: Redundant system is a fail safe system. Where there is stand by identical
system ready to take over when the main system is fail.
Q: Specific gravity of water is ------------ .
A: 1.
Q: Unit of radioactivity is ------------ .
A: Lbs/min.
Q: What is cascade control ?
A: Cascade means two controller in series, one of them is a master or primary
and the second is secondary or slave. The out put of master controller is set point
of slave controller output of slave controller operates the final control element.
Q: What is feed forward control ? What is advantages to using it ?
A: Feed- forward control system is a system in which corrective action is based
on measurement of disturbances inputs into the process. This mode of control
responds to a disturbance such that is instantly compensates for that error which
the disturbance would have otherwise caused in the controlled variable later in
time.
Q: Define CV.
A: CV= Q√gf/p. number of U.S gallons per minute of water which pass throw a
fully open valve at a pressure drop of 1 psi at 60 degree Fahrenheit.
Q: Normally, gap voltage is adjusted about -----for a vibration probe.
A: -7.5
Q: What is fault tolerant system ?
A: Voting logic is called fault tolerant system.
Q: What is the power factor of AC voltages ?
A: Power factor of AC voltage is current and voltage between of angle. It is also
called apparent power.
Formulae :- power factor = kw/kva, R/Z = true power/apparent power.
Q: Write relationship between absolute pressure, guage pressure and
atmospheric pressure .
A: Absolute pressure == guage pressure + atmospheric pressure.
 Guage pressure ==== absolute pressure – atmospheric pressure.
Atmospheric pressure ==== absolute pressure – guage pressure. The pressure
erected on a body by the air equal at sea level about 14.7 psi.
Q: Why seal pots are used ?
A: It is used in steam line service to condensate the water.

Q: A DP transmitter gives correct output while it is calibrated in

workshop. However when it is commissioned it gives constant or
errectic output and even after opening equalizing valve , does not come
to zero. What may be the reason ?
A: Cable is grounding.
Q: Write two reasons for using a barrier .
A: 1. Protect for short circuit in between LIVE supply.
Q: Two resistance of 10 ohms ,each are connected in parallel. The
combination is connected in series with a 50 ohms resistance . Find
equivalent resistance in circuit .
A: According to formulae :
1/r = 1/r1 + 1/r2 + 1/r3
= 1/10 + 1/10
= 10 +10/100 =1/5
so, resistance = 5Ώ +50Ώ =55Ώ
Q: What is fuse co-ordination ?
A: 1. Prevent the passage of full fault current during short circuit.
2. result is opening of fuse contact in less than 1 milli second.
3. Total operating time is reduced to less than 5 milli second.
Q: A flow transmitter showing higher reading, its calibration is alright.
Write any two possible reason for its abnormality .
A: 1. L.P side of lead line is chawk.
2. Cable is shot.
Q: A light bulb has specification written on it as 100w,100v dc, find
resistance of the bulb.
A: According to formulae :
R = V²/W =100²/100 =100*100/100 =100Ώ
Q: A control valve in the field does not respond to the signal from
controller in auto or manual. Write any specific reason for its
abnormality. Control valve positioner is all right.
A: Control valve diaphragm is puncture or air leak from gland.
Q: What are primary measuring elements in differential flow
measurement?
A: Orifice plate, DP cell, venturi tube, pitot tube, flow nozzle.
Q: Which one has more DP in orifice plate, flow nozzle and venturi
tube ?
A: Venturi tube.
Q: Explain turbine flow meter .
A: Turbine meters consist of a straight flow tube within which a turbine or a fan
is free to rotate about its axis which is fixed along the center line of the tube.
Straightening vanes upstream of the turbine minimizes possible rotational
components of fluid flow. In most units a magnetic pick-up system senses the
rotation of the rotor through the tube wall. The turbine meter is a flow rate
device, since the rotor speed is directly proportional to flow rate. The output is
usually in the form of electrical pulses from the magnetic pick-up with a
frequency proportional to flow rate. Turbine meters are primarily applied to
measurement of clean and non-corrosive hydrocarbons.
Q: What is the unit of viscosity ?
A: Centipoise.
Q: What is Reynolds number ?
A: In flow metering, the nature of flow can be described by a number – the
Reynolds number, which is the average velocity * density *internal diameter of
pipe ÷ viscosity.
In equation form, it is R = vDρ/μ,
Where. v = velocity, D = inside diameter of pipe,
Ρ = fluid density, μ = viscosity.
Q: Classify control valve depending on action .
A: 1. Air to open. (direct)
2. Air to close. (reverse)
Q: Classify control valve depending on body .
A: Globe valves single or double seated, angle valve, butterfly valve, pinch
valve, gate valve and ball valve.
Q: What are valve characteristics of control valve ?
A: 1. Linear 2. Quick opening 4. Equal percent
Q: Explain cage valve .
A: A cage valve uses a piston with ring seal attached to the single seated valve
PLUG. Here the hydrostatic forces acting on the top or the piston or below the
valve plug tend to cancel out. The seal ring is clamped in by a cage.
Q: Note parts of a control valve .
A: Actuator, diaphragm case, diaphragm, spring, stem, yoke, body,
seat, plug, bonnet, lantern ring etc.
Q: What is split range in control valve ?
A:

Q: What does it mean by positioner BY-PASS ?

