Question Why we use 4 - 20 ma?

*Also, since this is linear region

Answer 1}///in earlier days we had
*Not possible to cause spark
used BJT transister in signal conditioning
circuits for amplification purposes so in BJT *Since it is a current signal we can transmit it
transfer characteristics 4 to 20 milli amps is a into long
linear region,....but now-a-days we re using
distance.
cmos only.... as a convention only we are
following this 4-20 range
*Suppose if the instrument is dead we can
identify it.
2}///another reason...for not using 0 milli
amp coz if we use like that we cannot Question role of electrical engineer in the
distinguish between true signal zero and instrumentation industry?
dead zero(break in wires)
Answer Engineer means a person who
Answer To operate a Digital signal we supervises a team or a group of technical
need 1-5Vdc. For Analog Instruments we are people.. talking about electrical engineer..
using 250 ohms as load resistance. When He can perform various tasks at industry.
like:
we converting this signal into current By
Ohm's 1- Maintain electrical power to industry

Law V=IR 2- Trouble shoot major minor faults in

machines etc
I=V/R

Question Instrumentation engineer

Put, V=1V Then I=1/250=4mA
please reply me,I am electrical engineer
Put, V=2V Then I=2/250=8mA ,what is the future in instrumentation dept
{presently working (P&ID) Design} for
Put, V=3V Then I=3/250=12mA
me,whether good future for me as

Put, V=4V Then I=4/250=16mA instrumentation department.what side can i

get job in future
Put, V=5V Then I=5/250=20mA
Answer Instrumentation is a vast field Answer 4-20mA is used to identify the

and its ever green field as long as the process zero.

industries are there to to produce our daily

Answer This is only concept of live
needs But as an electrical engineer better
zero & dead zero.live zero is 4ma.because if
you should go for electrical testing also
any faulty in your sensor are signal
parellaly. But designing fiels itself got lots of
transmitting field cable are your power
scope in both elcl and insmn. ok
source fuse failure you can easily find out

Answer Instrumentation is a vast field that live zero concept.

and its ever green field as long as the

industries are there to to produce our daily
needs But as an electrical engineer better Answer 4 MA
you should go for electrical testing also
parellaly. But designing fiels itself got lots of
scope in both elcl and insmn. ok LIVE ZERO DEAD ZERO CONCEPT

Answer Future in design P&id is

always better surely it will help to widen ur
knowledge but as far as my point of view as 20MA

an electrical engineer u have lot many

core(Electrical) fields to do career.Knowledge
of instrumentation is always help u lot since ELECTRICALLY UPTO 20MA THERE IS NO
in many industries work OF Instrumentation CREATING A SPARK IN THE TIME OF
engineer done by electrical Engineer. SHORTED LOOP.ALSO CURRENT TRAVELLING
LONG DISTANCE WITHOUT NO DROP.(UPTO
Question why do we use 4-20 ma
1500m)
current why cant o-20ma?

Answer it gives us the ability for

knowing if there is cuttig in the wire.but if the main purpose for choosing 4to 20ma
we use 0-20 if there is a cutting in the wire it easily convert to
will indicate also 0 which we have and i will
voltage to add 250 ohms resistance with the
not give us any idea if there is cutting or not
help of ohm's
law for avoid trip conditions,after find out&
rectify it.In that operation can do it in a MOS
Question can i use 1 sq mm insted of
panel... simply change the selector
1.5 sqmm cable cable length 600 mts under
switch,after take out the job
ground laying Cable carrying 24 vdc 4-20ma
current Question how can we caliberate
interface level troll?
Question Submitted By :: Benq
Answer Interface level troll means:
Answer Yes you can.
When a vessel is filled with two liquids of

Question who to convert dc to ac ? two different specific gravities the level

measurement refers to as interface level.
Answer Inverter
DP = H (D - d)
Question Regarding MOS (maintenance
override switch), I want to know its function Calculation # 1 If the calibrating liquid is

and its state ( 1 or 0 when not activated ). water:

Answer all are digital signals,hence DO Process Liquid Density / 1* Displacer height

or DI = mm of H2O.

Calculation # 2 If the calibrating liquid is

other liquid: Process Liquid Density /
ACTIVATED - GIVES O/P 1 Calibrating liquid density * Displacer height =
mm of H2O. (Calibrating liquid height in
NORMAL IT GIVES 0. Whatever we required,
mm).
we can changes the o/p.

1. First close both the primary isolation

abt MOS panel
valves and drain the liquid inside the
In a industry having a lot of trip logic for chamber.
safety purpose or suitable process
2. Adjust the zero to get 0% output.
also.incase the txr or

3. Connect a transparent PVC tube to the

further inst will make it a problem or
drain point as shown in hook up.
mismatching value,we would make it a loop
4. Fill it to the center of the top flange.

5. Adjust the specific gravity or span Displacer length: L in mm

adjustment (Electronic Level).
Density Low : dl in Kg / 1
6. Fill it up to 50 %, check linearity.
Density High : DH in Kg / 1
40. How will you calibrate on interface level
Alarm / Trip point %: X
control. ?

HH Trip Point: Y in mm
On an interface leveltrol there are two liquid
of two different specific gravities. Question; how can we caliberate
interface level troll
1. The level will be zero when it is full of
lighter liquid. Answer Level troll calibration

Zero % level = H X d. 0% Zero 100% Span

H = Displacer length Liquid Level Displacer out of liquid Displacer

in liquid Interface Level Displacer in lighter
d = Specific gravity of lighter liquid.
liquid Displacer in heavier liquid
2 The level will be 100 % when it is full of
Wet Calibration with Water For Liquid level
heavier liquid.

Zero :
100 % level = H X D.

Hang displacer on torque tube arm rod.

D = Specific gravity of heavier liquid.
Adjust Zero to 3 psi .
Calibration with water:
Span :
1. Fill H X d level with water adjust zero.
Fill up water into the chamber.
2. Fill H X D level with water adjust Sp.
Adjust Span to 15 psi .
gravity or span.

0%, 25%, 50% , 75% & 100%. Mark on

3. Check linearity.
chamber.
Fill up & Drain water to check 0%, 25%, 50% , = 3.14 X 3.81 X 3.81 X 35.56
75% & 100%.Check output.
= 1620.84
Check function two three times.
Zero :
Note: Compensate specific gravity difference
For 0% Hang displacer or 2400 gram weight
of water & process liquid.
on torque tube arm rod .
Process liquid specific gravity is 0.7
Adjust Zero to 3 psi .
Water specific gravity is 1.0
Span :
To calibrate level transmitter 100% level.
For 100% Hang weight= Displacer weight –
Water level to be fill up in chamber = 0.7/1.0 Volume X Specific gravity
x 100 %
= 2400 – 1620 X 1
= 70 %
= 780.
Dry Calibration with Weights
Adjust Span to 15 psi .
Find out Displacer
Check function two three times for
W = Displacer weight in 2400Gram (2.4 kg) calibration.

Specific gravity of process liquid. (WATER)= Level

1.0
%
V = Volume of displacer. 1620.84
Hang weight
Displacer diameter 7.620 Centimeter (3
(Gram)
inch).

Transmitter O/P
Length of Displacer 35.56 centimeter (14
inch) (PSI)

Volume= 3.14 X r² X h 0 2400 3

25 1995 6 Fill up 100% water into the chamber.

50 1590 9 Adjust Span to 15 psi .

75 1185 12 Dry Calibration with Weights

100 780 15 Find out Displacer

For each 25% step subtract 405 Gram weight W = Displacer weight in 2400Gram (2.4 kg)
from hang weight.1620/4=405.
Specific gravity of process liquid. Oil= 0.7
Note: Compensate specific gravity difference
V = Volume of displacer. 1620.84
of water & process liquid.

Displacer diameter 7.620 Centimeter (3

Wet Calibration with Water For Interface
inch).
level

Length of Displacer 35.56 centimeter (14

Zero : Displacer in lighter liquid
inch)
Process liquid specific gravity is 0.7
Volume= 3.14 X r² X h
Water specific gravity is 1.0
= 3.14 X 3.81 X 3.81 X 35.56
Mark chamber at 70%
= 1620.84
Fill up water in chamber.
Zero : Displacer in lighter liquid
To calibrate level transmitter 0% level.
For 0% Hang weight on torque tube arm
Water level to be fill up in chamber = 0.7/1.0 rod .
x 100 %
Hang weight= Displacer weight – Volume X
= 70 % Specific gravity

Adjust Zero to 3 psi . = 2400 – 1620 X 0.7

Span : Displacer in heavier liquid. = 2400 - 1134

Process liquid specific gravity is 1 = 1266

Adjust Zero to 3 psi . For each 25% step subtract 121.5 Gram
weight from hang weight.(1620-
Span : Displacer in heavier liquid.
1134=486)
For 100% Hang weight= Displacer weight –
Volume X Specific gravity 486/4=121.5.

= 2400 – 1620 X 1 Question what is the difference

between Ethernet unmanaged and
= 780
managed Switch?

Adjust Span to 15 psi .

Answer In unmanaged switch it sends

Check function two three times for data to all the terminals regardless of

calibration. necessary.But managed switch sends data to

certain decided terminals hence it avoids
Level conjuction.

% Answer Like making VLAN on the

switch can be considered as managed
Hang weight
switch.Wheras in unmanaged switch there is
(Gram) no such network.

Transmitter O/P

(PSI)

0 1266 3
Question what is RPI and NUT in
25 1145.5 6 controlnet networx. what happen if we
are increase the NUT of controlnet
50 1023 9
networx?

75 901.5 12 I Answer RPI-REQUEST PACKET

INTERVAL NUT- NETWORK UPDATE TIME RPI
100 780 15
SHOULD BE GREATER THAN NUT LETS SAY
RPI=20MS AND NUT =10MS BECAUSE FOR
EACH REQUEST EXECUTION NETWORK parts MTU and RTU. MTU(Master Terminal
SHOULD BE UPDATED FIRST Unit)_ to control several RTU's(Remote
terminal Unit) with wire or wireless
Question What is the difference
technology.SCADA is composed of many
between HMI and Scada?
HMI's.

Answer HMI is a component of

Question What the basic of
SCADA...
communication?

Answer HMI IS Human to (Hand to)

Answer information
Machine Interface ie a Display Screen Like a
computer monitor wHICH HAS THE Answer EXCHANE OF INFORMATION
CONNECTIVITY TO MACHINE CONTROLS BETWEEN TWO MEDIA OR BODIES IS
THRU SPECIFIC SOFTWARE, It may have 3D TERMED
switches parameter setting alarm indication
AS COMMUNICATION
etc etc where as SCADA (Supervisory Control
And Data Aqusition)is a system combined a Question what is flow and flowrate?
software May be a PC with monitor or HMI definate and diffrentiate it?
by which one can monitor the process and
control it This has got lot of options in Answer Flow indicates the quantity

monitoring , recording of process data. So (mass or volume) of fluid passing through a

HMI is a part of SCADA System. particular vessel or pipe regardless of the

time whereas flowrate indicates the flow
Answer Actually HMI stands for with respect to time.
Human machine interface previously it was
called MMI(Man Machine Interface) but Question WHAT IS SMART SENSOR

MMI turm was out due to its sexiest tone.so AND DIFFERENT B/W SMART SENSOR AND

hmi is Monitoring station from where u can SENSOR?

see the process, control the process by

Answer SMART sensor do have some
giving cammands via software cmpitable to
additional accessories or you can say
it.
features.such as additional communication

Where as SCADA(Supervisory Control And interface,selfdiagnostic features etc.Whereas

Data Acquisition) Composed of mainly two

sensors only do the sensing job no any other Unit of temerature: Degree Centigrade,
features. Degree Fahrenheit, Degree Kelvin, Degree
Rankin.
Question what is the full formof
HART ? Unit of pressure: bar, Pascal, kg/cm2, mm
Wg, mm hg,
Answer higway adressable remote
transducer Question Is that Speed Probe and
Vibration Probe sensors are same,if yes
Answer Higway Adressable Remote
what is the diff b/w them?
Transducer(digital signal) is a
Answer normally we are measuring
digital circuitry in a transmitter, which is
vibration signals are amplitude, frequecy and
superimposed on analog 4 to 20 mA.This
phase.
superimpossed signal is separated in I/O
module and 4 to 20mA signal is given to the for this we are using the same
control system and HART(digital signal)is probe.vibration is measured as peak to peak,
given to Asset Management System a measure of the

Answer Higway Adressable Remote total excursion of the rotor or machine

transmitter casing in 'mils or micrometers'. Frequency is
measure of how fast a body is vibrating and
Question what are the pinciples &
is used to identify the source of vibrations.
units of flow, level, temperature,
frequency is expressed in shaft rotative

pressure, quality. speed. for calibrating or checking probe or

transmitter using for frequency (rotation /
Answer Unit of flow:kg / hr, litter / min )
min, gallon / min, m3 / hr,
1. adjust gap voltage at zero (-10V)at TK 3
Nm3 / hr. (Gases)
2. put some small sticker on wobbulating
part.

Unit of level: Meters, mm, cm, percentage. 3. increase the speed of wobulator (TK3)
3. your out put is measured from multi shutdown sequence .....PLC cannot have a
meter at HZ range HART compitable I/O ...where HART signls
are used for Asset management..DCS you
Question what difeerent between
can have all features such as asset man..
HART and BRAIN?
Answer The Basic difference between
Answer HART & BRAIN both are
the PLC and the DCS is PLC is Programmable
nothing but calibraters. rose mount make
Logic Controller in an n/w it control program
used HART protocol. yokogawa make used
logically.DCS is Distributed Control System it
BRAIN to calibrate transmitters.
will distripute and control the system in a

Question when we calibrate the DP n/w or more. So Group of PLC is know as

transmitter at that time which matrial we DCS.

used in pressure pump?

Question how can we calibrate the

Answer dead weight tester differential pressure transmitter by using

HART communicator
Answer hydraulic oil in dead weight
tester. Answer ICON CONTROLS PVT. LTD.

Answer if pressure pump is hydrolic Answer First do the 0 trime and span

then oil or water is used and if pressure trim, In this it self problem will solve....ealse

pump is penumetic teen only air. use hand pump in point(In HP or LP side it's
deponds up on the usage) applay the
Question why thermocouple called pressure check the reading
thermocouple?
Answer Probably HART communicator
Answer bcz here 2 matals are couple used for online & onfield calibration.As per
together my experience,I always used to do
calibration by step given bellow:
Question what is the different between
plc and dcs ? 1.First,put transmitter loop in CAL mode.In
CAL mode controller the hold last PV for
Answer The major difference between
reference.causes without stop or disturb
PLC and DCS is networking...and most often
PLC is used for ESD applications..for
process we can do calibration my experience,I always used to do
earlier(depends on process) calibration by step given bellow:

2.Connect HART to the transmitter +ve & -ve 1.First,put transmitter loop in CAL mode.In
terminal.observed parameter on HART CAL mode controller the hold last PV for
display.e.g.pressure,dp,current output reference.causes without stop or disturb
singnal.& note down. process we can do calibration
earlier(depends on process)
3.Then close the isolation valve of both HP &
LP tapping & loose the both HP & LP side 2.Connect HART to the transmitter +ve & -ve
vent plug.In this condition transmitter shoud terminal.observed parameter on HART
show zero dp because same atmospheric display.e.g.pressure,dp,current output
pressure actig both side.If transmitter singnal.& note down.
showing zero dp transmitter is normal & If it
3.Then close the isolation valve of both HP &
is not showing zero,then there is some error
LP tapping & loose the both HP & LP side
in dp.
vent plug.In this condition transmitter shoud
4.If transimtter showing error in dp then on show zero dp because same atmospheric
HART go to diagnosis-calibration-sensor pressure acting both side.If transmitter
calibration-dp trim.enter the zero dp at showing zero dp transmitter is normal & If it
atmospheric condition and come back on is not showing zero,then there is some error
basic setup display,transmitter will showing 4 in dp.
mA current output.means calibration is
4.If transimtter showing error in dp then on
ok.then u can take transmitter on line.and
HART go to diagnosis-calibration-sensor
don't forget to checked leakage from
calibration-dp trim.enter the zero dp at
impulse tubing & vent plug. Another
atmospheric condition and come back on
procedure is Bench calibration.Using
basic setup display,transmitter will showing 4
pressure & calibrator we can check
mA current output.means calibration is
transmitter.even without HART we
ok.then u can take transmitter on line.and
Question can do bench calibration. don't forget to checked leakage from
impulse tubing & vent plug. Another
Answer Probably HART communi cator
procedure is Bench calibration.Using
used for online & onfield calibration.As per
pressure & calibrator we can check
transmitter.even without HART we can do line there is less posibilities of flamable &
bench calibration. explosive source but as per NFPA standard
you must use Eex type instruments.
Answer first of all connect the 250
ohm resistence in series while connecting Question If mVolts can drop by
the HART to DPT for communication tnen resistance of wire as compare to mA, then
close all tabs and adjust zero.we can also how thermocouple mV reaches in CCR as
adjust the range,unit by using HART accurate value?
communicator.
Answer It depends on quqlity of cable
Question Dear friends, I have a and generally it is specified by the cable
question: manufacturer that for a perticular distance
what will be the loses and we add that
We work on a project which has some
quantity in our logic for accurate value
boilers to provide steam for desalination
unit. The boiler area is safe and the only Answer thats why we use single stand
hazard source is the fuel lines of boilers. I not multi core cable for thermocouple
want to know according to NFPA standard measurement
which type of instrument should be selected
Answer Each type of themocouple
on the fuel line: Eex Type or
different types of metals winding are used
Non-Eex type? Example k-type of thermo couple used
cromium aluminium metals are used, like
j,s,t ect. This metals used as per thermo

Answer First,you should read about couple mvolts droping is reducedu

NFPA 31 standard.My suggestion is that you

Answer the resistance of
shoud used Eex type instrument on fuel
thermocouple is les than resistance of
line,because most of fuel of boiler are
normal cable so voltage drop across wire not
flamable,so you must used flame
too big
proof/explosion proof instrument.but,my
question is that why people think too to take Answer bcoz use the specialy
decision about about safety? boiler is highly manufactured t/c cable and for each type of
hazardous area.I know that outside the fuel
t/c we use different t/c cable of that t/c P: manipulated variable our put is
material proportional to the system deviation. that
means variable only present if there is any
Question What is a PID controller and
system deviation.
how can it to applied to oureveryday life?
I: manipulated variable is continues to

Answer A PID controller is composed increase, the system deviation decreases.

of three components: this process continuous until system

deviation is zero.
P - Proportional
D: Differential compound evaluate the speed
I - Integral of change of the system deviation.so if using
the PID controls, we can control the flow to
D - Differential
our desired valve at a very short time.
It controls the overall response of a system.
Question what is a mapping in plc &
The "P" term controls the gain of the system.
dcs
The "I" term controls error and "D" term
controls the overshoot of the system. Answer Mapping is the process of
assigning the addresses to the controller for
Answer PID controller is use to correct
I/O integrity for e.g in GE fanuc PLC if we
the errors between measure value PV ( i.e
have to assign a single address for AND
process value ) and set piont (sp).
combination of two inputs then we simply
Answer At first you should understand connect these two inputs in series and assign
what is the controller. a single address for for combination of these
two inputs means (%I0001---%I0002----------
A controller is the device in a closed loop,
%M0003) Here I in input from field and M is
that compares the measured valve (actual
memory mapping address assigned for
valve) with the desired valve and calculate
combination of these two inputs
the out put manipulated variable. Then The
time (T) responds is determined by P,I,D Question what is the difference
between(Flame proof/Explosion
proof)&Fire proof instruments.Both are
same or different & if different in which
way because the transmitter which have instruments,there is no need of flameproof
approved ATEX flame proof enclouser but it instruments.
use PTPE O ring & PTFE Head Gasket,so its
Question what happens if we are
(fire safe/fire proof)?
having very very high cavity and flashing in
Answer Flame proof or explosion a control valve..??? is it stops
proof intruments are used for avoiding working...immediately... or eroded...slowly
explosion and avoiding posibilities of short
circuit in highly flamable & explosive area.In Answer Valve does not stop
this case flamable media probably being immediately, but of course, due to cavity /
gas,so flamable & explosive gases catches flashing, there will be a great impact on the
fire in electric field.Fire proof instruments valve body. This case, you need to consider
are used for protection due to any type of some solution to lessen this phenomena.
fire.So,finally I would say that flame One may be putting a restriction on valve
proof/explosion proof instruments must be inlet, or changing the trim construction of
fire proof,but out of explosive or flamable the
area we can use only fire proof
instruments,there is no need of flameproof valve, or using a high grade material.

instruments.
Question how to test rotor &stator

Answer Flame proof or explosion earth fault in turbine

proof intruments are used for avoiding

Answer STATOR EARTH FAULT
explosion and avoiding posibilities of short
PROTECTION :
circuit in highly flamable & explosive area.In
this case flamable media probably being Setting : 70% Time - 5 Sec.
gas,so flamable & explosive gases catches
Normally the generator stator neutral
fire in electric field.Fire proof instruments
operates at a potential close to ground. If a
are used for protection due to any type of
faulty phase winding connected to ground,
fire.So,finally I would say that flame
the normal low neutral voltage could rise as
proof/explosion proof instruments must be
high as line-to-neutral voltage depending on
fire proof,but out of explosive or flamable
the fault location. Although a single ground
are we can use only fire proof
fault will not necessarily cause immediate
damage, the presence of one increases the Settings : Less than 80K ohm Any rotor field
probability of a second. A second fault even winding of the generator is electrically
if detected by differential relay, may cause isolated from the ground. Therefore the
serious damage. The usual method of existence of one
detection fault is by measuring the voltage
ground fault in the field winding will usually
across the secondary of neutral grounding
not damage the rotor. However the presence
transformer (NGT). Here are two over
of two or more ground faults in the winding
lapping zones to detect stator ground faults
will cause magnetic and thermal imbalance
in a high impedance grounded generator
plus localized heating and damage to the
system, the two zones are put together cover
rotor metallic parts. The rotor earth fault
100% stator winding for earth faults. A
may be caused due to insulation failure of
fundamental frequency neutral over voltage
winding or inter-turn fault followed by
relay covers about 0-95% of the stator zonal
localized heat.
winding for all faults except those near the
neutral. Another third harmonic neutral Relays acted : a. Flag operation at Protection
under voltage relay covers remaining 96- panel.
100% of the stator zone 2 winding on neutral
side.Relays acted : a. Flag operation at b. Acting of Master relay

Protection panel.
c. Indication at Annunciation Panel.

b. Acting of Master relay

Consequences : a. Tripping of 220KV breaker

c. Indication at Annunciation Panel.

b. Tripping of Field breaker

Consequences : a. Tripping of 220KV breaker

c. Stop command to Turbine thro’ Mark-IV

b. Tripping of Field breaker

Status : a. Unit is at coasting down.

c. Stop command to Turbine thro’ Mark-IV

Question why we use 4-20 mA for

Status : a. Unit is at coasting down. calibration of the instruments.why we cant

use 0-20 mA?
ROTOR EARTH FAULT PROTECTION (64R) :
Answer The live-zero represented by 4
mA allows the receiving instrument to detect
some failures of the loop, and also allows 1.Bare Thermocouple wire.
transmitter devices to be powered by the
2.Duplex Insulated Thermocouple Wire
same current loop (called two-wire
transmitters) 3.Metal Sheathed Thermocouple Wire

Answer Logically Zero milli amps 1. Bare Thermocouple wire is without any
means no current in the circuit .if we have an insulation. normally it is sold on a spool and
initial value to be measured , we cant ordered as a pair. usage is typically for
measureit as zero milli amps . It means no making a small thermocouple in applications
current in the circuit or the circuit is open . requiring special considerations.
so we go for the span of 4 to 20 mA. this is
coz we can easily split 4- 20 as multiples of 2.Duplex Insulated Thermocouple Wire

four(4,8,12,16) which means Duplex Insulated thermocuple wire is

0%,25%,50%,75%and 100% respectively. probably the most

Answer logic zero is show no current common type of thermocouple wire. The

in circuit but we use 4 mili amp for type of thermocouple, insulation, and size

instrument is on and ready for use and lower are all some of the parameters considered

4 mili amp current relation with non linear .. for the application.

Question what should be minimum 3.Metal Sheathed Thermocouple Wire.Metal

length and size of impulse line for steam sheathed Thermocouple wire is

flow orifice and feed water orifice? thermocouple wire that is surrounded by
insulation material, typical magnesium oxid,
Answer Impels line is minimum length and enclosed in a metal sheath. A key
and size because of length is maximum feature of this type of wire includes the
water is condansate and abnormaltiys in ability to withstand vibration, high
steam flow orifice plate temperatures and pressures.

Question how many types of Question Which buffer solution is used

thermocouple cable are? for PH transmitter calibration?

Answer There are there types of Answer we are using the 4.7 10.based
cables is in the Thermocouple. on the configuration like 4 to 20 ma.if 4 ma
means 0 and 20 ma means 10.when we e=a1t1+a2t^2+a3t^3.....an+t^n
using the ph 10 it will get 20 ma..
Answer when two different metals
Answer Phosphates buffer solution is wire are connected it form two junction and
used when this two junction are kept in different
tempreture then the emf is produced
Question whats the working of
between them.
principal thermocouple
Answer thermocouple works on the
Answer thermocouple works on
principle of seeback & peltiar effect if any
seeback effect i.e when any two different
two metals are placed at two different places
metals are connected together,an
having junction j1 & j2 normally hot junction
e.m.f.generates, this e.m.f is a function of
& cold junction .heat is transferred from hot
the temperature The general form of this
junction to cold and an emf is produced. this
relationship is:
produced emf is equal to the temperature at

e=a1t1+a2t^2+a3t^3.....an+t^n that point

0 Surya2322 Question How the flow can be

measured by using DP Transmitter?
Answer thermocouple works on
seeback effect i.e when any two different Answer for flow measurment first

metals are connected together, an need creat difrential pressur by using of

e.m.f.generates, this e.m.f is a function of orific plat in flow path dp tranmitter have

the temperature The general form of this low and high side cannect high pressure and

relationship is: cannect low side of low presure of tapping

and transmitter will convert diffrential
e=a1t1+a2t^2+a3t^3.....an+t^n pressure in to 4 -20 ma

Answer thermocouple works on Question what's the reson that,Load is

seeback effect i.e when any two different not same on VFD I/P and O/P
metals are connected together, an Side.whenever DOL condition load is same
e.m.f.generates, this e.m.f is a function of I/P and O/P side.
the temperature The general form of this
relationship is:
Answer Input frequency and Voltage Answer The vent valve kept open
at the VFD is constant but at the output at while start up boiler is called start up vent
the VFD is variable.secondly the power valve.This valve is usefull to vent low
factor at the Driven end is changing wrt to temperature & pressure moisturised steam.
load.more over the Active and reactive part as well sa to raise steam pressure slowly.
of Power is deviating wrt to above factors
Answer Also if the turbine triped, the
thus the power at the input and output of
steam wil b vent throug this valve
VFD are different.in DOL none of the
parameter like Voltage or Frequency are Question how to calculate flow by dp
changed thus Power remain same. transmitter?

Question what is the significance of Answer You can use Q = sq.root of DP

hook up

Answer it shows how to isolate from

process also how it woks where Q = Flow rate

Answer Hook-ups are basically of two DP = differential pressure.

types Process Hook-Ups and Pneumatic

0 Gk3000
Hook-Ups. hook ups give complete
information required for installation of a Question what is the difference
particular instruments which indicates cable between active and passive loop ?
entries, support details, connection sizes. It
Answer active two wire
clearly defines the instrumentation scope for
installation and helps in identifying the passive four wire
materials and accesories required during
installation Process Hook-Ups covers all field Answer Passive Loop: The transducer

instruments installed on pipelines/vessels must be provided by an external power

and other process equipments and supply for its working. Then it generates the

Pneumatic Hook-ups covers all instruments signal according to the Process parameter.

which require instrument air to operate This may have either 2 wires, 3 wires or 4
wires.Active Loop: There is no need to give
Question what is start up vent valve ? external power supply for the transducer.
why it is used in boiler?
The sensor itself generates signal without 1250KiloWatts(KW), since as above VA = W.
giving power supply. This will have only 2
KVA = Kilo (Volts X Amps) = Kilo (Watts)
wires.

also
Question what's meanning of 1250KVA
and how to calculate with Volttage and 1000Watts = 1 Kilo Watt
Current. answer give with example.
Answer as we all known that p.f=
Answer This is really a basic electrical kw/kva
question but anyway,Power is measured in
Watts and the symbol for power is "P" then kw= kva*p.f. or kw = vicos@ where kva
= vi
and for watts "W"
and p.f. = cos@
The formula to calculate Power is Volts X
Amps Answer It might be better in the
future to ask electrical questions in the
So this can also be written in short as P = V X electrical section, rather that trying to find
A someone in instrumentation that can give
you answers on electrical problems you are
Since as you have learned in basic
struggling to understand.
mathematics that if there is no sign between
two symbols that means multiply, Here's what you need anyway,

so the above can also be written as P = VA Since watts is volts times amps, what is VA?
and the answer
VA (or volt-amps) is also volts times amps,
will be in Watts. the concept

The electrical people have different ways to however has been extended to AC power.
refer to Power
For DC current:
but it is all exactly the same thing.
VA = Watts (DC current).
They could either call it 1250KVA or say it
out fully like In AC if the volts and amps are in phase (for
example a
resistive load) then the equation is also: Or kilovolt-amps times power factor equals
kilowatts.
VA = Watts (resistive load)
When you want to know how much the
where V is the RMS voltage and A the RMS
electricity is costing
amperage.
you, you use watts. When you are specifying
In AC the volts and amps are not always in
equipment loads,
phase (meaning
fuses, and wiring sizes you use the VA, or the
that the peak of the voltage curve is does
rms voltage
not happen at the
and rms amperage. This is because VA
peak of the current curve). So in AC, if the
considers the peak of
volts and amps
both current and voltage, without taking into
are not precisely in phase you have to
account if
calculate the watts
they happen at the same time or not.
by multiplying the volts times the amps at
each moment in Finding the Power Factor:

time and take the average over time. How do you find the power factor? This isn’t
easy. For
The ratio between the VA (i.e. rms volts time
rms amps) and computer power supplies and other supplies
that are power
Watts is called the power factor PF.
factor corrected, the power factor is usually
VA•PF = Watts (any load, including inductive
over 90%. For
loads)
high power motors under heavy load the
In other words, volt-amps x power factor =
power factor can be
watts.
as low as 35%. Industry standard rule-of-
Similarly, KVA*PF = KW,
thumb is that you
plan for a power factor of 60%, which KVA•PF = KW (any load, including inductive
somebody came up with loads)

as a kind of average power factor. Where KVA stands for kilovolt-amps, KW

stands for kilowatts,
Converting VA to Amps:
and PF stands for the power factor.
How to convert VA to amps? Use the
following formula:

A = (VA*PF)/V Keep the factor of 1000 straight when

dealing with mixed units:
Where A stands for the RMS amps, VA stands
for volt-amps, V KVA•PF = W/1000 (any load, including
inductive loads)
stands for RMS volts and PF stands for the
power factor. VA•PF = 1000•KW (Kilowatts to VA)

Converting VA to Volts

How to convert VA to volts? Use the The Following equations can be used to
following formula: convert between amps,

V = (VA*PF)/A volts, and VA.

Where V stands for RMS volts, A stands for

the RMS amps, VA
Converting VA to Amps (voltage fixed)
stands for volt-amps, and PF stands for the
The conversion of VA to Amps is governed by
power factor.
the equation:

Amps = VA•PF/Volts)
What is KVA?
For example 12 VA•0.6/(12 volts) = 0.6 amp
KVA is just kilovolt-amps, or volts times amps
divided by 1000:
Converting KVA to KW (Kilovolt-amps to
Kilowatts)
Converting Amps to KVA (voltage fixed)
The conversion of KVA to KW is governed by
The conversion of Amps to KVA is governed
the equation:
by the equation:
KVA = KW/PF)
KVA = Amps • Volts/(1000•PF)
For example, if the power factor is 0.6
For example 100 amp * 110 volts/(1000*0.6)
120 KVA•0.6 = 72 Kilowatts = 18.3 KVA

Converting Watts to KVA (watts to kilovolt- Converting VA to Volts (current fixed)

amps)
The conversion of VA to Volts is governed by
The conversion of W to KVA is governed by the equation:
the equation:
Volts = VA•PF/Amps
KVA=W/(1000*PF)
For example 100 VA • 0.6/10 amps = 6 volts
For example 1500W/(1000*0.83) = 1.8 kVA
(assuming a power

Converting Volts to VA (current fixed)

factor of 0.83)

The conversion of Volts to VA is governed by

the equation:
Converting Amps to VA (voltage fixed)
VA = Amps • Volts/PF
The conversion of Amps to VA is governed by
For example 1.5 amps * 12 volts/0.6 = 30 VA
the equation:

VA = Amps • Volts/PF

Converting Volts to Amps at fixed VA

For example 1 amp * 110 volts/0.6 = 183 VA
The conversion of Volts to Amps is governed hose, letting the pressure build up, the water
by the equation: can have more

Amps = VA•PF/Volts power (like watts), even though it is still only

one gallon
For example 120 VA* 0.6 /110 volts = 0.65
amps a minute. In fact the power can grow
enormous as the

pressure builds, to the point that a water

Converting Amps to Volts at fixed VA
knife can cut a

The conversion of Amps to Volts is governed

sheet of glass. In the same manner as the
by the equation:
voltage is

Volts = VA•PF/Amps
increased a small amount of current can turn

For Example, 48 VA • 0.6 / 12 Amps = 2.4 into a lot of

Volts
watts.

Answer In steam turbine its totaly

Explanation depends upon require steam from

Amps are how many electrons flow past a extraction of turbine.

certain point per

but 10 mw seam turbine must be 9 stage.

second. Volts is a measure of how much

force that each
the biggest reason here ur power plant is
electron is under. Think of water in a hose. A
which type.
gallon a
capitive power plant or power station.at the
minute (think amps) just dribbles out if it is
extraction of
under low
steam wre r u used.
pressure (think voltage). But if you restrict
the end of the
Question What's the Installtion the impulse lines filled during the process
procedure of DP Transmitter for Gas,steam zero. (See below)
and water?
Steam - The DPT is installed below the pipe
Answer Gas(non condensing like hydro from impulse lines coming from the top of
carbon gasses and air) -Impulse line comes the flanges or pipe. There are condensation
from pressure taps installed on top of the pots (or T-pieces with a needle valve pointing
flanges or pipe. The DPT is also installed on up)installed at the highest point and they
top of the pipe so that any liquid that form should be at exactly the same height. From
will run back into the main line via the the bottom of these pots (or T-Pieces) the
impulse lines. It is best to work from a impulse lines run down to past and below
process zero if the line pressure is above the DPT and ends with a small valve at each
5Bar.Liquid - The DPT is installed below the end for draining purposes. The DPT is
pipe from impulselines installed on the sides connected with T-Pieces to these impulse
of the flanges or pipe and sloping down at a lines. The idea is to keep the condensation
soft angle to the DPT. It is preferred not to pots filled to the overflow level all the time
have any sharp bends in these liquid impulse with hot water so that if any condensation
lines. The idea is to keep these impulse lines takes place the pot will just overflow back
filled all the time and that pressure into the main line and the different pressures
differences to be transferred as directly as on the DPT will stay constant. In other words
possible. Keep in mind that in flow, the the zero stays constant. It is best to work
pressure differences are sometimes only a from a process zero if the line pressure is
few hundred pascals.You also need to make above 5Bar. Keep the impulse lines filled
sure these impulse lines are filled before you during the process zero. (See below)
do a zero calibration. The best zero you can
Note:
do is when the lines is completely filled but
there is no flow at all, but most of the time Impulse line are never installed at the
you will only be able to do a zero by isolating bottom of the flanges or pipe since any
the impulse lines from the pipe and then do flowing material will normally deposit some
the zero.It is best to work from a process stuff at the bottom inside of the pipe and
zero if the line pressure is above 5Bar. Keep this could run into the impulse lines and
block it or cause density changes. The flow
process zero:It all cases is best to do a different between US and UK is not of any
process zero if the normal flowing line importance to us. All of these difference are
pressure is above 5Bar. To do this on line also in the imperial system and there are no
isolate both the impulse lines and remove differences when you work in the metric
the upstream impulse line from the pressure system. In the area of pressure specifically,
tapping on the flange or pipe. Install a there is only the ton of force that are only
flexible tubing with a T-Piece in it, to the 1,2 more than the other and that is not
upstream pressure tapping. Connect this something you will ever use. The same is
flexible tubing to both sides of the DPT and true for all other UOM for temp, flow, level,
close the equalization valve on the manifold. density and all the ones we use.
Open the isolation valve on the pressure
Question IS IT POSSIBLE TO CALIBRATE
tapping so that the upstream line pressure is
A LEVEL TRANSMITTER INDICATOR(ABB)
now on both sides of the DPT. Most of the
USING HART COMMUNICATOR.? I MEAN TO
trapped air will flow up the flexible tubing
CHANGE FROM ONE UNIT TO ANOTHER
back into the main line but to be sure you
WITHIN INDICATOR (EG. INCH TO FEET)...?
can vent the DPT
PLZ NOTE THAT I HAVE MADE THE UNIT
at the manifold as well. Do a zero trim and CHANGE IN TRANSMITTER USING HART
set the span value.To make a more COMMUNICATOR..BUT WHAT ABOUT THE
permanent installation, install two T-Pieces INDICATOR..?
in each impulse line just before the manifold
Answer Ok I think I understand what
and install a needle valve between the two
you are asking. In most SMART transmitters
impulse lines.
you have a digital indication on the
Question differentiate different units of transmitter and you want to change what is
pressure like US & UK standards displayed on this indicator. You also said that
you have changes the unit of measure inside
Answer There are some difference in
the transmitter with the HART, and this also
some areas like "area" in sq feet and tons of
force but nothing that concern us in changed the UOM that is displayed. There is
instrumentation. PSI is PSI all over the world a different parameter that you need to
and so is all other units of measure we use in modify to change the display. The parameter
instrumentation. The UOM that are slightly is normally something like "set disply" or
something like that. Be aware that it will only water then do a zero on the PT before you
display UOM or percentage or display a do the final span calibration. Also remember
switching between the two. What ever you that the calibration you do on the PT must
have set be exactly the same as to what your DCS or
SCADA faceplate have been scaled to. In
your UOM to inside the transmitter, will be
other words if you calibrate the PT for 0 to
displayed on the indicator as the UOM. You
20Bar you must make sure the faceplate in
cannot set the UOM to mmH2O inside the
the CCR are also scaled to 0 to 20bar.
transmitter and then display mBar on the
display. Also note that for a level application Question how to connect 3 wire 4-20
this display is normally set to percentage and mA transmitter in Plc system PLC system
not UOM. If the operator look at it he needs and how explain how the measuring data
to see % level and not mm level. In a communicate with plc system.
pressure, flow or temp applications you want
Answer We normally use a clean
this display to indicate UOM again.
separate power source to power all the
Answer First of all,parameter's which instrumentation on the plant including the
need to be diagnostic in transmitter with DCS and PLC's. This instrumentation power
any of communicator will be in percentage source is going through a UPS and a inverter
.Like for flow eg: Kgs,temp eg:cc fh level eg: backup system to smooth and minimize
% ,pressure psi or bar. power failures. Each zone in the plant
normally have its own 24VDC power supply
Question how can we measure the
unit, but they are all backed up by the same
pressure in underground cooling water
UPS. The UPS can normally keep the
pipeline by using pressure transmitter?
instrumentation and other emergency and
what about thetapping position?
critical power for about 6 hours in case of a

Answer You can install the PT total main power failure. In your 3 wire

anywhere on the pipe. It is best to install on system the supply to your TX will be from

top in crude and slurry application but to this external power source, and the loop
power for your 4 to 20 ma will be generated
measure water you can install any where, by the same TX and will not come from the
even under the pipe.If you install on the side PLC or DCS as with a loop power 2-wire
or under the pipe fill theimpulse line with
systems. Since the external power to your TX points for steam & condensible vapor flow
is the same as the 24VDC measurement application?

power it generates for the signal, you can Answer Unfortunately I don't have a
use the negative as a common. This explanation for this one, sinceI cannot see
common(OV) and the 4 to 20mA(24VDC) the reason for it either.The standard on
signal is then connected to the PLC as for a steam flow is to use condensation pots as
normal 2-wire loop well, which are to me a bit of a waste of
money, time and effort since these pots have
powered TX. This common from your TX is
to be certified pressure vessels, the same as
0V and is the same as the 0V of
any other pressure vessel on the plant.I am

the PLC or DCS since they are all from the not sure how many people realize this.On

same UPS.The PLC or DCS will only get the wet leg levels, and in a case like this, I would

positive of your TX as the input signal, since rather

all the negatives of the inputs are all

use a 1/2" S/S T-piece instead of a
connected together on a common 0V bar
condensation pot, it
close to the the PLC or DCS and only one
wire from this negatives bar is then daisy does the job just as well and it is certified
chained to each input. The negative from and rated the
your TX you therefore also need to connect
same as the S/S impulse lines.I think the
to this common negative bar of the PLC or
principle behind this whole steam flow
DCS and only the positive goes to the input
installation was based on what we normally
connection. The only thing you need to
do in the level application of a pressurized
remember is that the 3 and 4 wire systems
steam drum. Since steam will condense, we
are externally powered systems and are
use this fact to our advantage by doing a wet
therefore active inputs or source inputs and
leg on it. The steam that condenses then
that the loop powered 2 wire system is a
make sure the wet leg stays filled to the
passive or sink type input. This you then
same level all the time.In steam flow it
need to set up inside the PLC or DCS input
seems like they have tried the same
configuration parameters.
principle, but according to me it is not
Question Why Differential pressure necessary, since the pressure taps will be
transmitter is located below the tappings installed on top of the flanges,as for normal
gas flow application, and not on the sides so about Archimedes theory as part of you
there is NO chance of liquid build up inside general knowledge about physics?
the transmitter or the impulse lines, which
Question hydrogen purity meter
are also installed above the orifice plate. Any
calibrating and commissioning procedure
condensed liquid will immediately run back
can be explained?
into the line.Doing the condensation pot
installation and installing the DPT below the Answer It is easy. Find a manual and
line works obviously very well and is a very read it, that's what we all do.The
good idea, I just cannot see why this is the manufacturer can give you all the details of a
standard or why it should be done specificinstrument much better that what
either.Anyway it is not up to me or you to anyone else can.
chance the international instrumentation
installation standards, so for now we have Question What is the purpose of
MATLAB?
to stick to this standard, but it is interesting
to question some of these original standards Answer MATLAB is the engineering

sometimes. software that helps to program of almost all

the mathematical enrineering problems and
Question Could you explain to me the give the most suitable solution ..\\
enraf (servo gauge) mechanism. How it
works ? and how it is working on like in computer we have C or C++ or VB ......

archimedes theory while it's not immersed we can make a programm as per our

into the surface? and how can we requirment the programmer

calibrate it ? gives the most suitable answers

Answer It is easy. Find a manual and Back to Questions Page

read it, that's what we all do.The

manufacturer can give you all the details of a
specific instrument much better that what Question During valve sizing from all
anyone else can although it seems that you calculation you got flow coefficient CV
already know quite a bit about it. Where did 12,than what it means? like for selecting
you find that information? From the manual
maybe, or are you a scientist that knows
pressure transmitter if your MAWP is 12 bar machines.For example, In some machines
than you selecta capsule of max. 20 bar cooling water is required for startup and
which cover your mawp 12 in same way for lubrication oil pressure should be available.
selecting control valve If CV is 12 than how In this above machine interlocking system is
we use to be done with cooling water flow and
lubrication oil pressure to avoid any unsafe
it in selecting valve?
condition for the machine.The machine can

Answer Go to the valve be started only if both the conditions are

manufacturer's manual and select a valve satisfied. During running of the machine if

with the next bigger cv that the one you any one fails then the machine must be

calculated. tripped. Interlock is necessary in industrial

machines for safeoperation of the machine
Question what is interlock ckt? why it as well as the process.
is necessary in industrial machines ?
Question in a electronic controller why
Answer Not sure what you refer to we are using 250 ohm resistance in input
with"ckt" but interlocks is all about starting a signal?is i/p is necessary in control valve
application or machine safely. when we are using electronic controller
give details?
For example if you want to start up a
compressor the discharge valve must be Answer The hardware electronic
closed, the recycle valve must be open, the controller you are using has a 1-5 Volt input
guide vanes must be at 10%, there must be but the transmitter you use in the field, is a 4
power available, there must be air available, to 20 mA transmitter. So in order for the
the oil must be at 60 degrees, the cooling hardware controller to accept this input, you
water recycle pump must be running and so install a 250 Ohm resistor on the controller's
on. The local control system(PLC) will only input which will convert it to a 4 to 20mA
allow you to start the compressor when all input.
these interlocks have been met.
Weather you need a I/P converter on the
Answer Interlock ckt or generally control valve depends on the positioner you
interlock means providing safe conditions will use. The hardware electronic controller
for startup and running of industrial will give a 4 to 20mA signal to the control
valve, so if you want to use a full pneumatic keeping the process on the desired
positioner on the valve, you need to install a controlset-point.In these applications if you
I/P converter and calibrate it for a 4 to 20mA do not install a positioner you will find that
input and a 20 to 100 Kpa pressure output. your process runs in a big sinuous wave form
You then need to calibrate the pneumatic and this will obviously cause a major chain
positioner for a 20 to 100 Kpa = 0 to 100% reactions through out the whole plant.
stroke. If you want to use any other type of
Answer yes it will operate. but we
positioner a I/P will not be necessary, since
have to see the actuator pressure rating
in electromechanical positioners the I/P is
range between that range it will
already part of the positioner and obviously
operate.with positionar a valve can run
in SMART positioners, the input to the
smoothly but without a positionar it will
positioner is 4 to 20 mA.
sluggish.
Question without a positionar can a
Answer Only the diaphragm actuator
control valve operate? give thedifference of
type control valves can be operated without
operating with positionar and without
positioners provided that the spring range of
positionar?
the actuator is within the range of control air
Answer we can control the control pressure.Cylinder actuator type control
valve accurately with the help ofpositioner. valves cannot be operated proportionally
without a positioner. only on/off can be
Answer There are applications where
the positioner is actually causing the process done.With positioner we can achive the
to run away, due to the valve reacting being exact position of the control valve with
too fast, and the control will be much easier speed. If positioner is not there then the
without the positioner. You can do this by actuation will be sluggish and we cannot get
installing a I/P converter, piped directly to exact postioning of control valve
the actuator.In 99,99% of applications
Answer There are two works of
however, the positioner is necessary to
positionar First is to boost up the pneumatic
control the process since process changes is
signal to desired spring range of actuator
normally very fast and smooth control will
and second is to get mechanical feedback of
be impossible without a positioner to speed
valve stem to accurate control over valve. if
up the reaction time of the control valve and
we do not use positionar then our valves
spring range must lie between 3-15 psig also Answer 4-20ma is the standard
we can't control accurately the process with value,because any small changes occurs we
higher variation. can simply identify when we use 4-20ma. if
any zero error occur we can identify it by
Question in the boiler in the main
using 4-20ma. according to pneumatic 3-
steam line and its bypass line and the
15psi is used.same reson for that. when 4ma
startup vent vales are only motorised
applied corresponding 3psi optain and 20ma
valves why cant weuse other types of
is
valves such as pneumatic.
applied then we get 15psi.
Answer The design engineers must
have had a reason why they selected to use Answer 4-20ma response is linear and
motorized valves in stead of pneumatic we can break it into several groups e.g '4-20'
valves. It might be that they felt the main is 16 means 0 = 4ma and full = 20 ma. half of
power is less likely to fall away than the plant that is 8 and quater of that is 4 again half of
air compressor tripping and there is no air to the quater is 2 and so on . so we can easily
operate these valves. It also sometimes calculate all the neccessary details relating
happens that the main instrumentation to the signal supply ,...now why we r not
supply UPS (24VDC) will trip and the whole using the 4 -40 ma -- cause difference is
plant looses the instrumentation supply but
36 here so the quater part of it , is 4.5 and
the main supply is still available. Also if the
half of the quater is 2.something so the
main power do fall away there is always the
calculation is complex in such
emergency generators that will kick in and
supply emergency main supply to all the a case .... also it ll not shows linear
critical systems.Just for interest they tend to responce....
select motorized valves for safety systems as
well like foam, fire pump control valves and Question why the steam drum and

deluge main control valves, most probably deaerator level transmitter range is in

for the same reasons. negative MMWC to zero

Answer In both cases

wet leg configuration you DPT.
with the are using
In thea
Question why we are using 4-20ma steam drum if
why cant we use 4-40ma you use the old fashion way by
changing the HP and LP legs around you will
get a positive
mmH2O reading. If you use a piped SMART
Tx or a SMART called transducers since they are stand alone

capillary type DPT, you will get this negative and their
mmH2O readings.

Iand
have already
look at done a writeup on this so go transmitters or monitors are in a different

previous questions. place.

In
thethe deaerator
same wet there is a vacuum but again Answer Well, transducer convert the
leg physical parameter like
thisisvacuum
done. I have already done a writeup on

applications as well so go and look at

previous questions. PRESSURE,LEVEL,TEMPERATURE & FLOW etc,
to an electrical

signal that can be used for the purpose of

moitioring or

Question difference between

control further signal conditioning is
transducer and converter in
required.
instrumentation

converter in process drawing & P&ID

Answer Pretty much the same thing
drawing we refer to it
since both convert one type of

as I/P OR P/I converter current to pressure or

energy into a proportional different type of
pressure to
energy. Like

current.more or less converter & tranducer

the pressure cell inside a pressure
sound the same.
transmitter which we

Question in split range control

call a transducer or sensor and a I/P
valve,two valve should be in two
converter which we

different line and that should have some

call a converter. Other examples are a analog
distance,and we
to digital

have only one positioner feed back link.so

converters or the sensors in a car's engine
how we connect
which are also

one feed back in two control valves?

Answer Before we start, something in feedback”, I have to assume must be from
your question is a bit of a the original valve

concern. Split range control is done by that was in there. You therefore only have
installing two two cables

valves in parallel in the SAME line, and NOT available to work four signals. One cable
two different from the CCR for

lines. The easiest to do this modification is to the control and another one for the
built a feedback signal back to

bypass line beside the original valve and the CCR.

install your
I understand why you would prefer not to
second valve in this bypass line right next to pull in any extra
the original
cables. These kind of modifications are big
valve. The bypass line only starts only about and troublesome
1 meter before
and pulling in new cables will mean
and end about 1 meter after the original documentation updates
valve.
and DCS software modifications and all the
rest.

Ok back to your question.

Ok so, I will do my write up based on the

assumptions that
If I read correctly between the lines, it seems
that you are you only have the two cables, one positioner
and one
doing a modification. The “one positioner”
and “one feedback positioner to work with and that
you have already
installed two valves in parallel in the same or decreases during the upward movement
line. I will of the valve stem.

also assume the original valve is one of the Based on this you need to replace this VR
valves you have with a smaller or

uses and we will call that the small valve. The bigger VR in order to get only half or double
second valve the resistance

which should be a bigger valve is installed in of the original full stroke value.
a bypass line
In other words if the resistance value in the
in parallel with the original valve in the same original valve
line, and we
changed from 0 to 1000 Ohm during a full, 0
will call that the big valve. to 100%, stroke

of the valve, the resistance will only be 500

Ohm at 50% of
All stand alone FB positioners work with a
variable the valve stroke.

resistor(VR). Movement of the valve stem Assuming the resistance value increases with
will turn this VR upward movement

and the resistance will change of this VR. you need to change to VR with a 50% smaller
This resistance VR (0 to 500

is then converted by the electronics of the ohm) and install a identical VR in the big
FB positioner valve as well. If

into the 4 to 20 mA signal back to the CCR you now connect them in series they will
controller. You give you a total of

need to measure this resistance and also see 1000 Ohm which is the same as your
if it increases original feedback
positioner resistance when you used only Small original valve:
one valve. Assuming
Install the original FB positioner on the valve
the calibration of this FB positioner is still as and connect
it was in
feedback signal cable to CCR as per normal
the original valve, at 100% stroke the FB for a one valve
positioner will
installation. Do a calibration on it as normal.
only see 500 Ohm and the output to the CCR Stroke it up
will only be
and down and measure the VR’s resistance
12Ma. As the big valve starts to open up the change and then
resistance of
disconnect the variable resistor and remove
the VR in the big valve will start to add itself it completely.
to the now
Replace it with the newly calculated VR.
fully open small valve’s resistance and the
2)
mA out to the

Valve Big:
CCR will change accordingly until both valves
are fully Either install a new small JB on the valve,
with the newly
open. In which case the total resistance will
be as per your calculated variable resistor in it or a
complete new FB
original valve’s resistance, 1000 Ohm, and
therefore your mA positioner, if available. If you install a new FB

out will be 20mA. positioner, disconnect the original variable

resistor inside

and remove it completely. Replace it with

To do this:
the newly
1)
calculated VR.
 Use other gland entry on the small valve FB
positioner and
To calculate the new variable resistors
values: connect a instrument cable to a small 2 way
JB mounted close
Values used are examples only.
by. From this JB connect another cable to the
Exp.
big valve FB

Original VR value = 0 to 1000 Ohm increasing

postioner. Connect the two variable resistors
with valve opening.
in series and

R1 refers to the new VR you will install on

then back to the PCB inside the small valve’s
the small valve.
FB positioner.

R2 refers to the new VR you will install on

Another way to do this is to install the VR’s
the big valve.
on each valve

and then connect them to a remote

RT = R1 + R2 = 500 + 500 = 1000 Ohm mounted SMART temperature

transmitter. The temperature transmitter is

then configured
Replace the original variable resistors in each
FB with the HART to take a resistance input
instead of “RTD
positioner with the newly calculated variable
resistors (in input” and VOILA you have built your own
FB positioner.
exp = 500 Ohm) and connect them in series
and then to the About the “only one” control positioner

small valve FB positioner electronics. To use only one positioner and try and do
split range
Suggestion how to do this:
control is NOT possible. I think you are more
concerned
about pulling in new cables and it is not a Ok to summarize, your two positioners will
matter of that be controlled

you do not have any more positioners from a single controller in the CCR. During
available. I am sure normal

you can get another one from your stores. operations, the small valve will control the
process and the
Ok so to do the split range control you need
to get another operator will see a feedback in the CCR of
below 50%. This
positioner and install one positioner on each
valve. is in relation to both valves and not just one
valve, so you
Make use of the second gland opening in the
small valve’s need to explain this to the operator before
you sign this
positioner and just daisy-chain( connect in
parallel) the mod off as complete.

wires to the big valve from the small valve's If the process changes and the small valve
positioner. cannot handle the

Both valve positioners will now receive the process, the bigger valve will starts to open
full 4 to 20 mA up and the

signal from the controller in the CCR operator will see a feedback of more than
simultaneously, and 50% in the CCR.

that’s what you want. Calibrate the Again explain and train the CCR operator on
positioner on the small this control

valve for 4 to 12mA = 0 to 100% stroke and system and the way it works.
the big valve 12

to 20 mA = 0 to 100% stroke.
You might find it difficult to find a PID tuning remote mounting of the I/P, was heat. The
set that electronics don’t

will suit both valves, due to the size like too much heat so in very hot areas,
difference, but you rather use a

might be able to do it if you compromise a pneumatic positioner with a I/P remotely

little on both. mounted where it is

In other words neither will give perfect a bit cooler. You can do this for the feedback
control but you as well by

will get them to control good enough with a installing the VR’s in small JB’s on the valves
average PID set. and mount

Above is just one way to do this and it will the electronics where it is a bit cooler.
depend on what
Question in split range control system
you use out there and what is available. we are using two control valves,but we
have only one positioner and one feed back
Some basic rules of thumb about
link.so how we use this one feed back link
installations and positioner
for two control valves Answer one

types: positioner using but it's output divided in

two position.one is 0-50 % and other is 50-
On all the split range installations I have 100%.and second think is one control valve
worked on we 100% travel calibrated for 0-50 % positioner
output,and second control valve 100% travel
used a pneumatic positioner with internal or
calibrated for 50-100 % positioner output.so
a remote
when positioner output between 0-50% then
mounted I/P converter. The reason for the one control valve will operated and when
pneumatic positioner output between 50-100% then
second control valve will operated.
positioner instead of a SMART positioner, as
well as the Answer If I read correctly between the
lines, it seems that you are doing a
modification. The “one positioner” and “one decreases during the upward movement of
feedback”, I have to assume must be from the valve stem. Based on this you need to
the original valve that was in there. You replace this VR with a smaller or bigger VR in
therefore only have two cables available to order to get only half or double the
work four signals. One cable from the CCR resistance of the original full stroke value. In
for the control and another one for the other words if the resistance value in the
feedback signal back to the CCR. I original valve changed from 0 to 1000 Ohm
understand why you would prefer not to pull during a full, 0 to 100%, stroke of the valve,
in any extra cables. These kind of the resistance will only be 500 Ohm at 50%
modifications are big and troublesome and of the valve stroke. Assuming the resistance
pulling in new cables will mean value increases with upward movement you
documentation updates and DCS software need to change to VR with a 50% smaller VR
modifications and all the rest. Ok so, I will do (0 to 500 ohm) and install a identical VR in
my write up based on the assumptions that the big valve as well. If you now connect
you only have the two cables, one positioner them in series they will give you a total of
and one feedback positioner to work with 1000 Ohm which is the same as your
and that you have already installed two original feedback positioner resistance when
valves in parallel in the same line. I will also you used only one valve. Assuming the
assume the original valve is one of the valves calibration of this FB positioner is still as it
you have uses and we will call that the small was in the original valve, at 100% stroke the
valve. The second valve which should be a FB positioner will only see 500 Ohm and the
bigger valve is installed in a bypass line in output to the CCR will only be 12Ma. As the
parallel with the original valve in the same big valve starts to open up the resistance of
line, and we will call that the big valve.All the VR in the big valve will start to add itself
stand alone FB positioners work with a to the now fully open small valve’s resistance
variableresistor(VR). Movement of the valve and the mA out to the CCR will change
stem will turn this VR and the resistance will accordingly until both valves are fully open.
change of this VR. This resistance is then In which case the total resistance will be as
converted by the electronics of the FB per your original valve’s resistance, 1000
positioned into the 4 to 20 mA signal back to Ohm, and therefore your mA out will be
the CCR controller. You need to measure this 20mA.
resistance and also see if it increases or
To do this: To calculate the new variable resistors
values:
1)
Values used are examples only.
Small original valve:
Exp.
Install the original FB positioner on the valve
and connect feedback signal cable to CCR as Original VR value = 0 to 1000 Ohm increasing
per normal for a one valve installation. Do a with valve opening.
calibration on it as normal. Stroke it up and
R1 refers to the new VR you will install on
down and measure the VR’s resistance
the small valve.
change and then disconnect the variable
resistor and remove it completely. Replace it R2 refers to the new VR you will install on
with the newly calculated VR. the big valve.

2)

Valve Big: RT = R1 + R2 = 500 + 500 = 1000 Ohm

Either install a new small JB on the valve,

with the newly
Replace the original variable resistors in each
calculated variable resistor in it or a FB
complete new FB
positioner with the newly calculated variable
positioner, if available. If you install a new FB resistors (in

positioner, disconnect the original variable exp = 500 Ohm) and connect them in series
resistor inside and then to the

and remove it completely. Replace it with small valve FB positioner electronics.

the newly

calculated VR.
Suggestion how to do this:
Use other gland entry on the small valve FB About the “only one” control positioner
positioner and

connect a instrument cable to a small 2 way

To use only one positioner and try and do
JB mounted close
split range
by. From this JB connect another cable to the
control is NOT possible. I think you are more
big valve FB
concerned
postioner. Connect the two variable resistors
about pulling in new cables and it is not a
in series and
matter of that
then back to the PCB inside the small valve’s
you do not have any more positioners
FB positioner.
available. I am sure

you can get another one from your stores.

Another way to do this is to install the VR’s
on each valve

Ok so to do the split range control you need

and then connect them to a remote
to get another
mounted SMART temperature

positioner and install one positioner on each

transmitter. The temperature transmitter is
valve.
then configured

Make use of the second gland opening in the

with the HART to take a resistance input
small valve’s
instead of “RTD

positioner and just daisy-chain( connect in

input” and VOILA you have built your own
parallel) the
FB positioner.

wires to the big valve from the small valve's

positioner.
Both valve positioners will now receive the If the process changes and the small valve
full 4 to 20 mA cannot handle the

signal from the controller in the CCR process, the bigger valve will starts to open
simultaneously, and up and the

that’s what you want. Calibrate the operator will see a feedback of more than
positioner on the small 50% in the CCR.

valve for 4 to 12mA = 0 to 100% stroke and Again explain and train the CCR operator on
the big valve 12 this control

to 20 mA = 0 to 100% stroke. system and the way it works.

Ok to summarize, your two positioners will You might find it difficult to find a PID tuning
be controlled set that

from a single controller in the CCR. During will suit both valves, due to the size
normal difference, but you

operations, the small valve will control the might be able to do it if you compromise a
process and the little on both.

operator will see a feedback in the CCR of In other words neither will give perfect
below 50%. This control but you

is in relation to both valves and not just one will get them to control good enough with a
valve, so you average PID set.

need to explain this to the operator before

you sign this
Above is just one way to do this and it will
mod off as complete. depend on what

you use out there and what is available.

 Question how can check the
loopchecking for valves?
Some basic rules of thumb about
installations and positioner Answer First I have explain about Loop
Check. Loop check means that we have to
types:
check the functionality of Field Instruments

On all the split range installations I have to DCS/PLC. For Valves,you have to simulate

worked on we the value from DCS/PLC in step by

step(0%,25%,50%,75% and 100%).Valve
used a pneumatic positioner with internal or actuation to be confirmed by actuator Scale
a remote which is in the Valve.

mounted I/P converter. The reason for the Question what is different betwen
pneumatic Process zero and atm zero?

positioner instead of a SMART positioner, as Answer Atmospheric zero is when you

well as the check the zero of your transmitter with HP
and LP sides of your Tx open to atmosphere.
remote mounting of the I/P, was heat. The
Process zero is when you check the zero of
electronics don’t
your transmitter with the actual process
like too much heat so in very hot areas, pressure, where this transmitter will be used,
rather use a applied to the HP and LP side of your
transmitter. In both cases the transmitter
pneumatic positioner with a I/P remotely
should read zero. So if you will be using this
mounted where it is
Tx on a vessel with a 100Bar process

a bit cooler. You can do this for the feedback pressure you need to apply 100bar on both

as well by sides simultaneously and make sure it still

reads zero, before you start your calibration.
installing the VR’s in small JB’s on the valves With such a high pressure there will
and mount definitely be a zero shift so you need to
compensate for it during the calibration. The
the electronics where it is a bit cooler.
lower the process pressure the smaller this
zero shift will be. If your process pressure is
below 5 Bar you do not have to concern any span within this 600UOM range.
yourself about doing a process zero check
For instance you can calibrate this
since the zero shift is so small you may use it
transmitter for -300 to
as is and just do the atmospheric zero check.
If you are not sure how to do this let me +250UOM or +140 to +300UOM and so on.
know. Any values as long as

Question how to define range of dp it falls within the range or capability of the
level xmeter in open tank transmitter.

Answer The question can be a bit You cannot in this case calibrate it for -400 to
confusing in that the word "range" +100UOM

sometimes seems to mean different things even though the top value is still withing the
to different people. range the

So let's just first of all clarify what we are bottom value is below the negative
referring to capability of the

when we use the words "range", "span" and transmitter. The area that you have
"zero" calibrated is called the

Range is the size or capability of the calibrated span. In other words the value
transmitter. This from zero to span

means that if the specs on the transmitter is also called the span.
says "range =
a Bit confusing in that we also refer to the
-300 to +300UOM (units of measure) it 100% value as
means you can
the span value and then we call the area
calibrate the transmitter for a total span of from zero to full
600UOM and not
scale the calibrated span as well. On Smart
more. It also means you can calibrate the transmitter it
transmitter for
is less confusing since we here refer to the correct range for a DP transmitter for a level
LRV and URV application.

instead of the zero and span values. Anyway Obviously very important to be able to do
the main thing but keep in mind

is to understand the difference between the this procedure below is ONLY for a dry leg or
range and span open tank

values on a transmitter. level application and NOT for wet leg or

capillary DPT's
So, using the above transmitter again, you
can say for selections.

instance that you have a differential pressure

transmitter
The fist thing you need to do is measure the
with a range of 600UOM but it has only been height of the
calibrated for a
tank in mm. The next thing is to find the
total span of 350UOM. To give a more detail density of the
description of
liquid you will be measuring and the third
how you have done this calibrated you can thing is to
also say that zero
decide where the transmitter will be
is -100UOM and span is +250UOM so the installed. The first
total calibrated span
two is easy enough to find but with the third
is 350UOM. one have one

Ok so back to the above question. Looking at or two extra things you want to consider. It is
it again I must always

assume this person is trying to find out how better to install any DPT below the bottom
to select the tap off point in
a close or open tank and you also need to want to measure and the answer will be the
think about the maximum

Instrument Tech that needs to do the calibrated span that can ever be done on a
installation or do instalation like

maintenance on it later on. Try and install this. So in this case say the liquid is diesel
the transmitter with a sg of

in a place that is easy accessible on a 2" pipe 0,85. The calculation will be 3500 x 0,85 =
or something 2975mmH2O

like that. Also look at where the tubing or Now you can convert this final mmH2O into
capillaries will any value you

run, cable rack and details like this. prefer to work in. Sometimes the
manufacturer might indicate
So finally if you have all the information you
can now make the range of the transmitter in Kpa or PSI so
all you need
a small calculation to see what the maximum
calibrated span to do is convert you calculated mmH2O into
that type of UOM
might be on a installation like this.
and you can then see how big your
Measure the distance from the transmitter
transmitter needs to be.
to the bottom of
This maximum calculated value should fall in
your vessel and add this value to the total
between 60 to
height of your
80% of the maximum positive capability of
vessel. Let's say in total this distance is
the transmitter
3500mm. You
you select. If your transmitter is to big it will
then miltiply this 3500mm with the density
be very
of the liquid you
insensitive and if it is to small you will not be Question how to calibrate the radar
able to transmitter for measuring the exact tank
level if tank is having agitator moving
calibrate the correct span on it.
continiously because due to agitator tank

NB!! surface level will vary every time.

There is one more important thing to

Answer Just increase the damping on
remember when working
the radar's 4 to 20mA output.This should

on open tanks or when you do a dry leg stabilize the output, even if the local display

installations. The still jumps around. In the DCS there is also

damping that will help with the input from
calibration can only be in the positive so the
the radar. You will never be able to measure
range of the
an "exact" level in a turbulent application
like this so the best you can do is to use the
transmitter you select must be marked as for
average over a period of time and that is
exp in this
what the damping does. It smooths out the
case: - 3200mmH2O to +3200mmH2O and ripples in the output by taking samples of
not give a total range the level measurement and then give a
average output.
of 3200 like -1600 to +1600mmH2O.

Answer there are sensors available

The calibration in open tanks or dry legs are
which allows you to select the
always done

nature of fluid like weather it is turbulent of

from atmospheric zero up into the positive
steady so according to that it adds the
area of the
damping factor to it and gives you out put

transmitter and the negative area of the

Question How can we loop powered
transmitter is not
for a transmitter.How we can do

used at all.
Wiring?

Watch out for this.

Answer There are only three ways to
wire any instrument in the
field. We called them two, three or four wire 1 wire Pos 24VDC (4 - 20mA signal)
systems.
1 wire 0V (for signal)
Loop powered is the most common and
Question if a tank is contaning oil and
widely used everywhere
water than how can we measure the oil
to connect the field instruments to PLC's or and water level separately?
DCS.
Answer In a case like this “how to
2 wire = 1 wire Pos 24VDC (4 - 20mA signal) measure a interface level?” is
(loop Powered)
not a straight forward answer since I cannot
1 wire 0V know what the

3 wire = 1 wire Pos 24VDC (Instrument vessel looks like, know what type of tap-off
supply V) points is

1 wire 0V (Common for supply and available and so on so I will give you a
signal) generic rule of

1 wire Pos 24VDC (4 - 20mA signal) thumb explanation on interface levels and
tell you what is
4 wire = 1 wire Pos 24VDC (Instrument
supply V) the perfect solution to all interface level
problems. I will
1 wire 0V (for supply)
also tell you what you must not do.
1 wire Pos 24VDC (4 - 20mA signal)
Since this is a very confusing subject to a lot
1 wire 0V (for signal)
of

Also in 4 wire system:

technicians and engineers, although very few

4 wire = 1 wire Live 110VAC (Instrument will admit it,

supply V)
so it might be worth the effort to do a detail

1 wire Neutral 0V (for supply) explanation

on the subject. measure the variance of the bottom product.
I don’t thing a

application like this exist but anyway this is

First of all regardless of what anyone tells
the theory of it.
you, you NEVER
The moment the top product level changes,
use a differential pressure transmitter for a
even by a couple
oil/water
of mm, your whole calibration is invalid and
interface level application. Neither a piped
therefore your
nor a capillary
level control becomes unstable. So if you
type DPT is suitable to measure interface
have a application
level. Believe me
like this you can try it but other than, that
I have tried as well, and have done the
stay away from
calculations front
the DPT to measure interface levels.
to back and back to front and saw that it is
theoretically Further more this is whole installation is
dependent on
possible to do, but believe me in practice it
just doesn’t work. product density so you can image for
yourself what will
The only application where it might have a
small chance of happen if the top or bottom product density
changes so this
success is if you work on a vessel with a very
stable and is just not the way to do it, it’s to unstable. It
is like
constant top product overflow. In other
words your top standing on a knife edge. Yes you might be
able to stand
product is always at exactly the same level
and you only straight and upright for a couple of seconds,
but not for long.
 product and then ask them to drain that and
fill the vessel
a Lot of people will tell you the capacitance
probe it the up with the bottom product again. They will
most probably
answer, it’s not. The capacitance probe can
only measure one start laughing at you, thinking you are joking.
I have tried
product. There is a special interface
capacitance probe this the one time since the cap probes I was
working on was
available on the market but most people are
not even aware installed in a separate stand pipe on the side
of the vessel
that the probe they are working with is not a
interface so I thought if I can fill this standpipe I will
not
measuring probe and that it is just a single
measuring probe. interfere with operations but eventually this
didn’t work
100% of the bottom product is 0% of the top
product and then either since production will not allow you to
open a
100% of the top product is 0% of the bottom
product they pressurized vessel that is online with single
isolation
would say is the way to do it. In theory that
makes sense only. So in theory something might sound
easy to do but in
but in practice it is not so easy to do.
practice it is not always so easy. The normal
Image you are on a live plant and you now
capacitance
want the
probe calculations are also just for
production to fill up the vessel to 100% with
measuring a single
only the top
product in a vessel under perfect conditions product levels accurately all the time.
so they are

useless as well.
But even if they do, you still sit with a
problem of

Don’t trust your sight classes either since blockage when working with crude and
with interface other high viscous

levels most sight glasses do not work products and big vessels where the level
accurately all the changes very

time. These sight glasses were designed to slowly. Is this now a accurate level indication
measure a single or is the

product and not the variance of two sight glass blocked again?
products in a vessel.

Draw yourself a vessel and vary the levels of

So in theory, if you can trust your sight glass
the two
and your
products and see for yourself how it will
sight glass is installed in a stand pipe
reflect on the
attached to your
sight glasses. You will find that at various
vessel and you can open this stand pipe up
points the
to fill and drain
sight glass cannot reflect the levels
it as you please, you can set these probes up
accurately due to the
like that, but
sight glass tap-off points. Yes I know about
this is a lot of if’s.
the overlapping

type of sight glasses but even they do not

reflect the The best result I eventually got with these
Cap probes was
to setup my TDR radars (radars and cap product and one for just the interface level in
probes installed on the vessel.

same vessel for control and ESD) perfectly The CCR is normally interested in both these
according to the readings. These

design specs and then calibrate the radars are not influenced by density
capacitance probes to changes, temperature

the same zero and span positions as the changes, pressure changes or condensation
radars. This or vapor changes.

eventually resolved the whole problem. If I They even still work perfectly after the
had my way I product have

would have thrown them out and installed a attached itself and started building up on the
TDR in their probes after

place as well. long periods of time.. Most other

instruments will stop

working in a case like this or start to become

THE TDR RADARS ARE THE BEST INTERFACE
inaccurate
MEASURING INSTRUMENT
even cap probes don't like it.
ON THE MARKET TODAY.

The only thing that will influence them, but

You can accurately and reliably (up to mm)
only slightly
measure the top
is changes in the dielectric constants of the
and bottom product continuously and give
products.
two separate 4 to
The chances of these DC changes is very
20mA outputs to the CCR, one for the level
remote and will
of the top
hardly ever occur, so it is not a major and learn them from scratch, there is no
concern. Even if easy way. They were

they do occur it takes two minutes to make a specially designed to resolve the decades of
adjustment on problems of

one of the parameters and it will be accurate measuring interface levels and they work like
again. a charm if you

The negative side of these radars is that set them up properly. I would recommend
most technicians you go this way as

and engineers find them very difficult and well.

confusing to work

with and I know about instances where the

There are other devices as well like a
people struggled
magnetic float that
for three years and still could not get them
will float only on the bottom product and
working
not on the top
properly and reliably. This gives a negative
product and work by magnetically closing
name and
reed switches in
reputation to the TDR radar, but the truth is
series with resistors inside a guide pipe but
the same as
again they
with anything else, unless you calibrate them
will only measure only one product per
correctly you
instrument.
cannot expect them to work correctly.
To install one for the top and one for the
TDR is new technology and you cannot use bottom product
your previous
might be a solution if you need both
experiences to help you understand them. readings but they tend
You need to study
to get stuck on the guides from time to time you read it the first time it will be very
due to product confusing but is

build up, but this might be possibility if you you study it for a while you will see that it is
have a clean not that

product. Definitely not suitable for crude. difficult, and once you have actually done it
Keep in mind in the field,

these are also density dependent you will find it is actually quite easy to do.
instruments but they will The main

not be as unstable as a DPT. If the products thing is to do it the way I have described
have a lot of below. The

turbulence, you can also install them inside a manuals is sometimes a bit confusing so I
round damping have developed my

standpipe opened to the product, this will own way to set them up and this is much
make the readings easier to understand

a bit more readable and stable. I would also than the procedures in the books. The ones I
not consider have worked on

them for critical applications only for more is the Khrone BM100A (2x S/S rods probe
or less low type) as well as the

priority applications and just for indication. BM100C (coaxial probe type)

Re: ON RADAR INTERFACE LEVEL

TRANSMITTER IF DI-ELECRIC IS
Below is a previous write up I have done for
another WRONG WITH CONTINIUS PROCESS THAN
HOW CAN INDENTIFY OR HOW
question from someone struggling to
understand the TDR. If CAN I PUT NEW DI-ELECTRIC VALUE?
(ROSEMOUNT-TDR-3300-COXIAL
PROBE TYPE) Answer If you are still having problems you need to
do a complete
#1
setup from scratch. In order to do this you
You said interface level so I must assume you
need to get hold
are measuring
of the design engineer's internal vessel
oil and water. My experience is on the
drawings and look
Khrone BM100 A but
what the calibrated span should be. What
your radar might be similar since the both
you are interested
use TDR technology.
in is the exact mm measurements from
The dielectric constant of crude is about 2 to
vessel bottom to Z/S
4 and water
points or positions. From there it is just a
is 80. The variance in dielectric constant will
matter of
have a small
taking exact measurements in the field of
effect, so in order to find the right valve one
your vessel and
quick way is
your radar installation and make yourself a
to use your sight glass to set the dielectric
neat, accurate
constants so
detailed drawing to indicate the design spec
that the radar reads the same as the sight
positions and
glass on the
the actual position of your probe in relation
water and oil. a Good average is normally 2,5
to the vessel,
and 80.
and put these measured values in the output
Unfortunately this will not work unless you
1 and output 2
have setup your
parameters, keeping in mind zero position is
Z/S parameters correctly.
measured from
the probe bottom up and 100% is also from them both the same instead of trying to set
the probe bottom each one to it's

up and not from zero position up. So if you individual span. Both Spans are setup in
can see where reference to actual

the design engineer have said zero should be vessel level %. Interface is also a actual level
and you can see measurement

in exactly what position your probe is in in relation to the whole vessel and not to
relation to those just half the

points it is a matter of calculating how high vessel where for instance to where your weir
you need to plate is. If

measure up from probe bottom to get to you do this it will have the effect that you
those Z/S points have a very

marked by the design engineer. It takes a bit sensitive interface measurement to a slow
of level measurement

trigonometry to do but is easy enough. making your control very difficult. We have
done it at one

point and it worked eventually, but it was

Typically these parameters should look
very difficult to
something similar to
optimize and get stable control, and even the
this. Output 1 (Top product level) 4mA =
smallest upset
150mm, 20mA =
will cause everything to go crazy again.
2500mm, Output 2 (Bottom product) 4mA =
150mm, 20mA = 2500mm.

Look strange I know but we have found it is In this example the 150mm might be the mm
better to set you need to
measure from the probe bottom up to get to experimentally by valve manufactures. It is
the Zero position expressed as the

of the actual vessel as indicated by the flow rate of water in m3/h for a pressure
design drawing and drop of 1 bar

the same with the 2500mm. Obviously just across a flow passage.
examples. This is

where your exact measurements in the field

Flow coefficient = Cv or Kv
comes in.

Cv = Imperial
NB!!

Kv = Metric
Also make sure you have the right probe
length in the "tank Selecting the correct size control valve:

Height" parameter and not the real vessel When the flow coefficient is calculated for
height. the required

This probe length is normally stamped on flow rate and known pressure drop, the
the little spec selection of a proper

plate on the head by the supplier. control valve is normally done by selecting a
control valve

with the next bigger flow coefficient(cv)

Question what is the meaning if the
control valve CV is 27,in terms So in your case here are some info that
might help,
of selecting procedure?

With a control valve with a cv of 27 in a clean

Answer Flow coefficient is the
water line
proportional constant between

with a 100mm pipe dia size, a DP across the

pressure drop and flow rate and it is
valve of 1Bar
determined
will give a volumetric flow rate of 23m3/h With a control valve with a cv of 27 in a clean
and a fluid water line

velocity of 2973m/h with a 100mm pipe dia size, a DP across the

valve of 1Bar
With a control valve with a cv of 27 in a clean
water line will give a volumetric flow rate of 23m3/h
and a fluid
with a 200mm pipe dia size, a DP across the
valve of 1Bar velocity of 2973m/h

will give a volumetric flow rate of 23m3/h With a control valve with a cv of 27 in a clean
and a fluid water line

velocity of 743m/h with a 100mm pipe dia size, a DP across the

valve of 2Bar
With a control valve with a cv of 27 in a clean
water line will give a volumetric flow rate of 33m3/h
and a fluid
with a 300mm pipe dia size, a DP across the
valve of 1Bar velocity of 4205m/h

will give a volumetric flow rate of 23m3/h With a control valve with a cv of 27 in a clean
and a fluid water line

velocity of 330m/h. with a 100mm pipe dia size, a DP across the

valve of 3Bar
So the volumetric flow rate stays the same
regardless of will give a volumetric flow rate of 40m3/h
and a fluid
pipe dia if the DP stays the same. The only
thing that will velocity of 5151m/h

change is the flow velocity. And,

With a control valve with a cv of 27 in a clean

water line
So,
with a 200mm pipe dia size, a DP across the will give a volumetric flow rate of 23m3/h
valve of 1Bar and a fluid

will give a volumetric flow rate of 23m3/h velocity of 330m/h

and a fluid
With a control valve with a cv of 27 in a clean
velocity of 743m/h water line

With a control valve with a cv of 27 in a clean with a 300mm pipe dia size, a DP across the
water line valve of 2Bar

with a 200mm pipe dia size, a DP across the will give a volumetric flow rate of 33m3/h
valve of 2Bar and a fluid

will give a volumetric flow rate of 33m3/h velocity of 467m/h

and a fluid
With a control valve with a cv of 27 in a clean
velocity of 1051m/h water line

With a control valve with a cv of 27 in a clean with a 300mm pipe dia size, a DP across the
water line valve of 3Bar

with a 200mm pipe dia size, a DP across the will give a volumetric flow rate of 40m3/h
valve of 3Bar and a fluid

will give a volumetric flow rate of 40m3/h velocity of 572m/h

and a fluid
So to summarize if you have a control valve
velocity of 1288m/h with a cv of 27

And, you need to have a look at the maximum

volumetric flow rate
With a control valve with a cv of 27 in a clean
water line that will be required in the line that this
control valve
with a 300mm pipe dia size, a DP across the
valve of 1Bar
will be installed in, in order to see if this pressure tx with a range of 1176Bar does not
valve is big exist.

enough to control this flow.

Keep in mind the perfect control position for So unless you ask a sensible question with
any control accurate and

valve is between 40 to 60% valve opening. detail information with it, and look at what
You need to select you write

a valve with a cv that will allow control to be before you post the question, no one can or
in that area would want to

under normal operating conditions, so it is help you.

important to
Question I want to measure level
consider minimum, normal and maximum under vaccum by using DP Tx and vaccum
flow conditions during vary between -500 to -670 mmHg and
process fluid is accetic anhydride if consider
the selection process. To be safe select the
process fluid density 1 kg/cm2. how to
next bigger cv
calibrate Tx ? consider level is 0 to 100 Cm.

than what your calculations says the correct

size will be. Answer I would not do a installation
like this with a piped DP tx
Question I want to measure flow by
using DP Tx and range is 0 to 1200 and think that you should reconsider your
Kg/cm2 ? position before

Answer Your UOM for flow is wrong, it you do this.

cannot be a pressure UOM.
In hazardous or corrosive applications you
The 1200Kg/cm2 cannot be the DPT range might need to
either since a diff
make a modification in order to install a
instrument that
will contain the process permanently. modify the installation to a capillary DP tx
with chemical
If this is not a safe application at the moment
you need to seals(exp-Teflon).

put in a chance proposal with a safety Find out from the liquid supplier what type
justification and a of material is

proposal for a new instrument that will make resistant to the liquid and ask you Tx supplier
the application to supply

safe. you with a capillary type smart transmitter

with this type
Do not do something just because you we
instructed by of material chemical seals on the pad cells.

someone to do it, you need to satisfy The supplier will ask you the length capillary
yourself that the length

inhalation is safe, reliable and accurate, not needed. The capillary lengths should always
someone else. be as short as

If it is not, it is your right, duty and possible to prevent drifting, so look at the
responsibility to installation

do something about it. and decide where you are going to install the
new cap DPT
In your case the liquid you are working with
is corrosive, and double the distance from the
transmitter to the top tap
hazardous, flammable and will causes violent
chemical off point on your vessel to get the right
capillary lengths.
reactions with various other liquids. I would
recommend you Do the calibration as normal for a capability
type DPT and
forget about the vacuum inside since it is To do the process zero you might need to
irrelevant in install a piece of

your calibration. tubing temporary between the HP and LP

tap off points in
Just some important calibration information
when working order to get a equal vacuum on HP and LP
side of tx. That is
with capillary DPT's.
if you cannot drain your vessel and just keep
After the installation, open both pad cell to
the vacuum
atmosphere and
pressure inside the vessel.
have look at the displayed value. When you
do a process zero (We normally install 316SS flushing rings for
this purpose
you might find that the displayed zero have
shifted slightly but you need to look at the corrosive
properties again
from the atmospheric zero. It is therefore
important to before you install these SS flushing rings. You
might have
check the process as well as the atmospheric
zero especially to order them in a similar material as what
you used on the
if you are working on a small span. This small
shift will pad cells.)

cause big inaccuracies if you do not work Use the displayed value as your process zero
from your a reference and

process zero. (yes, similar thing to the old just add your measured mm, multiply by
pneumatic DPT 1,08(sg for acetic

static alignment problem) anhydride), to get your L/URV's.

If there is a difference between atm zero and readings and then use the average in the
process zero middle as my final

always use process zero for the calibration process zero.

since the DPT
This is called splitting the error. Your final
will measure the level while under vacuum level
and not at
indication after your calibration will fluctuate
atmospheric pressure. as well,

but since you have split the process zero

error, the reading
Something else you might encounter in a
application like will be pretty accurate and you can apply
some damping on
this is that this process zero could fluctuate
slightly due the tx to stabilize it some more.

to the variance in vacuum and you might Below is a previous discussion on a similar
find it difficult to application but

read. I had similar experiences before on a for non hazardous liquid and no way to
FPSO where the modify the piped DPT

whole vessel moves all the time and installation to a better type of instrument.
therefore the process You can have a

zero keeps on changing all the time. I have look at it for information but again, in your
compensated for case you

that by standing there and watch the reading should not use a piped DP transmitter.
fluctuating for

about 15 minutes and write done the lowest

----------------------------------
and highest

----------------------------------
First of all there is no difference between a this is a capillary type, but according to your
vessel with a question it

process pressure of 10 or 50Bar or a vessel seems you already have a piped transmitter
with a vacuum. in place. This

These pressures cancel each other across the makes it a bit more troublesome to do, but
LP and HP legs by working

on our tx's, and are therefore not taken into carefully and accurately you can achieve
account in our accurate and

calibration. reliable results.

To explain in more detail: Take your time, this is one of the MOST
DIFFICULT DP level
If there is 100Bar on the LP side there is also
100Bar on setup's you will ever came across in any
industry.
the HP side so the DP across the tx is still
zero. It is always better to use a wet-leg since
condensation will
If there is 750mmHg vacuum on the LP side
there is also a cause your DP to chance in time. If I look at
the sg of the
750mmHg vacuum on the HP side so the DP
across the tx is product you most probably are working with
hydrocarbon
still zero.
condensate, so you would want to install a
So work with the transmitter as if there is no
wet leg in a
pressure or
application like this.
vacuum in the vessel.
Process zero with LP leg filled:
The best transmitter to use in a vacuum
application like
1st open both legs to atm and do zero trim. start closing needle valve slowly and keep
Even better if filling

you know how to do a factory reset and then to make sure lp leg is filled properly. Playing
do a zero trim. with the

Connect a 1/2" T-piece to top of LP leg just main LP isolation valve and the needle valve
on the bend will give best

before it goes to the top tap-off point with a results to get the LP leg filled to max.
needle valve
This should put you in the situation that your
pointing upwards. tx has been

With main process isolation valves still close, zeroed at atmospheric pressure, so the
fill LP leg vacuum pulled

to max and close needle valve. on both sides of diaphragm now and LP leg
filled to max,
Try to use glycol since it's density is higher
than water's, should now give a accurate process zero to
work from.
and will prevent contamination of the wet
leg. Write down this displayed value.

You can also use glycerin or diesel.

Close 5-way manifold equalization valve and What ever this value is is not important you
open main will use this

process isolation valves and then only open reading as your process zero reference point
both isolation to work from

valves on manifold. so it can be anything as long as you are sure

this is a
Open needle valve and fill again LP leg as
much as possible, accurate and reliable process zero.
To double check if the process zero is good, I am also assuming that the bottom tap-off
isolate the tx point is zero

again and open it up to atm again not position and the top tap-off point is 100%
draining the LP leg.
You should now have something like (+/-)
It should still give a zero indication with both -750mmH2o on the tx
sides open
display.
to atm.
Let's say the value is exactly -750mmH2o.
Put it back on line and make sure the LP leg
Measure from the middle of the tx's
is still filled
diaphragm to the bottom
to max by making use of the needle valve
tap-off point. We make this say 300mm
and LP main

Measure from the bottom to the top tap-off

isolation valve again.
points. We make
You should be back at the previously
this say 500mm.
displayed value. Do

this a couple of times to make sure you get

to the same Calculation:

values every time. Only then can you be sure LRV is -750 + 300 = -450mm x .95 = -427,5
that your mmH2o

process zero value is reliable and accurate. URV is -750 + 300 + 500 = +50mmH2o x .95 =
+47,5 mmH2o
To calculate the LRV and URV:

Modify your L/URV's to these new values.

Like I said I am assuming now that the tx had
There is no need to
been installed

use a hand pump when working with smart

300mm below the bottom tap-off point.
tx's, just modify
the values with the HART, make sure it's on head of the pressure measuring instrument
line and give it where the

back to production. transmitter is situated.

Since it is such a small span the level might Transmitter is any device that can take a
be to generated signal

sensitive so you might want to increase the and transmit that signal via any means, be it
damping as well via cable or

on the Tx. radio waves to a receiver.

Good luck. We normally refer to any measuring

instrument's transmitter
Question what is actual difference
between pressure Transducer & Pressure section due to it being the most important
Transmitter. area to us. The

Answer Transducer is any device that transmitter's ability to transmit the

can converts one type of generated 4 to 20mA

energy into another type of energy. In a signal is what we work on and not the cell or
pressure measuring transducer area.

instrument the transducer is the actual If you talk about your car do you talk about
pressure cell that your 4 cylinder

converts the measured pressure energy into or do you talk about your Toyota Corolla?
a proportional
Answer pressure transducer sences
electrical energy. pressure and gives output in

This pressure cell is connected via a ribbon electrical form if using active transducer
cable to the
pressure transmitter transmits the pressure
measured in
electrical form but after amplifying for Answer because of getting the
sending this data to accurate results we using 0-20ma in
instrumentation instead of voltage
remote(far distance from workstation)
location. Answer Please let us know where you
have seen this in a instrument in the field.
Answer Pressure Transducer is a
The normal standard signal is 4 to 20mA.
device that converts one form of
Question Foe selecting control valve if i
energy(pressure) into elctrical signal.
have the min,normal & max data of flow

Pressure Transmitter is a device whcih is rate,inlet pressure& outlet pressure,inlet

transmits the tem.&density than how can i assure that

these data are correct,pl. let me know if
converted (electric signals)signals from therew there is any method to check it.&
Transducer. also how we assure that the Cv we get from
this data is suitable for valve for controlling
Answer Transducer is a device that can
require flow.
converts one type of

Answer Calculate the cv of a LIQUID

energy into another type of energy. pressure
ONLY control valve for a given
transducer

flow, dp and sg
converts nonelectrical energy to electrical
energy. Cv = 11.7 q (SG / dp)1/2

transmitter is a device that can transmits where

these electrical
q = Expected flow rate (m3/h)
energy.
Sg = Specific gravity of the liquid (1 for water
in this

Question where using the 0-20ma in example)

feiled instrumentation? why its using?
dp = Pressure drop across the valve at
expected flow rate (kPa)
Example 1. Dp over valve during 30m3/h flow = 110kpa

So if q = 5m3/h Do manual calculation:

Sg for water = 1 Cv = 11.7 q (SG / dp)1/2

Dp over valve during 5m3/h flow = 10kpa 1) 11,7 x 30 = 351

Do manual calculation: 2) 0,97/110 = 0,008818

Cv = 11.7 q (SG / dp)1/21) 11,7 x 5 = 58,5 3) ½ = 1/2 = 0.5

2) 1/10 = 0,1 4) 0,008818 to the power of 0,5 =

0.0939042
3) ½ = 1/2 = 0.5
5) So 0.0939042 x 351 = 32,96
4) 0,1 to the power of 0,5 = 0.31622776
So a valve with a cv of 32,96 is needed to do
5) So 0.31622776 x 58,5 = 18,49
a flow of

So a valve with a cv of 18,5 is needed to do a

liquid (sg=0,97) at 30m3/h and a dp over the
flow of
valve of 110kpa

water(sg=1) at 5m3/h and a dp over the

Look at manufacturer valve manual for
valve of 10kpa
available valves and

Look at manufacturer valve manual for

select a valve with a next bigger Cv
available valves and
---------------------------------------
select a valve with a next bigger Cv.
Example 3.
----------------------------------------
So if q will be 64m3/h
Example 2.
Sg for liquid is 0,87
So if q = 30m3/h
Dp over valve during 64m3/h flow is 210kpa
Sg for liquid = 0,97
Do manual calculation:
Cv = 11.7 q (SG / dp)1/2 Control Valve selection Flow Coefficient - Cv -
for Air and
1) 11,7 x 64 = 748,8
other Gases
2) 0,87/210 = 0,00414285
For critical pressure drop the outlet pressure
3) ½ = 1/2 = 0.5
- po - from

4) 0,00414285 to the power of 0,5 =

the control valve is less than 53% of the inlet
0.06436497
pressure -

5) So 0.06436497 x 748,8 = 48,196

pi. The flow coefficient can be expressed as:

So a valve with a cv of 48,196 is needed to

do a flow of
Cv = q [SG (T + 460)]1/2/ 660 pi
liquid (sg=0,87) at 64m3/h and a dp over the
valve of 210kpa where

q = free gas per hour, standard cubic feet per

hour (Cu.ft/h)
Look at manufacturer valve manual for
available valves and SG = Specific gravity of the gas relative to air
at 14.7
select a valve with a next bigger Cv
psia and 60oF
------------------------------------------
T = flowing air or gas temperature (oF)
To do the power off calculation on your
windows calculator: pi = inlet gas absolute pressure (psia)

Example: Example:

5 to the power of 4 ------- press 5 then x^y 5000 = Gas flow (Cu. ft./h) (f.a.d)
then 4 then =
100 = Inlet Gas Absolute Pressure (psia)
--------------------------------------------
1 = Specific gravity of the
60 = Gas Temperature (oF from the control valve is greater than 53% of
the inlet
Do manual calculation:
pressure - pi. The flow coefficient can be
Cv = q [SG (T + 460)]1/2/ 660 pi
expressed as:

1) 60 + 460 = 520
Cv = q [SG (T + 460)]1/2/ [1360 (dp po)1/2]

2) 520 x 1 = 520
where

3) ½ = 1/2 = 0.5
dp = (pi - po)

4) 520 to the power of 0,5 = 22,8035

po = outlet gas absolute pressure (psia)

5) 22,8035 x 5000 = 114017,5425

Example:

6) 660 x 100 = 66000

6000 = Gas flow (Cu. ft./h) (f.a.d)

7) 114017,5425 / 66000 = 1,727

140 = Inlet Gas Pressure (psia

So a valve with a cv of 1,73 is needed to do a

110 = Outlet Gas Pressure (psia
air flow
1 = Specific gravity of the gas
(sg=1) at 5000Cu.f/h, at a air flow temp of
60F and a inlet 60 = Gas Temperature (oF)

gas absolute press of 100PSIA Do manual calculation:

Cv = q [SG (T + 460)]1/2/ [1360 (dp po)1/2]

Look at manufacturer valve manual for 1) 60 + 460 = 520

available valves and
2) 520 x 1 = 520
select a valve with a next bigger Cv
3) ½ = 1/2 = 0.5
-----------------------------------------------
4) 520 to the power of 0,5 = 22,8035
For non critical pressure drop the outlet
5) 22,8035 x 6000 = 136821,051
pressure - po -
6) 140 – 110 = 30 Please note the "1/2" in the formulas is not
as it seems, it
7) 30 x 110 = 3300
is surpose to be a small "1/2" on the top
8) ½ = 1/2 = 0.5
right hand corner

9) 3300 to the power of 0,5 = 57,445

of the bracket, in other words a "to the

10) 57,445 x 1360 = 78126,05199 power of 1/2" and

11) 136821,051 / 78126,05199 = 1,75 not " bracket times 1/2 as it is displayed"

So a valve with a cv of 1,75 is needed to do a Cannot seem to get it displayed like that on

air flow this page -

(sg=1) at 6000Cu.f/h, at a air flow temp of sorry if it is confusing but look at he

60F and a DP of calculation to see

30PSIA absolute press where the "power of" is used and you will
understand what I
Look at manufacturer valve manual for
available valves and mean.

select a valve with a next bigger Cv

--------------------------------------------------

To do the power off calculation on your

windows calculator:

Example:

5 to the power of 4 ------- press 5 then x^y

Question can any one pl explain me in
then 4 then =
brief that how we select the

--------------------------------------------------
leakage classification in valve,means for
liquid or gas
there is any standard for selecting leakage valve have repaired and overhauled the
classification valve, we had to do

or its depend upon valve size or any any the final testing and acceptance with them.
other parameter. They would

Answer I cannot remember to much supply us with the specs on the valve so that
about this but I remember that the we can see

leakage rate is dependent on the valve what class valve it was and what the
classification. a acceptable leakage

Class 6 valve is a tight shutoff valve with not tolerance was. After this we would witness
leakage the testing of

tolerance at all. a Class 5 is classified as a the valve and sign a acceptance certificate.
modulating
I suggest you get hold of your valve shop or
valve and have a tolerances of a small the original
amount of droplets
manufacturer to supply you with a list of the
per minute and so on. The lower the class
classifications of the valves you are currently
valve the higher
using or
the acceptable leakage rate. This leakage
want to use as well as the various
rate is tested in
acceptable leakage rate
a valve shop either by the manufacturer or
for each class.
on your own site

Answer Class VI for Gas service as gas

if you have the right equipment to do it with.
requires tight shutoff &
We normally had it done by our valve shop
class I , II, III, IV, V for liquid service as per
after we send a
process
valve to them for a complete overhaul. Once
requirement shutoff
the control
Question how to calibate level Therefore span = 150 UOM (units of
transmiter ?range -150 to +150.what measure)

is the zero and span? or

Answer This means that your You can also calibrate the tx for any span in
transmitter is capable of measuring a between this

differential pressure of 300. Whatever this 300 range.

units of measure
To find the correct Z/S values for your
is. You can calibrate the transmitter for any application measure
of the
the distance from the transmitter to zero
following conditions: position on the

LRV = -150 = 0% vessel and multiply this with the density of

the product you
URV = +150 = 100%
want to measure (LRV). Do the same with
Therefore span = 300 UOM (units of
your 100% (URV) value.
measure)
Question what is Potential free
or
contact? where it is used?

LRV = 0 = 0%
Answer Potential free contacts are

URV = +150 = 100% simply contacts which are physically

operated with the main device, but not
Therefore span = 150 UOM (units of electrically connected to it
measure)
Answer Potential free contacts (also
or called "dry contacts") are

LRV = -150 = 0% simply contacts which are physically

operated with the main
URV = 0 = 100%
device, but not electrically connected to it. closed) contacts are presented to the user
For example a for connecting

motor contactor often has auxiliary contacts in his system as he pleases,the contact is said
that are to

operated by the main coil and open and be "potential-free".

close at the same

time as the main contacts but are not used

for control of

Question WHAT IS THE DIFFERENCE

the motor starter. If they are connected to
BETWEEN A TRANSMITTER & A SMART
an outside

TRANSMITTER.
circuit to indicate the status of the starter
without being Answer SMART transmitter will uses
the ,HART communicator for the
powered by the motor supply they would be
considered purpose of Tx-calibration,while the other
normal transmitter
potential free contacts.

needs an extra care at the time of calibration

These type also called Signal-Contacts.
,bcz in the
In case of relays and switches if the
normal we have to use the external air
common/pole is
supply for the
connected internally to a given potential like
pressure application ,,,hence it will be gud to
a 110V phase
have and use
etc., the contact is not POTENTIAL FREE but
the SMART tx
if both the

Answer We went through various eras

common and the normall open (and at time
or technology time periods in
also the normally
instrumentation. Believe it or not but that we had to calibrate our pneumatic
measurements of flow pressure transmitters

and level had been done by the old and controllers to give this output of 20 to
Egyptians that build the 100Kpa. You

pyramids already. They had use for instants a really had to know instrumentation when
stick with you worked with

marks on it to see what the level was in one these pneumatic stuff. We even had
of their tanks pneumatic relays and

and various other simple measuring and pneumatic chart recorders back then.
control devices as well.
Later we moved on to electromechanical
We normally are not to concerned with the instruments and some
type of
very simple electronic indicators and chart
instrumentation that was used that long ago. recorder.
We normally say

that instrumentation only started to take off

After the transistor and micro processors
during the
were developed
pneumatic era where all measurement and
things started to move along very fast and
controls were done
we started to see
by pneumatic and some electrical
various electronic instrumentation and
instrumentation. The world
transmitters on the
standard instrumentation signal was also a
market. I call this the 4-20mA era. These very
pneumatic one
advanced type
then. It was 20 to 100Kpa or 3 to 15Psi. What
of transmitters had to be pumped up with a
this means is
small hand pump
as normal, but all you then had to do was technology of SMART TRANSMITTERS. You
make small even get SMART valve

adjustments with a small screwdriver to a positioners that can accurately detect the
zero and span pot erosion of it's

to calibrate the transmitter. Very advanced control valve's plug and seat and send a
to what we were alarm signal to the

use to. These were called the electronic 4 to CCR that a overhaul on the valve is needed.
20 mA All just

TRANSMITTERS. computer software and programming like

anything else in
The new electronic world standard signal
then started as the today's world. Look what you can do with a
cellphone today.
4 to 20 mA signal, but keep in mind that the
pneumatic world Very smart little gadget.

standard signal, even today, is still the 20 to Not to worry they will never be as smart as a
100Kpa signal. instrument tech.

Since then we have moved on to the smart Question i have one tank of 500mm
instrumentation era height, which is in under vacuum of

where we calibrate the transmitters with a 735 mmHg, I want measure level of the
HART communicator same using DPT , SO WHAT

and the transmitter itself is actually a small WILL BE THE URV & LRV, DENSITY OF THE
computer that TANK FLUID IS 0.95. is

can even detect a error on itself or tell you if there necessary to fill the LP side with fluid.
the

Answer First of all there is no

calibration you are trying to do is invalid.
difference between a vessel with a
From there the
process pressure of 10 or 50Bar or a vessel this is a capillary type, but according to your
with a vacuum. question it

These pressures cancel each other across the seems you already have a piped transmitter
LP and HP legs in place. This

on our tx's, and are therefore not taken into makes it a bit more troublesome to do, but
account in our by working

calibration. carefully and accurately you can achieve

accurate and
To explain in more detail:
reliable results.
If there is 100Bar on the LP side there is also
100Bar on

the HP side so the DP across the tx is still Take your time, this is one of the MOST
zero. DIFFICULT DP level

If there is 750mmHg vacuum on the LP side setup's you will ever came across in any
there is also a industry.

750mmHg vacuum on the HP side so the DP

across the tx is
It is always better to use a wet-leg since
still zero. condensation will

So work with the transmitter as if there is no cause your DP to chance in time. If I look at
pressure or the sg of the

vacuum in the vessel. product you most probably are working with
hydrocarbon

condensate, so you would want to install a

The best transmitter to use in a vacuum
wet leg in a
application like
application like this.
Process zero with LP leg filled: Open needle valve and fill again LP leg as
much as possible,
1st open both legs to atm and do zero trim.
Even better if start closing needle valve slowly and keep
filling
you know how to do a factory reset and then
do a zero trim. to make sure lp leg is filled properly. Playing
with the
Connect a 1/2" T-piece to top of LP leg just
on the bend main LP isolation valve and the needle valve
will give best
before it goes to the top tap-off point with a
needle valve results to get the LP leg filled to max.

pointing upwards. This should put you in the situation that your
tx has been
With main process isolation valves still close,
fill LP leg zeroed at atmospheric pressure, so the
vacuum pulled
to max and close needle valve.
on both sides of diaphragm now and LP leg
Try to use glycol since it's density is higher
filled to max,
than water's,
should now give a accurate process zero to
and will prevent contamination of the wet
work from.
leg.
Write down this displayed value.
You can also use glycerin or diesel.
What ever this value is is not important you
Close 5-way manifold equalization valve and
will use this
open main
reading as your process zero reference point
process isolation valves and then only open
to work from
both isolation
so it can be anything as long as you are sure
valves on manifold.
this is a
accurate and reliable process zero. I am also assuming that the bottom tap-off
point is zero
To double check if the process zero is good,
isolate the tx position and the top tap-off point is 100%

again and open it up to atm again not You should now have something like (+/-)
draining the LP leg. -750mmH2o on the tx

It should still give a zero indication with both display.

sides open
Let's say the value is exactly -750mmH2o.
to atm.
Measure from the middle of the tx's
Put it back on line and make sure the LP leg diaphragm to the bottom
is still filled
tap-off point. We make this say 300mm
to max by making use of the needle valve
Measure from the bottom to the top tap-off
and LP main
points. We make
isolation valve again.
this say 500mm.
You should be back at the previously
Calculation:
displayed value. Do

LRV is -750 + 300 = -450mm x .95 = -427,5

this a couple of times to make sure you get
mmH2o
to the same

URV is -750 + 300 + 500 = +50mmH2o x .95 =

values every time. Only then can you be sure
+47,5 mmH2o
that your

Modify your L/URV's to these new values.

process zero value is reliable and accurate.
There is no need to
To calculate the LRV and URV:
use a hand pump when working with smart
Like I said I am assuming now that the tx had tx's, just modify
been installed
the values with the HART, make sure it's on
300mm below the bottom tap-off point. line and give it
back to production. Keep in mind that once the wet leg is filled
the vacuum is pulling against a closed end.
Since it is such a small span the level might
Test this the next time you drink a Coke out
be to
of a can . Suck the straw full and close the

sensitive so you might want to increase the end with your finger and try and suck the

damping as well on the Tx. Coke out.(please use a metal tube and not a
plastic straw, LOL)

[email protected]
Answer i agree the above answe in
case of wher vacum is not 0 Sam

present if we r disussing about the vaccum Question what is absolute pressure and

,,the vaccum will not allow tha fluid to come where use in process?

in contact with tx. as same case with in

Answer You first need to understand
condenser so we have to use here a float typ
what pressure is. Without a thorough
or displacer type tx. as acc to me DP type will
understanding of pressure you will never
not work
understand some of the basic concepts of

Answer Have to agree with Naman instrumentation.Air have weight. This can be

that this is not the best way to do it and proven by a simple primary school

there are other devices that will work better experiment of taking a balancing beam and

if the current instillation can be modified to attached two balloons to it. With the two

accommodate a different type of instrument balloons deflated the balancing beam hangs

like a capillary type of DP Txor a level troll. exactly horizontal and the weight is

According to question, the DPT is already in obviously equal on both sides of the beam. If

place and needs to be used so above is the you now inflate one balloon the balancing

way to do it, and yes it is possible to do since beam will drop down on the inflated end

I have done it myself on a d-aerator column proving that air have a definite and specific

under constant 0,98Bar vacuum and a span weight, since the volume of air on the one

of only 300mm. My situation was the same side is now more than on the deflated side

in that I could not just modify the installation and therefore the weight is more. Pressure is

and had to work with what was installed. measured on the surface of the earth as the
weight of the air from space pushing down
on the surface of the earth. The reason air the same. This atmospheric air weight is the
and any other body have a weight is due to reason why we have a measurable amount
the earth's gravity. Since the gravity of the of air pressure and is therefore referred to as
earth pull less the further you move away the atmospheric air pressure pushing down
from the earth's surface, the atmospheric onto the surface of the earth. This
pressure changes as well and become less atmospheric pressure is a specific amount of
since the weight of air from that point to pressure and is the same all over the world
space is less. Therefore on top of the at sea level. The amount is 101,3 Kpa (a) or
Himalayas the atmospheric pressure is much 14,7 PSI.(a) or 760mmHg(a). You should
less than at sea level. It takes a lot of years to memorize these values. These values is also
get use to the low density of the air up there refer to as the ABSOLUTE pressure or 1
and us normal people that are use to higher atmosphere. Note the (a) on the end? If you
density air find it difficult to breath up there. write atmospheric pressures down you have
The reason is the lower atmospheric to add the (a) to indicate to other people
pressure or the lower density of the air due that you are referring to atmospheric
to the shorter distance from space to that pressure and not gauge pressure.
height. We all know that water is always at
Gauge pressure is very simply what we call
the same level due to the earth's gravity
zero pressure at 1 atmospheric pressure at
being the same all over the world, so
sea level. Just makes life a bit easier to work
therefore if we look at the level of the sea it
in gauge pressure than trying to work in
will be at the same level in Canada as it is in
atmospheric pressure all the time. So to
Africa and the same at the coast in China. It
summarize, zero gauge pressure is equal to 1
is therefore accurate to use the sea as our
atmosphere or 14,7 PSI atmospheric or
reference point when we measure the
absolute pressure. Be aware you will find
atmospheric pressure. So we therefore
that some people will also write it like this:
always refer to world standard atmospheric
14,7PSIA or 101,3KpaA. NB!! Zero pressure
pressure as it is at sea level and is therefore
absolute, is a complete vacuum and a
a standard throughout the world. In simple
complete vacuum is impossible to achieve on
terms the distance from sea level to space at
earth. The closest you will ever get is
any place on the surface of the earth is
-0,99999Bar but never -1,013bar. Where
exactly the same. