Examination CA Mid- End- Total

Term Term
Marks (15) (25) (60) (100)
Distribution
Module I - 15 10 25
Module II 15 10 10 15+10 (avg M
& E)
Module III 10+5 - 10+5 20+5 Avg
(CA+ ET)
Module IV - - 25 25
Total 15 25 60 100

Mid-Term Syllabus:
15 (Introduction terminology, Pressure, Temp, Level, Flow)
10 (2nd Order, Controller, and Control Valve)

Additional Sample Questions:

1. List the main types of indicating instruments used in process control.

2. Explain the working principle of a capacitive transducer with a schematic diagram.
3. A piezoelectric sensor is used to measure vibration. Explain the principle of
piezoelectricity and how it helps in vibration measurement.
4. Apply the basic working principles to suggest a suitable sensor for motion detection in
industrial applications.
5. Analyze the advantages and disadvantages of ionization-based transducers compared to
photoelectric transducers in chemical process monitoring.
6. Evaluate why inductive transducers are preferred in high-precision displacement
measurements.
7. Design a system using multiple sensors (thermal, mechanical, electromagnetic) to monitor
the operational safety of a reactor.
8. Analyze how the resolution of a measurement instrument impacts the detection of small
changes in process variables. Provide a real-world example where high resolution is
crucial, and discuss the trade-offs involved.
9. Design a comprehensive calibration procedure for a pressure measurement instrument
used in a chemical reactor. Explain how you would account for potential sources of error
and the impact of calibration on process accuracy and safety.
10. Evaluate a scenario where both dead band and hysteresis affect the performance of a
temperature control system. How would you address these issues to ensure precise
temperature regulation in a chemical process?
11. Discuss how repeatability and reproducibility are tested in a flow measurement system
used for a critical chemical reaction. Suggest methods to improve both parameters in a
real-world application.
12. Explore a case study where a trade-off between accuracy and resolution needs to be made.
How would you determine the optimal balance between these factors for a specific
chemical process measurement?
13. Analyze how span shift and zero shift can affect the performance of a flowmeter in a
chemical plant. Propose strategies to minimize these shifts and ensure reliable
measurements.
14. Assess the impact of hysteresis on the performance of a temperature sensor in a high-
temperature chemical reaction. How would you mitigate its effects to ensure consistent
and accurate temperature readings?
15. Design a new type of sensor that maximizes sensitivity and linearity. Discuss your
challenges in achieving these goals and how your design addresses them.
16. Compare filled system thermometers and pressure-actuated thermometers in a high-
pressure chemical reactor. Discuss their advantages and limitations regarding accuracy,
response time, and maintenance.
17. Analyze the role of a thermowell in a high-temperature corrosive environment. How does
it protect the temperature sensor, and what design considerations are necessary to ensure
its effectiveness?
18. Discuss how the Seebeck and Peltier effects can be utilized in designing an advanced
temperature control system for a chemical process. Please provide examples of their
applications and potential benefits.
19. Explain how the Thompson effect influences the performance of a thermocouple in a
chemical process. How does it impact temperature measurement accuracy, and what
measures can be taken to minimize its effects?
20. Evaluate the Law of Intermediate Metals when selecting thermocouples for industrial use.
How does this law affect the choice of materials for thermocouple construction?
21. Analyze how the Law of Intermediate Temperature is applied in calibrating thermocouples
for different temperature ranges. Discuss its implications for ensuring accurate temperature
measurements.
22. Propose a novel method for improving the accuracy of thermocouple temperature
measurements in a chemical reactor. Discuss how reference-junction compensation and
lead wires play a role in enhancing measurement precision.
23. Design an industrial thermocouple for use in a highly corrosive environment. Discuss the
material selection, construction techniques, and performance considerations necessary for
reliable operation.
24. Explain how compensating leads are constructed and their role in ensuring accurate
thermocouple readings. Discuss the factors influencing their performance and how they
are selected for specific applications.
25. Evaluate the performance of a practical thermocouple used in a chemical process with