A: Positioner by-pass mean the signal air which is going to the valve through the
positioner. It will go directly to the valve when we will put positioner by-pass.
Q: What is bench set in control valve ?
A: Bench set in control valve is a spring range sitting.
Q: What are valve accessories in control valve ?
A: Positioner, regulator, I/P and pressure gage.
Q: Explain OHMS law .
A: Volt is directly proportional to current multiply by resistance.
V= IR.
Q: What will be the result resistance in parallel and series ?
A: In parallel ------------- resistance will be decrease.
In series ---------------- resistance will be increase.
Q: Define resistance .
A: The opposition in the current path is called resistance. Symbol is R. or,
Resistance is an electrical circuit refers to the resistance to current flow.
Q: Define capacitance .
A: Capacitance is the property which resist a change in voltage.
Q: Define inductance .
A: Inductance is the property of an electrical circuit that resist a change in
current.
Q: What are the units of resistance, capacitance and inductance ?
A: Resistance = ohms.
Capacitance = farad.
Inductance = Henry.
Q: Name two semiconductor crystals .
A: 1. silicon 2. germanium.
Q: What is peak inverse voltage ?
A: Peak inverse voltage is maximum reverse voltage across the diode during the
cycle.
Q: What will be the effect in capacitance in series ?
A: When it will be connected in series, it will increase of stroboscopic effect.
Q: Henry is the unit of --------- .
A: Inductance.
Q: Hertz is the unit of ----------- .
A: Frequency.
Q: Name a semiconductor thermal sensor .
A: Thermister.
Q: Name unit of electrical conductance .
A: mhos, A mhos =1/1ohm.
Q: How do you calibrate D/P transmitter in line ?
A: procurement of work permit, controller in manual mode and if trip exist,
disable the same by informing the operator. Close both main isolation valve, open
equalizer and drain if any. Adjust zero and then apply maximum calculation span
and if require adjust span.
Q: What is the seal liquid used for filling impulse line on crude/viscous
liquid.
A: Glycol.
Q: What are the types of thermocouples in industrial use ?
A: 1. Iron constantan (j) 2. Chromal alumal (k) 3. Chromal constantan (e)
4. Copper constantan (t) 5. Platinum-pt-rhodium (S and R).
Q: What are the types of RTD ?
A: 1. Platinum 2. Nickel 3. Copper
Q: What does PT-100 means ?
A: Pt 100 means 100 ohms at 0 degree Celsius.

Q: What does it mean by interface ?

