I'm using ABB differential Pressure Transmitter to calculate air flow in a circular pipe.

The Pressure transmitter is

calibrated using HART communicator in units of mmH2o at 20degcelsius.
Min-0 mmH2o (4mA)
Max- 78 mmH2o (20mA)
I would like to convert mmH2o to m3/hr. Any functional block or formula/Standard chart available for this conversion?

The formula is Constant*(Square root of the Diff Press) where constant depends on your instrument installation. The
manufacturer of the instrument should be able to tell you the constant.
To get flow rate from a DP transmitter assumes that you have a primary flow element mounted in a pipe or duct,
something like an orifice plate, an averaging pitot tube (Annubar), or one of several other specialized primary flow
elements.
Primary flow elements are designed to produce a certain differential pressure at a certain flow rate as calculated from
design information including medium viscosity, density, temperature, upstream static working pressure, and a dozen
others.
The manufacturer of the primary flow element provides a "sizing sheet" with the primary flow element that includes all
the data used to calculate the flow rate at a given DP. You need that sizing sheet, because that sizing sheet tells you
what flow rate 100"W.C. equals for your specific primary flow element.
And you need to know whether the DP transmitter is configured to output the 'raw' DP or whether it extracts the
square root of the DP.
And you should be aware that you cannot get SCFM (standard cubic feet per minute, a mass flow measurement)
from just a primary flow element and a DP transmitter, unless your static working pressure and temperature never
vary from the design standard, which never happens in the real world. 'Standard' cubic per minute is referenced back
to STP. Your DP transmitter does not measure gas temperature and the static pressure and compensate for those
changes, so your engineering units are CFM (a volumetric measurement), not SCFM (a mass flow measurement).
What is three element control system how is it work?
A single element control system is one with just one control input; a two element control system is one with two control inputs,
etc.
I anticipate that you have a three-element boiler water level control system in mind. This is one which typically uses the
measured water level, the steam flowrate from the boiler, and the water flowrate into the boiler to regulate the flow of water into
the boiler.
Although you might think that measuring water level alone is sufficient, you have to bear in mind that the boiler water contains
lots of steam bubbles. Bubble size is affected by pressure, so if a boiler experiences a sudden extra demand for steam, its pressure
drops. The drop in pressure causes the steam bubbles in the boiler water to expand, and the level measurement can show an
increase in level.
The false high reading makes the water level control system reduce the flow of water into the boiler. Once boiler pressure is
restored the steam bubbles contract, and the measured water level drops suddenly. The level control system responds to this by

increasing the flow of water into the boiler, which effectively deluges the boiler with relatively cold water, and boiling is arrested.
Some of the steam bubbles in the boiler water collapse, and the boiler water level drops significantly - possibly to a low-level
alarm or lockout.
By adding water and steam flow measurement into the control system, we can identify any major disparity between the two, and
make compensation to the measured water level. This means that any transient peak demands on the boiler are recognised as
such, and the feedwater control is appropriately applied.
Incidentally, it is possible to achieve the same results using a two-element control system (level and steam flow), but it is easier to
commission three-element systems.
Three-element boiler water level control systems are sometimes referred to as "feed forward" control. This is becasue the system
identifies a transient high demand for steam before it has any effect on the boiler water level, and therefore starts to put extra
water into the boiler in anticipation of demand.
This is a topic that requires reading and operational experience to understand - and even then it can still be difficult to figure out.
I took control courses in university, but it was not until I had real life experience in the field with controllers I was able to fully
understand the tuning process.
A three element control is a cascading feed-forward control loop. Its simple description/purpose is to keep water inflow the same
as water outflow (where inflow is your feedwater demand). The controller applies a proportional action to the error between the
drum level (signal) and the set point.
The controller looks at the drum level error + the steam flow = feedwater signal demand.
The feedwater signal is compared to the water flow input (i.e. current feedwater flow) - the difference is the new output of the
feedwater controller (i.e. your new feedwater flow). This happens according to the frequency of you process logic controller. The
problem is that if you constantly try to hit the set point many times each second you end up overshooting or undershooting your
setpoint and you drum level fluctuates uncontrollably. This is why Integral action is also provided. The combination of
proportional + integral control helps to establish predictable feed water flows at common loads and can react to load
changes/adjustments as required) if the system is properly tuned (the constants used for proportional and integral control are set
to match normal operations).
Honeywells C300 Controller provides powerful and robust process control for the Experion platform. Based on the unique and space-saving
Series C form factor, the C300 joins the C200, C200E, and the Application Control Environment (ACE) node in operating Honeywells fieldproven and deterministic Control Execution Environment (CEE) software.
What Is It?
Ideal for implementation across all industries, the C300 controller offers best-in-class process control. It supports a wide variety of process
control situations, including continuous and batch processes and integration with smart field devices. Continuous process control is achieved
through an array of standard functions that are built into control strategies. The C300 controller supports the ISA S88.01 batch control standard
and integrates sequences with field devices, including valves, pumps, sensors, and analyzers. These field devices track the state of the sequences
to perform pre-configured actions. This tight integration leads to quicker transitions between sequences, increasing the throughput.
The controller also supports advanced process control with Honeywells patented Profit Loop algorithm as well as custom algorithm blocks,
which let users create custom code to run in the C300 controller.
How Does It Work?
Like C200/C200E and the ACE node, the C300 operates Honeywells deterministic Control Execution Environment (CEE) software which
executes control strategies on a constant and predictable schedule. The CEE is loaded into the C300 memory providing the execution platform for
the comprehensive set of automatic control, logic, data acquisition and calculation function blocks. Each function block contains a set of predefined features such as alarm settings and maintenance statistics. This embedded functionality guarantees consistent process control strategy
execution.
The controller supports many input/ output (I/O) families, including Series C I/O and Process Manager I/O, and other protocols such as
FOUNDATION Fieldbus, Profibus, DeviceNet, Modbus, and HART.
What Problems Does It Solve?
C300 allows engineers to address their most demanding process control requirements from integration with complicated batch systems to
controlling devices on a variety of networks such as FOUNDATION Fieldbus, Profibus, or Modbus. It also supports advanced control with Profit
Loop, which puts model-based predictive control directly in the controller to minimize valve wear and maintenance.
The C200/C200E integrated control and safety systems are embedded in the compact Series A Chassis hardware form factor. Users of these
controllers benefit from a robust and superior control execution and scheduling environment with high reliability.
What Is It?
Released with PlantScape R200, the C200 controller operates Honeywells field-proven and deterministic Control Execution Environment (CEE)
core software. Introduced with Experion PKS R400, the C200E Controller provides the same capabilities as C200 but adds more functionality
and memory. For example, the C200E fully supports Experion Batch Manager and the ISA S88.01 batch control standard so that users can
execute complete batch control in a redundant environment with the controller.
The CEE resident in the control processor provides an efficient and effective control environment as well as access to a comprehensive library of
control-related function blocks. The controllers can be implemented in a single or fully redundant configuration.
How Does It Work?

Like the C300 and the ACE node, the C200 and C200E integrated control and safety systems operate Honeywells deterministic CEE software
which executes control strategies on a constant and predictable schedule. The CEE is loaded into the C200/C200E memory, providing the
execution platform for the comprehensive set of automatic control logic, data acquisition and calculation function blocks. Each function block
contains a set of predefined features such as alarm settings and maintenance statistics. This embedded functionality guarantees consistent process
control strategy execution.
The controllers support many input/output (I/O) families, including Series A I/O, Rail A I/O, Rail H I/O and Process Manager I/O, and other
protocols such as FOUNDATION Fieldbus, Profibus, DeviceNet, and HART.
What Problems Does It Solve?
The C200 and C200E controllers enable process engineers to tackle several process control problems by supporting batch applications with ISA
S88.01 and providing robust process control through CEE. When used with Honeywells Profit Loop that anticipates future process behavior, the
controllers know exactly how much to move the process in order to meet the desired control objectives, thus offering stronger process control.
Distributed System Architecture (DSA) is the ideal solution for integrating processes when there are multiple units, control rooms or
geographically distributed locations. With Distributed System Architecture, users experience a single, totally integrated system instead of several
independent systems, while retaining the ability to autonomously manage each system. The result: optimum functionality and flexibility.
What Is It?
Distributed System Architecture allows multiple Experion Process Knowledge Systems (PKS) to operate as one across multiple units, sites and
facilities across the enterprise. This single integrated system enables seamless global access to data, alarms, alerts, interactive operator control
messages and history across groups of systems.
Configuration takes just minutes through automatic discovery of points, thus reducing engineering costs and improving system integrity. This also
eliminates costly, error-prone database duplication.
DSA delivers this integration amongst multiple systems while retaining a coherent, global security scheme. Individual Experion Systems can also
be operationally integrated while retaining their own engineering autonomy.
How Does It Work?
Distributed System Architecture dynamically adjusts to changing user and application demands for information. Point data, alarms, history, and
operator messages are delivered only to current subscribers, and only when there is a change in status. Additional efficiencies are achieved
through the transfer of information between clusters of interested users, rather than between individual users. Therefore, if multiple users are
interested in the same data on another site, the request is sent only once.
These and other techniques allow Distributed System Architecture to be extremely efficient with its network usage, allowing satellite and other
low bandwidth/high latency networking possibilities. DSA being a single integrated system also doesnt require any dedicated networking and
can leverage existing WAN infrastructure. Firewall friendly features allow Distributed System Architecture to adapt to existing firewall
configurations to allow existing infrastructure to be used.
What Problems Does It Solve?
Honeywells patented Distributed System Architecture (DSA) technology offers users unmatched scalability by seamlessly integrating the
operational data of multiple Experion systems together at the same site or across different geographical locations without additional engineering
or configuration.
Fault Tolerant Ethernet (FTE) is the industrial control network of the Experion Process Knowledge System (PKS). Combining Honeywells
expertise in designing robust control networks with commercial Ethernet technology, it goes beyond providing fault tolerance. FTE ensures the
performance, determinism and security required for industrial control applications.
What Is It?
The FTE network connects clusters or groups of nodes such as servers and stations, typically associated with the same process unit. It provides
multiple communication paths between these nodes so the network can tolerate all single faults and many multiple faults.
FTE ensures rapid detection and recovery in case of communication failures with a switchover time of less than a second. It allows normal
Ethernet nodes to connect to the FTE control network and benefit from its highly available communications environment. With FTE, users can
leverage commercial Ethernet technology found in IT networks to lower the costs of the FTE control network infrastructure, connections to IT
networks and third-party Ethernet devices, and ongoing maintenance and support.
How Does It Work?
FTE ensures that the switchover time in case of a communication failure is less than one second. This is because it uses a single network and does
not require a server or station to re-establish its network connection. In addition, the nodes in the FTE control network continually check the
status of each communication path to ensure high availability.
Conventional Ethernet redundancy schemes employ two separate Ethernet networks with each node connected to both networks. If a
communication failure occurs, the elapsed time for a particular node to switch to the other network can be over 30 seconds, depending on
network equipment and how the system is configured for network failover.
What Problems Does It Solve?
With FTE industrial control network, users benefit from efficient fault tolerance as well as fast response, determinism and improved security. The
solution does not require purpose-built network switches as it uses commercial, off-the-shelf (COTS) technology. FTE is simpler to operate and
manage since it allows seamless connection to non-FTE Ethernet nodes and online additional/removal of nodes.

Unified Simulation Environment

With a protected simulation environment, users can test their control strategies and optimize processes. Honeywells Unified Simulation
Environment allows the entire Experion PKS system to be simulated to offer a range of benefits, including efficient control, lower operator
training costs and improved plant performance.
What Is It?
Each Experion PKS controller, including the Application Control Environment (ACE), C200/C200E and C300, has a matching simulation
environment. The simulation system environments are identical to the real controllers in terms of control execution, supported I/O and control
capacity. This guarantees that a configuration developed on a simulation system will fit the actual controller platform and vice versa.

By using a protected process simulation environment, users can effectively test and modify their control strategies to implement tighter and more
efficient process control. In addition, high fidelity process simulation can be used to train plant operators for normal process operations and to
deal with specific abnormal situations encountered on the job.
How Does It Work?
The Unified Simulation Environment executes multiple simulated controllers on a PC platform. For larger systems, multiple PCs can be used.
The simulated controller developed on a simulation system executes the same control execution environment (CEE) as the physical controller, so
the functionality is the same regardless of the environment.
Simulated control strategies can read from other on-process controllers through a restricted peer-to-peer communication architecture. This ensures
that the simulation cannot influence the real process.
Since the simulation system environment is comparable to the real controller from its functionality and configuration capacity point of view,
changes or additions to control strategies can be tested offline before implementation.
What Problems Does It Solve?
The Unified Simulation Environment provides a protected environment for users to test new or existing control strategies without influencing the
real process. It guarantees that a configuration developed on a simulation system will fit the actual controller platform. In addition, it delivers cost
savings by providing simulation capabilities without requiring dedicated controller hardware or process connections. It enables better training for
operators since it uses the same control and operation interface as the real system.

High Performance Process Manager

What Is It?
Ideal for implementation across all industries, the Process Manager controller family is the most mature and field tested controller available. The
High Performance Process Manager (HPM) is a process-connected device on the UCN that provides regulatory control and sequence operations.
The HPM includes a powerful set of pre-built data acquisition and control algorithms.
How Does It Work?
The HPM controller supports the classical process control functions for continuous, discrete and batch operations. The embedded object oriented
control language provides flexibility for development of customized control functions in addition to the standard ones provided with the product.
The HPM controllers have the ability for direct peer-to-peer communication with controllers connected to the UCN or to Programmable Logic
Controllers (PLC) using serial interface connection.
The controller supports Process Manager I/O, and other protocols such as Modbus, HART and Smart protocol for direct communication with
Honeywell transmitters.
What Problems Does It Solve?
The High Performance Process Manager controller enables process engineers to apply field proven and customized control strategies for plant
operation. It can be connected to different data acquisition and control devices using various field communication protocols.

Field Device Manager

Honeywell Field Device Manager (FDM) simplifies maintenance tasks, saves time and provides the flexibility and scalability to perform
complete device configuration and management tasks in the plant environment through smart plant instrumentation.
What Is It?
FDM is a centralized asset management system for remote configuration and maintenance of smart field devices based on HART, PROFIBUS
and Fieldbus Foundation protocols. FDM is integral to supporting Experion-connected devices, yet it easily handles non-Experion
networks. FDM supports a large number of devices through FDM clients connected to multiple, distributed FDM servers. With complete
command and control of all instruments through the plant, FDM saves time by greatly reducing the number of field trips that would otherwise be
required. By simplifying and reducing effort normally involved in plant debugging, FDM improves overall asset effectiveness.
How Does It Work?
FDM conforms to industry open standards for HART, Fieldbus and PROFIBUS and does not require additional files or programming to support
devices or access device-specific features. This includes unmodified use of both Device Description (DD) and Device Type Manager (DTM)
technologies as provided by the device vendors. FDM uses a unique remote communication infrastructure that allows widely distributed devices
to communicate over a local or wide area network, providing anytime, anywhere access in the plant environment. FDM requires no point
engineering or database building. Once the communication networks are configured, FDM automatically detects smart devices and adds them to
the database. This saves considerable time for commissioning, troubleshooting or just performing routine maintenance.
What Problems Does It Solve?
Smart plant instrumentation requires sophisticated tools to configure, maintain, troubleshoot, and diagnose. In a large plant spread out over a
considerable physical area, it is imperative that this tool will cover the distance, perform the right job, simplify the work, and save time. FDM is a
versatile, accessible and predictable plant instrumentation solution that simplifies smart instrument maintenance.

FOUNDATION Fieldbus Interoperability Support

To allow interoperability with Experion Process Knowledge System (PKS) and other host systems, all FOUNDATION Fieldbus device vendors
create and make available files known as DD (Device Description) and/or EDDL (Electronic Device Description Language) files. The files allow
Experion to understand the device functions, features, and parameters. Honeywell and Flowserve device firmware files are also available.
What Is It?
DD and EDDL files are provided by every device vendor and contain the information required by Experion to utilize the device capabilities and
functions in the Experion system. DD files are the original standard while EDDL represents the next generation of the technology and augments
the DD technology with added features to better support the needs of more complex devices such as valves. All vendors must provide a DD for
every device while EDDL is optional. Honeywell maintains a Fieldbus Interoperability Test Laboratory for testing FOUNDATION Fieldbus
devices and their DD/EDDL files. Users can access test information and download the vendor device DD/EDDL files from the "Documentation"

tab of this page. In addition, device firmware files are also available for select vendor devices. These files can be used to update device firmware
from Experion Control Builder.
How Does It Work?
DD and EDDL files are used in the Experion Control Builder environment to create device-specific templates that integrate the associated device
with Experion and allow the device blocks to be used in the control scheme.

Experion R400 is the first release to support EDDLs

For all releases prior to R310, users must download the DD from the Honeywell website

For R310 and above, users should download the DD directly from the FOUNDATION Fieldbus website

In case of any DD or device-related issues, users should contact their local Technical Assistance Center (TAC)
What Problems Does It Solve?
By accessing and downloading the required DD, EDDL, and Firmware files, users can seamlessly integrate Fieldbus devices into their
Experion systems.

HART Integration
HART is an open protocol that delivers the benefits of smart field devices while offering the simplicity and ease-of-use associated with traditional
I/O. Experion Process Knowledge System (PKS) integrates HART devices to improve system performance, process availability, safety and
throughput, while reducing lifecycle costs for upgrading and maintaining smart field devices.
What Is It?
Honeywell ensures seamless integration with Experion with its HART enabled I/O modules. Available in the Chassis-A, PMIO, and Series-C
form factors, the modules enable the effective use of HART digital data for control, display, diagnostics, parameterization and asset management.
Users can improve availability by implementing the modules in an optionally redundant fashion.
Experion PKS provides the freedom to communicate with HART devices removing barriers such as scan rate limitations. Access to detailed
device performance and abnormal condition information lets users report device malfunction or failure and information about process-related
abnormalities. In addition, the HART solution provides plant operators and maintenance personnel full access to all field device information
directly through Experion.
How Does It Work?
Experions best-in-class, open HART solution automatically populates HART process and status data through the I/O cards into the C200 and
C300 process controllers, and finally into standard operator displays. Absolutely no additional configuration is required. The I/O cards also
provide a pass-through capability that enables full asset management using the Honeywell Field Device Manager (FDM) application.
The complete solution is based on open standards and is fully compliant with the HART protocol specification. The handheld solution is available
on open pocket PC-based platforms and works equally well with devices from all vendors. All device-specific data is gathered from the HART
standard device description (DD) files and no special vendor files are required to integrate the device with the Honeywell solution. If no DD file
is available, the HART universal and common practice data and diagnostics can be utilized.
What Problems Does It Solve?
Smart field devices provide valuable process and diagnostic information that enhances every facet of the process and improves plant
operations and availability. Experion HART integration allows users to access and utilize this valuable information in a cost-effectively manner,
using a technology that is easy to implement. This results in improved process availability and enhanced safety management of the process, plant
and personnel.

Magnetic Flow Meter :

Application of Magnetic Flow Meters : Magnetic Flow meter measures the volumetric rate of flow any liquid that has adequate electrical
conductivity. Most petroleum hydrocarbons have insufficient conductivity to be measured with a magnetic flow meter. It is rarely used in
Petroleum Industry.
Magnetic Flow meters are widely used on slurries

Advantages of Magnetic Flow Measurement

1.They respond only to the velocity of Fluid .Independent Density Viscosity and Static Pressure
2.High Rangebility 10:1
3.Bidirectional Flow Measurement
4.Fluid Temperature range -40 Deg C to +260 Deg C
5.Pressure Drop is negligible
6.Wide Variety of Size
Disadvantages of Magnetic Flow Measurement
1.Conductivity of the process fluid should be greater the 2 micromhos per centimeter
2.Special care is required for erosive application
3.Difficulties in on site calibration
4.High cost
5.Large Sizes are very heavy
Installation Consideration :
Magnetic Flow Meter consist of two parts
Primary elements installed directly in the processline
Secondary elements is an electronic transmitter
Magnetic flow meter tube may be installed in any position but it must run full of liquid for accurate measurement
DP Transmitter Installation
Gas line: the transmitter is installed above the orifice plate to prevent the condensation of gas in the signal line and in the HP & LP chambers.
Liquid line: the transmitter is installed below the orifice plate to prevent the gas trapping in the signal line and in the HP & LP chambers.

Static Head
Static Head = pgh
p= Density of the liquid
g= Gravity
h= height of the liquid column
Type J Thermocouple - Iron Constantan
Type T Thermocouple Copper Constantan
Type K Thermocouple Chromel Alumel
Type N -Nicrosil Nisil
Type E - Chromel Constantan
Type S- Platinum 10 % Rhodium
Type R - Platinum 13% Rhodium
Type Cu - Uncompensated
Type C - Tungsten Rhenium

How to identify (ATEX/CENELEC/IEC) label?

ATEX MARKING FOR EXPLOSION APPARATUS (Directive 94/9/EC (ATEX 95)) Distinctive mark for the putting into circulation of
explosion-protected apparatus

DEVICE GROUP (CENELEC/IEC)

Device GROUP I : applies to devices for mining operations above ground and
underground that may be endangered by methane gas and/or inflammable dust
Device GROUP II : applies to devices for use in all other areas that
can be subject to the hazard of an explosive atmosphere

Interview Question : Hazardous Area Zoning

Two types of standards are there
For Europe
CENELEC in process of being transferred to IEC/EN (European Committee for Electrical Standardization)
IEC
(International Electrotechnical Commission)
North America
NEC 500
NEC 505
(National Electric Code)
Hazardous Area Zoning For Gases Vapor & Mists (CENELEC & IEC)
Zone 0 - Explosive gas atmosphere is present continuously or for long periods
(typically > 1000 hours/year)
Zone 1 - Explosive gas atmosphere is likely to occur under normal operating condition
Zone 2 - Explosive gas atmosphere is not likely to occur in normal operation and if it occurs, will only exist for a short period (typically < 10
hours/year)
Hazardous Area Zoning For Dusts (CENELEC & IEC)
Zone 20 - Explosive gas atmosphere in the form of a cloud of combustible dust in air is present continuously or for long periods or frequently
Zone 21 - Explosive gas atmosphere in the form of a cloud of combustible dust in air is likely to occur in normal operation occasionally

Zone 22 - Explosive gas atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but if it occurs,
will only exist for a short period
HAZARDOUS AREA ZONINGFor Gases, Vapors & Mists (NEC 500)
Division 1
An area in which an explosive atmosphere exist continuously or some time under normal operating conditions
Division 2
An area in which explosive atmosphere is not likely to exist under normal operating conditions
EXPLOSION MEDIUM CLASSIFICATION (NEC 500)
There are 3 general classes which define the flammable materials present in the atmosphere :
Class I Mixture of Gas/Vapor with atmosphere
Class II Mixture of Dust with atmosphere
Class III Mixture of Fibers with atmosphere
LOCATION TERMINOLOGY(NEC 500)
CLASS 1, DIVISION 1
Location where ignitable concentrations of flammable gases, vapours or liquids
Can exist under normal operating conditions
May exist continuously, intermittently, or periodically because of repair or maintenance operations or because of leakage
May exist because of equipment breakdown that simultaneously causes the equipment to become a source of ignition
CLASS 1, DIVISION 2
Location where ignitable concentrations of flammable gases, vapours or liquids
Where volatile flammable liquids or flammable gases
May exist continuously, intermittently, or periodically because of repair or maintenance operations or because of leakage
May exist because of equipment breakdown that simultaneously causes the equipment to become a source of ignition
Usually for the non-incendive, non-sparking, pressurized, hermetically sealed or sealed device type

Different Types of Instrument errors are

Any given instrument is prone to errors either due to aging or due to manufacturing tolerances. Here are some of the common terms used when
describing the performance of an instrument.
RANGE
The range of an instrument is usually regarded as the difference between the maximum and minimum
reading. For example a thermometer that has a scale from 20 to 100oC has a range of 80oC. This is also called the FULL SCALE DEFLECTION
ACCURACY
The accuracy of an instrument is often stated as a % of the range or full scale deflection. For example a pressure gauge with a range 0 to 500 kPa
and an accuracy of plus or minus 2% f.s.d. could have an error of plus or minus 10 kPa. When the gauge is indicating 10 kPa the correct reading
could be anywhere between 0 and 20 kPa and the actual error in the reading could be 100%. When the gauge indicates 500 kPa the error could be
2% of the indicated reading.
REPEATABILITY
If an accurate signal is applied and removed repeatedly to the system and it is found that the indicated reading is different each time, the
instrument has poor repeatability. This is often caused by friction or some other erratic fault in the system.

STABILITY
Instability is most likely to occur in instruments involving electronic processing with a high degree of amplification. A common cause of this is
adverse environment factors such as temperature and vibration. For example, a rise in temperature may cause a transistor to increase the flow of
current which in turn makes it hotter and so the effect grows and the displayed reading DRIFTS. In extreme cases the displayed value may jump
about. This, for example, may be caused by a poor electrical connection affected by vibration
TIME LAG ERROR
In any instrument system, it must take time for a change in the input to show up on the indicated output. This time may be very small or very lar
ge depending upon the system. This is known as the response time of the system. If the indicated output is incorrect because it has not yet
responded to the change, then we have time lag error.
RELIABILITY
Most forms of equipment have a predicted life span. The more reliable it is, the less chance it has of going wrong during its expected life span.
The reliability is hence a probability ranging from zero (it will definitely fail) to 1.0 (it will definitely not fail).
DRIFT
This occurs when the input to the system is constant but the output tends to change slowly. For example when switched on, the system may drift
due to the temperature change as it warms up.

Bench set on a control valve actuator

On a pneumatic control valve, this is the minimum and maximum air pressure to be applied to achieve the full stroke length of the actuator

Double seated control valve

It is a control valve whose trim (plug and seat) has two seats (contact points). A double seated control valve is commonly used in high
differential, huge capacity, turbulent flow lines.

Name of the cable used to connect a thermocouple to a measuring instrument

The intermediate cable used for connecting a thermocouple from the field to the control room instrument is called a compensating cable

Convert a pressure gauge into a level gauge

Calculate the static head in kpa using the formula pgh. Select a pressure gauge and calibrate it for the calculated static head. Graduate the
pressure gauge scale in terms of % of level.

DCS Engineer Interview Questions - Fundamentals (Refinery ,Power Plant, Chemical Plant ,Paper)
Some of the Interview questions for Control System Engineers - DCS (Distributed Control System )
Q) Definition of DCS?
A microprocessor based control and Data acquisition system consisting of number of modules operating over a network.
Q)Typical functions available in DCS
1 PID Control
2 Discrete control
3 Advanced control capability
4 Alarm management
5 Graphical and Schematic displays
6 Trending of real time and historic data

7 Communication between other device and subsystem

8 Data acquisition
9 Report generation
10 Data Historization
Q) Different type of PID function included in DCS?
PID Basics controller
PID Ratio
PID cascade
PID Bias
PID Differential gap
PID adaptive gain
PID non linear
Manual station
PID self tuning
External output tracking
Reset limiting
Q)Math functions included in DCS?
ADD
Subtract
Multiply
Division
Summation
Difference
Square root
Square
Absolute Value
Logarithm
Exponential
Polynomial
Q) Dynamic functions included in DCS?
Lead/Lag
Dead time
Velocity limit
Totalize
Q) Logic controls included in DCS?
And
OR
Exclusive OR
On/Off Delay
Inverter
Flip-Flop
Pulse
Nand
Nor

Reset action with an example

Reset action in a controller is the integration of the proportional action by the set period. The reset action repeats the proportional actions output
per the reset time set, until the error signal becomes zero or the output gets saturated.

For example :if the reset action is set for 30 sec.

For a 0.5 volt correction output ;by the proportional action will be repeated by the reset action every 30 secs., until the error signal becomes zero
or the output gets saturated.

Fahrenheit to Centigrade temperature conversion formula

Deg C = ( Deg F 32 ) / 1.8

Single seated balanced trim
It is a trim having a single seat and balance holes on its plug. A single seated balanced trim is used in a process line where the DP across the valve
is high. These kind of trims are useful in reducing the vibration on the valve body and also assists in closing the valve.
Brief Idea About Hazard and Hazardous Area Classification?
Meaning of Hazard.
Anything which has the potential to cause:
Harm, ill health or injury to people Damage to property, products or environment
Meaning of Hazardous Area
Area in which an explosive atmosphere is, or may be expected to be, present in quantities such as to require special precautions for the
construction, installation & use of electrical apparatus
Meaning of Hazardous Area Classification
Method of analyzing and classifying the environment where explosive gas atmospheres may occur so as to facilitate the proper selection an
installation of apparatus to be used safely in that environment

Explosion protection enclosure types

Ex d
Flameproof Enclosures
Motors with sliprings & commutators
3 phase squirrel cage motors
Equipment that could ignite an explosive atmosphere housed within a substantial enclosure without transmitting internal explosion to
surroundings
Ex e
Increased Safety
3 or 1 phase rotor with cage rotor
Current & voltage transformers
Increased measures taken to prevent generation of arcs, sparks & excessively hot areas in equipment, preventing risk of explosion inside/outside
of enclosure
Ex i
Intrinsic Safety
Switches, plugs & socket, terminal boxes
Energy is limited to this equipment in such a way that a spark or a hot surface would not be hot enough to ignite the explosive atmosphere
Ex m
Encapsulation
Relays, signal &

control units
Apparatus is totally encapsulated by a non-porous compound & electrical connection is by flying leads
Ex n
Non - Incendive*
Gives a level of protection by housing electrical equipment in substantial enclosures that inhibit mechanical damage & give some degree of
ingress protection
Ex o
Oil Immersion
Switchgear
Transformers
Equipment is totally immersed in oil preventing an explosive atmosphere from reaching the equipment

Control valve parts

a) Trim
b) CV
c) Actuator
d) Stem travel
e) Valve body
f) Yoke
g) Gland packing
Trim : Trim is a matched pair of plug and seat
CV : The amount of water flow in gallons through the control valve when the valve port is fully open and the pressure differential across the
valve is 1 Psi.
Actuator : The drive unit having a diaphragm and a piston that operates the valve stem.
Stem travel: The scale that shows the stem movement in inches or centimeter.
Valve body: The bottom portion of a control valve installed on a pipeline to control a process. The valve body contains a trim, pipe flange,
bonnet, gaskets, guide bush, gland packing, lantern ring, grease, cooling finsetc.
Yoke : A portion of the actuator which connects the actuator to the valve body carrying a stem travel plate.
Gland packing: A sealing system in the valve body which prevents the process fluid coming out through the valve stem.
Calibration of a leveltrol for an interface level measurement
Fill the leveltrol chamber 100% with the lower density liquid and adjust its zero for 4.00mA output.
Drain the liquid and fill the leveltrol chamber 100% with the higher density liquid and adjust its span for 20.00 mA output.
The transmitter on line measures the percentage of higher density liquid in the lower density liquid at a known height.

Upstream and downstream straight length run is essential for an orifice plate flow measurement
The upstream can be identified by the orifice plates Tag number markings. Tag numbers are always marked on the upstream of the orifice plate.
An upstream of 28D and a down steam of minimum 7D is essential for an a
Zero check and static zero check on a DP flow transmitter
Zero check- A procedure for checking the transmitter output is equal to 4.00 mA when its HP & LP chambers are equalized and are at the
atmospheric pressure
Static zero check- A procedure for checking the transmitter output is equal to 4.00 mA when its HP & LP chambers are equalized and are at the
operating pressure.

Valve positioner and its working

Valve Positioner is a unit used on a control valve to keep the valve in position. It works as a booster relay with a valve stroke feed back. A
controller output is fed to the valve positioner and the valve position provides an output to the control valve actuator to achieve the pre-calibrated
stroke length. In case the require stroke length isnt achieved, then the positioner either increases or decreases its output until the valve achieves
the desired stroke length. This situation may occur when there is a great change in the process pressure, gland is too tightetc.

Volumetric and Rate of flow

Volumetric Flow: The total amount of fluid passed through a process line. Generally it is measured on counters. The measuring unit is cubic
meter, Barrelsetc.
Rate of flow: The amount of fluid moving through a process line per period of time. Generally it is measured on indicators, recorders. The
measuring unit is cubic meter per day, barrels per dayetc.

Possible reasons if a control valve fails to open/close

Gland packing is too tight
Actuator bench set is not proper or suitable
Process load change is too high
Trim is an unbalanced type
Actuator spring is broken
Air supply to the valve positioner / actuator is close or high ..etc
Zero suppression and Zero elevation in level measurement
Zero suppression: when a static head transmitter is installed below the zero liquid level, the transmitter gets a +ve error in the level measurement.
This error is corrected by a zero suppression kit.
Zero elevation: when a static head transmitter is installed above the zero liquid level, the transmitter gets a ve error in the level measurement.
The error is corrected by a zero elevation kit.

Over sized control valve

A control valve is said to be oversized when a minimum signal to the valve (minimum opening of the valve) brings process to the set point
rapidly. This situation leads to an imbalance and high gain in the control loop. The problem can be solved by changing the valve trim to a reduced
trim size or by replacing the control valve for the correct size.
Direct acting and Reverse acting control valve
Direct acting control valve : The valve port closes on air failure.
Reverse acting control valve: The valve ports Opens on an air failure.

QUESTION PAPER PAER FOR THE ELECTRICAL AND INSTRUMENTATION CANDIDATE

1.

What is the supply frequency in India?

a) 60HZ
b) 55HZ
c) 50HZ
e) 40HZ

2.

What will be the total resistance in a parallel circuit?

a) Higher than that of the higher resistance value
b) Lower than that of the least resistance value
c) Higher than that of the all resistance
d) It may all of the above

3.

Mass of an electron is.?

a) 9.109x10-31
b) 109.9x10-31
c) 19.109x10-13
d) 0.9x10-31

4.

What will be the color cored of 21x106 10% ?

a) Red , brown, blue, silver
b) Red, black, blue, silver
c) Red, red, black silver
d) Red, brown, violet, silver

5.

Unit of the inductance will be ?

a) Hertz
b) Fared
c) Henry
d) Tesla

6.

Expansion of PLC will be?

a) Programmable logic convertor
b) Programmable logic contactor
c) Programmable logic controller
d) Programmable logic connector

7.

Frequency of a DC current will be ..?

a) 0HZ
b) 100HZ
c) 50HZ
d) None of the above

8.

Dielectric of paper capacitor will be ?

a) Polyester
b) Mica
c) Paper
d) Can mica or polyester

9.

1/1000000Ampere will be? The sum of the voltage drops across the resistances of a closed circuit equals the total voltage applied to
the circuit
a) 1 lack ampere
b) Mille ampere
c) Mega ampere
d) Micro ampere

10.

The sum of the voltage drop across the resistance of a closed circuit equal to the total voltage applied to the circuit - statement is
related to . low ?
a) Ohms low
b) Lows of electro magnetic induction
c) Lows
c) Kirchhoff low
d) Charles low

11.

What can the principle of conductivity sensor?

a) Reluctance
b) Both (a) and (b)
c) Resistivity
d) Non of the above

12.

Ladder logic is related to . ?

a) PLC
b) MCB
c) ELCB
d) OLR

13.

VFD is controlling the . ?

a) Speed
b) HP
c) Frequency of supply
d) Torque

14.

Total capacitance in parallel connection will be ?

a) Always higher than that of series connection

b) Always less than that of series connection

c) Always constant
d) None of the above
15.

Resistance of dry skin ?

a) 1000 to 660
b) 100Kto 660k
c) 200to 300
d) 600 k to800k

16.

In a sign wave maximum positive voltage will be at ?

a) 2700
b) 900
c) 3600
d) 800

17.

Formula for the inductive reactance?

a) 2fL
b) 2 xL
c) 2 L
d) fL

18.
a) High tension transformer is rated in ?
b) KWA
c) KVA
d) KWh
19.

Instead of 0mA we are taking 4mA the for the transmission ?

a) Differentiate 0 input and fault disconnection of the wire
b) It is the minimum current we can measure
c) We can use ay current
d) Non of the above

20.

SCADA stands for

a) Supervisory control and data Acquisition
b) Sub control data addition
c) Super control data action
d) No expansion is available

21.

Rota meter is using for measuring?

a) Conductivity
b) Flow
c) Pressure
d) Temperature

22.

Working principle of the thermocouple?

a) Ohms effect
b) Zee back effect
c) Thermal effect
d) Non of the above

23.

Expansion of the MMI?

a) Man machine Interference
b) Man mechanism interference
c) Man mechanical input
d) Man made input

24.

Boosting of the power factor can de by?

a) Capacitors
b) Indictors
c) Resistors
d) Cant able to boost up

25.

Write down the expansion of the following points?

a) OLR..
b) SDF..
c) VFD..

Working of Leveltrol

A Leveltrol in and instrument used for measuring the liquid level between two known points. The Leveltrol works on the buoyancy principal.
Leveltrol has a float, which submerses proportionately with liquid level raise in the float chamber. The amount of submersion of the displacer
depends on the liquid density, which produces a torque. The amount of torque produced in measured in terms of % of level.
Parts of Leveltrol:
Float chamber, Float, Torque lever, Knife edge, Feedback Bellows, Air Relay, Restriction, Flapper, Nozzle, Feedback link, Density range, Action
change lever, HP and LP flange,

Use of a DP (differential pressure) transmitter for level measurement

A differential pressure transmitter gives a linear output for the differential pressure measured across its HP and LP chambers.
Connect the transmitters HP leg to the bottom of the tank and its LP leg to the top of the tank. The transmitter will read the liquid level accurately
irrespective of the change in process pressure above the liquid surface.
Brief Idea About Thermocouple Extension and Compensation Cable?
Extension and compensating cables are used for the electrical connection between the open ends of a thermocouple and the reference junction in
those installations where the conductors of the thermocouple are not directly connected to the reference junction.
Extension cables are manufactured from conductors having the same nominal composition as those of the corresponding thermocouple. They are
designated by a letter "X" following the designation of the thermocouple, for example "JX".
Compensating cables are manufactured from conductors having a composition different from the corresponding thermocouple. They are
designated by a letter "C" following the designation of the thermocouple, for example "KC". Different alloys may be used for the same
thermocouple type, they are distinguished by additional letters such as, for example, KCA and KCB.

Instrumentation Interview question : Vortex meters are used in which services?

Vortex meters are commonly used in following services
1.Steam
2.Cooling water
3.Process water
4.Light hydrocarbons where large turndown is required.
5.Gas flow where large turndown is required
Function of an orifice plate in flow measurement
An orifice plate creates a differential pressure in a flow line. The DP created is use for measuring the flow through the process line
d (orifice diameter) id permitted in a pipeline
0.25 D<d<0.75 D
d the Orifice diameter should be in-between 0.25 and 0.75 of the pipeline D diameter.
The orifice plate used in a gas line will be having a small drain whole at the bottom of the orifice plate.
Lantern ring location on a control valve
A greasing ring placed in the valve bonnet across the gland packing. The unit provides lubrication to the valve stem when lit travels up and down.

What are the regular problems occured by control valves in maintainance

Major problems are
1.Dead band
2.Stiction
3.Positioner overshoot
4 Incorrect valve sizing
5 Nonlinear flow characteristic
Flow factor and its derivation
A flow factor is to multiply the flow transmitter signal measured on a 0-10 square root or 0-100 linear scale to get the flow calculated by flow
metering. This is used due to the standardization of the transmitters signals, to 20-100 kPa or 4-20mA.
The following points are considered for flow calculation and in deriving the flow factor:
D = pipe diameter,
Small d = orifice diameter
Service = gas or liquid
PI = operating pressure
DP = Transmitter differential pressure
T =operating temperature
Small p= density or molecular weight
Small v= viscosity
Cold junction compensation
Cold Junction Compensation is used in temperature measurement by means of a thermocouple. This compensation is to correct the error caused
by the room (ambient) temperature. The mv produced by a thermocouple is proportional to the temperature difference between its hot and
Cold junction. The cold junction is the ambient temperature (control room). Without cold junction compensation the temperature at the hot
junction will measure inaccurately.
Selection of a level switch for a particular process
While selecting a level switch, the following points are to be considered:
- The characteristic of process (corrosive or non corrosive)
- The process pressure
- The liquid density
- The flange ratings
- Proof pressure of the switch
- The micro switch contact rating
Type of orifice tapping is commonly used in P.D.O
PDO in general, is using the Flange Tapping. The upstream and downstream orifice tapping are taken from the flanges.
Contact selection on high and low pressure alarm switches
On a high pressure switch, the wiring is terminated on the common and the normally close contact terminals.
On a low pressure switch, the wiring is terminated on the common and the normally open contact terminals.
This type of contact termination is done to achieve a close contact from the switch during a normal (healthy) process condition which is a fail safe
method.
Why RTD measurement use 3 wires for a field signal connection
3 wire system is used in temperature measurement by an RTD to compensate the line resistance. Three wire system provides a Wheatstone Bridge
in the measuring instrument.
New flow factor if a DP transmitter is re-ranged from 25 kPa to 50 kPa
A simple calculation is as follows:
Q1/Q2 = Sq root of DP1/ Sq root of DP2
Q1 = Q2 * Sq root of DP1/ Sq root of DP2
Q1 = New flow factor, Q2 =Existing flow factor
DP1 = Transmitter new range, DP2= Transmitter existing range
Q1 = Q2*SQ ROOT OF 50/25
Q1 = 1.41*Q2
The new flow factor will be 1.41 times higher than the existing flow factor.

Process Instrumentation : Flow Measurement Application Advantages and Disadvantages of Turbine Meters . Installation Consideration
Application of Turbine Meters : Custody transfer and in line blending. Turbine Meters are used where high
ability are required.Pulse output from the Turbine Meter may be scaled for direct totalization in engineering
are ideally suitable for batch Control application

accuracy and range

unit.Turbine meters

What is the meaning of SAT and FAT ( Site Acceptance Test and Factory Acceptance Test )
Factory Acceptance Test : FAT is to verify that the system and its components function properly that all manufacturing assembly software
generation and configuration have been done correctly and completely and that the system performance is in compliance with the agreed upon
procurement specification
Site Acceptance Test : SAT takes place after the complete installation and final configuration. This test should repeat FAT or an acceptable subset
of the test to verify that no damage occurred during shipment and installation.

Analogue IO cards
Normal analog I/p is in the range of 0 to 10V or 4-20ma signals.For that type of signals normal analog input cards are used. But RTD ouput are in
resistance variation and Thermocouples output are in the range of mv which require special conditioning before processing. For this type of
signals , we are using special type of analog input cards. Example for Honeywell DCS, For normal analog input using HLAI cards(High Level
Analog Input) and for RTD and T/C using LLAI cards(Low level Analog Input).

Function of a hair spring in a pressure gauge

Hair spring in a pressure gage eliminates the Hysterisis (backlash/angularity) error caused in the quadrant (gear and pinion mechanism) and the
weight of the pointer.

What is to be done, if a transmitter gives a maximum output , where the transmitter range (jumper) is already in maximum selection
Replace the capsule (sensor) for a higher range in the transmitter.
Separation between the ESD System and the F&G System; standard or just a good practice?
Separation of systems has nothing to do with the fact that one is fail safe and the other is non-fail safe. Nor does it have anything to do with alarm
segregation.

There is no standard which specifies the requirement for independent ESD and F&G systems. However, if you read between the lines you will
find that this is more often than not implied and common sense.
One of the important things to remember here is that if going for independent systems, you can take credit for these systems as independent layers
of protection. So for instance, if the pressure in a vessel goes about High and into the HiHi range you can consider the ESD HiHi trip as a layer of
protection. If this fails then a flange leak may lead to loss of containment which could be picked up by F&G detectors and prevent further
escalation of events.
If using an integrated system, you have to ensure that there are no common mode failures because of sharing the same PLC.
Generally it will be difficult to prove that no common mode failures can originate and this is why it is generally advisable to consider 2
independent systems up front, rather than changing things after orders have been placed.
If your F&G system is small, localized and has specific trip actions for electrical isolation then these may be treated as F&G executive actions
and you need not implement these in a separate ESD system.
The design also depends on the nature of process risk associated with your operations. If risks are low then there is no need to go for independent
systems.
Always analyze risk before making decisions, this will make the answer clear to you.
Relation (formula) between a gain and proportional band
A controller gain is inversely proportional to its proportional band.
. g = (1/p)*100
. g = gain
. P = proportional band
Bump-less transfer in a controllers auto/manual change over
Bump-less transfer is to eliminate the change in the controllers output when the controller is changed from auto to manual control and viceversa.
Basics of Control loop
Control loop is consist of all the elements necessary to move the final control elements.
Different types of final control elements are Valve,Motor,Fan etc.. Final control elements allows to keep controlled variable on target.
Process measuring elements sends a signal to the controller.At the same time the already determined setpoint is compared with the signal coming
from measuring device.
The error detector makes a comparison between the signal from process and the setpoint signal.
If there is a difference between this an error signal is sent to the control logic that changes the position of final control device. The change in the
Final control device will cause a change in process.This process will continue until the setpoint is maintained.
Elements of Control loop are
1.Measuring Device
2.Controller
3.Final control device
Terms used are.
Process Variable
Manipulated Variable
Controller Error
Set point

Instrumentation standards & codes

STANDARD DESCRIPTION
ISA INSTRUMENT SOCIETY OF AMERICA
ANSI American National Standards Institute
BS British Standard
API AMERICAN PETROLEUM INSTITUTE
IEC INTERNATIONAL ELECTROTECHNICAL COMMISSION
IS INDIAN STANDARD

NEMA NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION

NFPA NATIONAL FIRE PROTECTION ASSOCIATION
OISD OIL INDUSTRY SAFETY DIRECTORATE
IP INSTITUTE OF PETROLEUM
INSTRUMENTATION STANDARDS
Installation standards for all instruments API RP 551
Refinery Control Valves API RP 553
Control Valve Seat Leakage ANSI 70.2
Hydro static testing on control valves ANSI B 16.37
Specification for PVC insulated instrument cables BS-5308
Intrinsically safe apparatus in div 1 hazardous location NFPA 493
Specification for degrees of protection provided by enclosures IEC 60529

Calibration of a static head level transmitter for an interface measurement

Static head level transmitter is not commonly used for measuring the interface level. But the following procedure may be used for calibrating it to
measure the interface level in a tank.
Fill the vessel 100% with the lower density liquid and adjusts its zero for 4.00 mA output. Drain the liquid and fill with the vessel 100% with the
higher density liquid and adjust its span for 20.00mA output. 100% transmitter level is to be continuously maintained.
The transmitter on line measures the percentage of higher density liquid in the lower density liquid in a know height.
How does HART( Highway Addressable Remote Transducer) works?
The HART Protocol provides two simultaneous communication channels on the same wire: 4-20mA current loop analog and a HART digital
signal. While the analog signal continues to provide primary values to and from field instruments, the digital signal provides additional device
information. This is a very robust method with roots in the Bell 202 Frequency Shift Keying (FSK) standard, which originally superimposed a
digital communication signal "on top of" the 4-20mA current loop to bring Caller ID technology to the field of telephony
Common Interview Questions: Instrument and Control Engineers
1.

What are the process Variables?

2.

Define all the process Variable and state their unit of measurement. ?

3.

What are the primary elements used for flow measurement?

4.

What are the different types of orifice plates and state their uses?

5.

How do you identify an orifice in the pipe line?

6.

Why is the orifice tab provided?

7.What is Bernoulli's theorem and where it is applicable?

7.

How do you identify the H. P. side or inlet of an orifice plate in line?

8.

How do you calibrate a D. P. transmitter?

9.

What is the seal liquid used for filling impulse lines on crude and viscous liquid ?

10.

How do you carry out piping for a Different pressure flow transmitter on liquids, Gas and steam services Why ?

11.

Draw and explain any flow control loop ?

12.

An operator tells you that flow indication is more, How would you start checking?

13.

How do you do a zero check on a D.P. transmitter ?

14.

How would you do Glycol filling or fill seal liquids in seal pots 7 Draw and explain.

15.

How do you calculate new factor from new range using old factor and old range?

16.

How will you vent air in the D.P. cell? What if seal pots are used?

17.

Why flow is measured in square root?

18.

What is absolute pressure?

19.

What is absolute zero pressure?

20.

What is the maximum Vacuum?

21.

What is Vacuum?

22.

What are the primary elements for measuring pressure?

23.

How will you calibrate an absolute pressure transmitter using vacuum manometer. Range 0-400mm abs?

24.

You are given a mercury manometer range 0 -760 mm ? A vacuum gauge reads 60 mm vacuum. The test manometer reads 50
vacuum ? Which of the two in correct.

25.

Why is an inclined manometer used ?

26.

What is the principle of a pressure gauge ?

27.

Draw and explain a pressure gauge ? What is the used of a Hair spring ?

28.

Briefly explain the different methods of level measurement?

29.

Explain how you will measure level with a different pressure transmitter.

30.

How is D.P. transmitter applied to a close tank?

31.

How is D.P. transmitter applied to an open tank?

32.

How is D.P transmitter applied to a close tank & open tank with Dry leg?

33.

What is purge level system?

34.

Explain the working of a leveltrol.

35.

How will you reverse an action of the leveltrol?

36.

What is interface level? How do you calculate it?

37.

How will you calibrate a leveltrol in the field?

38.

How will you calibrate on interface level control. ?

39.

How will you apply wt. lest calibration to a leveltrol.

40.

What will happen if the displacer has fallen down while in line ?

41.

What will happen if the displacer has a hole in it while in line?

42.

What is the used of Suppression and elevation?

43.

How will you commission D.P. transmitter in field in pressurized vessel.

44.

How will you check zero of a level D.P. transmitter while is line?

45.

Explain the working of an Enraf level gauge?

46.

What are the different methods of temperature measurement? Explain

47.

What is Pt 100 mean?

48.

What is two wire and three wire R.T.D. system?

49.

Draw a potentiometer temp. Measuring circuits and explain its?

50.

What is the constant voltage unit?

51.

Explain the working of a balancing motor.

52.

What is burnout feature ? Explain

53.

Why are Thermowells used ?

54.

What type of sensing element would you use to measure very low temperature ?

55.

What are skin temperature thermocouples ?

56.

What is the specialty of thermocouples lead wires ?

57.

What is the difference the a wheatstone bridge and a potentiometer ?

58.

Explain the application of proportional integral and derivative action?

59.

Where is on off control used?

60.

What is reset-wind up?

61.

Why is reset called integral and Rate derivative ?

62.

Explain tuning of controllers.

63.

Explain the working of an electronic P.I.D. controller.

64.

What is an analogue integrator and an analogue Explain the working of Rotameter?

65.

Explain the working of a magnetic meter.

66.

Explain the working of a turbine meter.

67.

Explain the working of a Pitot tube.

68.

Where is the integral orifice used ?

69.

What are types of taps used for orifices ?

70.

What is Reynolds number ?

71.

How would you choose differential range ?

72.

What is positive Displacement meters ?

73.

What is a control valves ?

74.

What are the different types of control valves ?

75.

What is the use of single seated valve ?

76.

What is the use of double seated valve ?

77.

What is Cv of a valve ?

78.

What are the different types of actuators ?

79.

What types of bonnets would you use of high temp. and very low temp. ?

80.

How will you work on a control valve while it is line ?

81.

What is the use of a valve positioner ?

82.

When can a by pass be not used on a positioner ?

83.

What is the use of butterfly valves ?

84.

What is the use of three way valves ?

85.

What are the different types of plugs ?

86.

What is a cage valve ?

87.

What is the use of link connected to the valve positioner ?

88.

What is the use of booster relays ?

89.

What is the use of Angle valves ?

90.

What are the different valve characteristic ?

91.

What is a solenoid valve ? Where it is used ?

92.

How will you change the valve characteristics with positioner ?

110.How will you change the action of a control valve ?

93.

How will you select the control valve characteristics ?

94.

What is the effect of pipe reducers on valve capacity?

95.

An operator tells you that a control valve in a stuck ? How will you start checking ?

96.

Where is an Air to close and Air to open control valves used ?

97.

Why does control valve operate at IS psi ?

98.

differentiator ?

99.

What is an anti reset wind up ?

100.

What are De-saturators ?

Types of Bourdon tubes

The following are the commonly used Bourdon tubes used in industries:
- Spiral Low range 10 100kpa
- C type Medium range 100 5000kpa
- Helical High range 5000 20000kpa
Application of Twisted Pair Cable:
Twisted pair cabling is a form of wiring in which two conductors are wound together for the purposes of canceling out electromagnetic
interference (EMI) from external sources.
*Twisting wires decreases interference because the loop area between the wires is reduced.
*The two wires typically carry equal and opposite signals which are nutralized because of phase shift. twisted pair cables are very qualitative in
nature as they prevent electromagnetic interference from external sources and crosstalk from external wires. They are majorly used in telephone
networks, data networks and cable shielding. Our twisted pair cables are of two types, which are: Shielded Twisted Pair Cables: These cables
protect cable from external electromagnetic interferences and are used with token ring networks. Unshielded Twisted Pair Cables: These
are the unshielded twisted pair cables which are highly flexible and long lasting in nature. Our cables are used in many Ethernet networks and
telephone systems

Basics of Foundation Fieldbus

All digital serial two-way communication system interconnects field equipment (sensors, actuators and controllers) architecture for building
inter operable distributed real time control systems.
Multidrop wiring ( 32 devices on a single pair of wires (called a segment)
Multivariable Instruments (Multiple variables from one field device )
Two-way communication
New types of information
Control in the field
Interoperability :Device from different suppliers can be communicate with each other and perform their function in multi-vendor environments.
(standardize communication protocol from Physical layer through Application Layer)
Interchangeability: Device from different suppliers can be functionally interchanged by providing the same functionality for the same type of
devices. (Standardize various function blocks)
What user wants is to provide interoperability and the same basic functionality for the same type of devices and room for innovation by suppliers
for additional unique functionality (Provide a common way to describe/understand suppliers specific features (DDL).
Foundation fieldbus communications model
The Physical Layer
Data Link Layer and Application Layers
The User Layer
Physical Layer: Translating messages into Physical signals on the wire and vice versa
Physical Layer: Provides the common Electrical Interface for all foundation fieldbus devices. (H1 segments -Power supply 9-32 Volts DC Power
and 15-20 mA of current per device communication rate 31.25 kbaud 32 devices per segment; upto 240 devices total with repeaters.
Data link and Application layers: Control transmission of data on the fieldbus.
Standard way of packaging the data as well as managing the schedule for communication and function-block execution.
User Layer: contains transducer block, resource block and function blocks that describe and execute device capabilities such as control and
diagnostics. Device descriptions enable the host system to interact with and understand these blocks without custom programming.
Benefits of Fieldbus
System can be built from devices manufactured by different vendors
No single company controls the evolution of the standard
Interoperability
Reduced Cost
Less wiring installation and maintenance cost because of multi-drop
Better diagnostics through software
Control distributed in the field
More data available from the devices
Diagnostic Data
Multiple variables

Interview Question for Automation,DCS,PLC Engineers

1.
Draw system architecture showing PLC, SCADA/MMI, networking devices communication protocol details like IP address etc.
2.
Draw detailed block diagram of any field parameter like temp, pressure reading coming to PLC can be shown on SCADA/MMI.
3.
Explain 2 wire & 4 wire wiring concept.
4.
Draw block diagram of close loop control. Difference open and close.
5.
Draw server client architecture with example.
6.
Name different types of timers used in PLC.
7.
Subroutine, instruction types,
8.
Explain PID?
9.
PID Cascade mode, primary secondary
10.
Ramp, feed forward
11.
Name communication protocols and basic parameters required to establish communication between two nodes.
12.
What is difference between signal ground and power ground?
13.
Explain redundancy of controller.
14.
Master slave concept in Modbus
15.
Modbus addressing
16.
What is CRC? Parity?
17.
Thermocouple RTD difference
18.
Room temp resistance for RTD.
19.
IP Address classes.
20.
Scan time of PLC.
21.
Why 4-20 ma not 0-20 ma?
22.
Bump less transfer

Foundation Fieldbus
An open, bus-powered, digital, multi-drop communication technology for intelligent field devices and automation systems.
enables digital replacement of 4-20 mA
enables unification of field with business / control
enables some basic and even advanced process control in the field
How is Fieldbus Different from 4-20
Fieldbus devices are connected in parallel on the bus, which carries digital data from/to all the devices on the bus
Fieldbus devices provide almost unlimited information to all other devices on the network
Data has cyclical redundancy checking (CRC) to ensure receiving devices use only good data
A multidrop fieldbus does not have the shortcoming of point-to-point wiring
FOUNDATION Fieldbus Differentiators
Supports Intrinsic Safety and Existing Wiring
Uses IEC/ISA fieldbus standard.
Secure Process Data Messages
Time-critical process data first priority
Alarms and events second priority
Background MMI messages, downloads, etc., in free bandwidth
Function Blocks
Standard Set (AI, AO, DI, DO, PID, ML, SS, ...)
Modeled after DCS points
Supports distribution of control to field devices
Device Description Language (DDL)
Defines parameters and function blocks in a device
Provides interoperability between devices
Supported by major global controls suppliers
Less wiring and commissioning time
Access to diagnostics for better asset management
what is cascade loop and how it work and why it used instead of PID single loop? In cascade, Which loop is faster and slower? Please explain
with loop drawing and example...
A.1) In cascade loop the parameter to be controlled is in series with another parameter which is to be measured for normal operating conditions
i.e 2 manipulated variables are in series
it is used in fractional distillation system , boiler operation in power plants etc In pid
only one variable is measured and controlled at a time .it is used for temperature , pressure , flow control system
A.2) cascade loop is the combination of two pid control.where 1st controller output ie mv is the input of 2nd controller.1st contrroler more fater
than second controoler.
it's used in boiler three element.it's control feed water flow,drum level and steam flow.
The 250 ohm resiatance is necessary to support the communication between transmitter and HART because it equalizes
1. loop resistance
2. barrier resistance
3.wire resistance
4. receivers resistance

What is Dry Leg Calibration and Wet Leg Calibration?

Dry leg calibration and Wet Leg Calibration are used for closed and pressurized vessels level measurement.
Difference:
Wet leg calibration is used for vapourised liquid (which will be condensated by atmosphere) level.In LP side
Tapping ,liquid filled .
Dry leg calibration for the liquid under pressurised condition which will not be condensated.

what is bevel? why bevel required in orifice plate?

Orifice plates which are used in flow measurement are mostly concentric "square-edge" type. The bore of the orifice is not constant when one
moves from the upstream side to the downstream side along the cross section. The bore size is constant for a few mm only and then expands till it
reaches the downstream face. This inclined cut is called the bevel in an orifice.
The main reason to have a bevel in the orifice is to avoid turbulence thereby providing more accuracy to the measurement. Restriction Orifice
plates are not beveled since their intent is to reduce the pressure only.
What is difference between fault tolerant and redundant system?
In a fault tolerant system, there may not be a back-up component to take over in the event of a component failure. Redundant systems will have
back-up components that take over in the primary component fails.
For instance, a DCS system may have redundant processors that take over control if the primary processor fails for some reason. Typically, these
systems have redundant power supplies as well. You may also see redundant field devices on critical systems. Boiler drums will usually have
several level transmitters set up so that any one failure would not impact the operation of the boiler.
In a fault tolerant system, you may not have any back-up components. The system is designed to continue operations in the event of a failure of
one or more components. In thinking about this topic, a newer model automobile engine came to my mind. The emissions controls on these newer
engines use inputs from several sensors to control the engine and limit emissions. Typically, these systems would run on what is called a closed
loop control, where the sensor inputs are used by the computer to control parameters to the engine. If one of the components fails in the emissions
control system, the engine will continue to run, but not as efficiently. The emissions control system will go into open loop mode where a set of
fixed parameters is used to let the engine continue to operate at some reduced efficiency level.

Change a controller from auto to manual and vise-versa

Pneumatic controllers :While taking the controller from auto to manual, the manual output is to be balanced to the auto output and then transfer
the auto-manual switch to manual. While changing the controller from manual to auto, the controller set point is matched to the manual output
and then auto-manual switch is transferred.
Electronic controllers :Auto to manual control may be transferred directly as the electronic circuit keeps the auto and manual output matched. But
while changing the controller from manual to auto, the controller set point is to match to the process variable and then auto-manual switch is
transferred