varying temperature conditions. Discuss its merits, limitations, and potential
improvements.
26. Compare radiation shields and thermowells in a high-temperature chemical process.
Discuss their roles, benefits, and limitations in protecting temperature sensors and ensuring
accurate measurements.
27. Choose a temperature measurement instrument that does not require temperature
compensation and discuss its advantages and limitations. Provide examples of where such
an instrument would be suitable and why.
28. Develop a case study involving a chemical reactor requiring absolute and gauge pressure
measurements. Discuss how you would select appropriate instruments for each
measurement and the implications of using incorrect pressure measurements.
29. Analyze the working principle of a Bourdon tube pressure gauge with a schematic
diagram. Discuss its limitations in measuring high-pressure gases in a chemical plant and
propose potential solutions or alternative instruments.
30. Compare and contrast various diaphragms used in pressure measurement. Develop
selection criteria for choosing an appropriate diaphragm type for measuring corrosive
 chemicals in a high-pressure environment. Include a schematic diagram for each
diaphragm type.
31. Design a bonded strain gauge pressure transducer for a high-temperature chemical
reaction. Provide a schematic diagram and discuss the critical design considerations,
including material selection and construction techniques.
32. Compare bonded and unbonded strain gauges with schematic diagrams. Discuss their
respective chemical process control system applications and analyze how their
characteristics affect measurement accuracy and reliability.
33. Design a self-generating pressure transducer for a chemical processing application. Include
a schematic diagram and discuss how it generates its power and the advantages of this
design for specific pressure measurement applications.
34. Explain the operating principle of a piezoelectric pressure transducer and provide a
schematic diagram. Discuss its advantages and disadvantages in measuring transient
pressure changes in a chemical process. Propose scenarios where this type of transducer
would be most beneficial and justify your choices.
35. Given a situation where you have both an open tank and a closed tank with varying
pressure conditions, analyze how the pressure difference would affect the performance of
a float-type level indicator and suggest modifications to improve accuracy.
36. Design a hybrid liquid-level measurement system using ultrasonic and radar technologies
for a corrosive chemical tank. Justify your choice of technologies and describe how the
system addresses the limitations of each technology.
37. For a highly viscous liquid in a large storage tank, propose an innovative level
measurement technique that combines multiple sensor technologies. Explain how your
solution overcomes challenges such as sensor fouling and high viscosity.
38. Evaluate a scenario where a chemical reactor's liquid-level measurement system must be
optimized for high temperatures and pressures. Recommend an appropriate technology
and suggest design improvements to enhance performance and reliability.
39. Imagine a new level measurement instrument integrating artificial intelligence for
predictive maintenance. Describe how this instrument could improve the monitoring of
liquid levels in a dynamic industrial process.
40. Assess the implications of using a sight glass versus an ultrasonic level detector in a highly
flammable environment. What safety and efficiency considerations must be addressed, and
how would you ensure the chosen method meets safety standards?
41. Compare the use of capacitive versus radar level measurement technologies in terms of
accuracy, cost, and maintenance for measuring levels of slurries. Discuss which
technology would be more suitable for a given industrial application and why.
42. Propose an advanced instrument for measuring the interface between two immiscible
liquids in a tank. Discuss the principles behind your proposed instrument and how it
addresses common measurement challenges for such interfaces.
43. Design an experimental setup to test the performance of a new level measurement
technology under extreme conditions (e.g., high temperature, pressure, and corrosiveness).
Outline the key parameters to measure and how you would validate the technology’s
performance.
44. Develop a novel method for measuring the flow rate of a non-Newtonian fluid in a pipeline.
Discuss the principles of your process and how it addresses the challenges associated with
non-Newtonian fluids.
45. Design a comprehensive flow measurement system for a chemical processing plant that
handles liquid and gas phases. Explain how you would integrate different flow meters to
ensure accurate and reliable measurements.
46. Propose a solution for measuring flow in a multiphase system where traditional flow
meters fail. Describe the technology you would use and how it adapts to the complexities
of multiphase flow.
47. Derive a formula to calculate the pressure drop across an orifice meter for a gas flow. Use
this formula to evaluate the performance of the orifice meter under different operating
conditions.
48. Compare the performance of thermal mass flow meters versus Coriolis flow meters in
high-accuracy applications. Discuss the advantages and limitations of each technology and
recommend one based on specific application requirements.
49. Analyze the impact of varying Reynolds numbers on the accuracy of a Venturi meter
versus an orifice meter. How does each meter perform under laminar, transitional, and
turbulent flow conditions?
50. Design a flow measurement system for a chemical reactor with high particulate matter
content. Discuss the choice of flow meter and how it will handle the challenges the
particulates pose.
51. Evaluate the suitability of electromagnetic versus ultrasonic flow meters for measuring the
flow of corrosive chemicals. Discuss the design considerations for ensuring long-term
reliability.
52. Evaluate the use of advanced thermal sensors (e.g., infrared sensors) in monitoring and
controlling the temperature of exothermic reactions. Discuss how these sensors could
enhance safety and efficiency in such processes.
53. Design an experiment to compare the performance of different types of thermal sensors
(e.g., thermocouples vs. RTDs) in a high-temperature chemical reaction. Discuss the
factors that influence sensor choice and the impact on measurement accuracy.
54. Design an electromagnetic flowmeter for measuring corrosive fluids in a chemical plant.
Include material selection and sensor configuration considerations to ensure accurate and
reliable flow measurement.
55. Propose an application of electromagnetic sensors for non-contact measurements of
material properties in a chemical processing environment. Discuss the advantages and
limitations of this approach.
56. Discuss strategies for mitigating electromagnetic interference in sensitive chemical
process measurement systems. Provide examples of shielding, grounding, and filtering
techniques.
57. Design a mechanical sensor for measuring pressure or level in a harsh chemical
environment. Discuss the material selection, construction, and potential design
modifications to ensure sensor durability and accuracy.
58. Compare mechanical and optical sensors for measuring displacement or position in a
chemical processing system. Discuss the trade-offs in terms of accuracy, response time,
and maintenance.
59. Propose a calibration procedure for a mechanical sensor used in a high-vibration
environment. Discuss how you would address calibration challenges and ensure consistent
performance.
60. Develop a system using motion sensors to monitor and control the movement of materials
in a chemical processing facility. Discuss how motion sensors can be integrated with
control systems to improve process efficiency.
61. Analyze the use of motion sensors in safety systems for chemical reactors. Discuss how
these sensors detect abnormal movements or vibrations and trigger safety protocols.
62. Design an experiment to evaluate the performance of different motion sensors (e.g.,
accelerometers vs. gyroscopes) in a chemical processing environment. Discuss the factors
influencing sensor selection and their impact on system performance.
63. Design a capacitive transducer system for measuring small displacements in a chemical
process. Discuss the design considerations, including sensitivity, linearity, and
environmental factors.
64. Compare inductive and capacitive transducers for measuring displacement in a chemical
plant. Discuss the advantages and limitations of each type and provide recommendations
for specific applications.
65. Propose a system using piezoelectric transducers to monitor vibrations in a chemical
reactor. Discuss how these transducers can be used to predict equipment failures and
improve process reliability.
66. Design an ionization transducer system for analyzing trace gases in a chemical process.
Discuss this type of transducer's operating principle, advantages, and limitations.
67. Compare photoelectric and photoconductive sensors for detecting light levels in a chemical
plant. Discuss their respective applications, performance characteristics, and challenges.
68. Analyze photoelectric sensors' use to detect the presence or absence of materials in a
chemical process. Discuss the factors influencing sensor selection and the impact on
process control.