A: Interface is any spurious voltage or current arising from external sources and
appearing in the circuits of a device.
Q: Explain wet calibration of a level troll .
A: 1. Adjust the zero to get 0% output.
2. Connect a transparent pvc tube to the drain point .
3. Fill it to the center of the top flange.
4. Adjust the specific gravity .
5. Fill it to the 50% to check linearity.
Loss of weight at 0% === weight of displacer
Loss of weight at 100% = (weight of displacer- volume)* Ώ
Where volume = Πr²h, Ώ = specific gravity.
Q: Explain weight calibration of an interface level troll .
A: Wt. test calibration method :
Remove the displacer from the torque arm.
Apply equivalent weight on the torque arm that is equal to the wt. of the
displacer. Adjust zero % output.
For Span : V =
‫ﻩ‬r 2 h
loss in weight = Wt . of float - wt .of the float immersed in liquid
Loss in weight = [wt . of float - Vol . xd]
Span wt. = (wt. of float – loss in wt.)
r = radius of the displacer.
h = ht. of displacer.
Apply equivalent wt. equal to the (Wt.of float - Loss in weight). Adjust Span
to get 100 % out put.
To check linearity apply average of the two weights.
Q: What will happen if the displacer has fallen down while in line ?
A: Out put will be maximum.
Q: What will happen if the displacer has a hole in it while in line ?
A: Out put will be minimum.
Q: What are limitation of level troll ?
A: 72 inches.
Q: What is the CV of a valve ?
A: CV= Q√GF/P. Number of U.S gallons per minute of water, which pass throw
a fully open valve at a pressure drop of 1 psi at 60 degree Fahrenheit.
Q: What types of bonnet would you use for high temperature and very
low temperature ?
A: High temperature ---------- Radiation bonnet.
Low temperature ----------- Extension bonnet.
Q: What is the use of valve positioner ?
A: 1. Fast action 2. Split range 3. Hysterisis 4. Action
5. Characteristics
Q: When can a by-pass not be used on a positioner ?
A: 1. Split range operation 2. Reversing action positioner
3. Valve bench set not std.
Q: Why does a transmitter o/p signal start from 3-15 PSI or 4-20 MA ?
A: The transmitter output starts from that is known as LIVE ZERO. This system
has specific advantages :
1. The system automatically alarms when the signal system becomes
inoperative.
2. The output areas is linear. (ratio of 1:5).
Q: How will you calibrated an absolute pressure transmitter, using a
vacuum measurement range 0-400 MMABS HG?
A: 1. Connect air supply to the transmitter .
2. Connect test guage of 0- 1.4 kg/cm² to the output.
3. Connect vacuum pump with tee-off to the manometer .
4. Apply 760 mmhg vacuum and adjust zero.
5. Apply 360 mmhg vacuum and adjust span.(760-360=400mmabs).
Q: What is the principle of a pressure guage ?
A: Pressure guage works on Hook’s law.
˝measuring the stress in an elastic medium.˝
Q: Why the flow measurement in square root ?
A: Flow varies directly as square root of D.P. Since this flow varies directly the
pen does not indicate flow directly. The flow can be determined only by taking
the square root of the pen.
Q: Define accuracy.
A: Accuracy is the instrument’s ability to indicate the true value of the variable
being measured.
Q: What is the absolute zero pressure ?
A: It is total pressure in the system.
Absolute pressure ==== guage pressure + atmospheric pressure
Q: What is the maximum and minimum vacuum ?
A: Maximum vacuum =760 mmhg.
Minimum vacuum = -760 mmhg.
Q: What are the primary elements for a pressure measurement ?
A: Bourdon tube, Bellows, Capsules, Diaphragm.
Q: What is dry leg in DP measurement ?
A: In open tank, LP side is open in atmosphere. That LP leg is called dry leg.
Q: Calculate calibration range of a D/P level transmitter, open tank
height 1000mm and specific gravity .85 .
A: 850 mm of water column.
Q: Name any one application in instrumentation using electrochemical
principle .
A: oxygen trace analyzer.
Q: While specifying a control valve, where would you specify
extension bonnet ?
A: Extension bonnet are used for low temperature service, i.e. for fluid
temperature below -20 degree Fahrenheit. Its purpose is to keep packing box
from freezing. To achieve this heating coils are sometimes wrapped around the
bonnet.
Q: Explain cascade control system.
A: Cascade means two controllers in series, one of them is a master or primary
and the second is secondary or slave. The output of master controller is set point
of slave controller and output of slave controller operates the final control
element.
Q: Explain ratio control.
A: A ratio control system is characterized by the fact variations in the secondary
variable do not reflect back on the primary variable.
Q: What is feed back control ?
A: Feed back control involves the detection of the controlled variable and
counter acting of changes in its value relative to set point by adjustment of the
manipulated variable.
Q: What is feed forward control ?
A: It is a system in which corrective action is based on measurement of
disturbance inputs into the process.
Q: Mention where can be use single seated valve .
A: It is used for low pressure line.
Q: Mention where can be use double seated valve .
A: It is used for high pressure line.
Q: What is the use of a link connect to the valve ?
A: The link serves the feed-back to the positioner. A valve movement is sensed
by this link. Sometimes due to line pressure changes on H.P. service the valve
position may be changed, the link in turn senses this change and the positioner
will produce an output which will operate the valve to the original position.
Q: define proportional action .
A: By which the controller output changes proportionally from minimum to
maximum and vice-versa, when the measurement deviates from the set point.
Q: Explain what is gain ?
A: Gain = 100/proportional band setting.
Q: Define integral .
A: It is called reset action also. Reset action in controller is the integration of
proportional action by the set period. The reset action repeats the proportional
action's
output per the reset time set, until the error signal becomes zero or the output gets
saturated.
Q: What is differential gap control ?
A: Differential gap control is similar to on-off control except that a band or gap
exist around the control point.
Q: What is the proportional band ?
A: It is the range in percentage, which is exist in controller.
Q: What are the skin temperature thermocouple ?
A: Skin thermocouples are those which are directly connected to the process
without any thermowell. Used for measuring the skin temperature of heaters,
furnace, flue gas etc.
Q: what is controller ?
A: That instrument which compare process variable to set point and take a
correct action.
Q: what is transmitter ?
A: That instrument which sense process variable and convert it to standard
signal, then transmit that standard signal to recorder or controller.
Q: what is primary element ?
A: That element which sense process variable, called primary element.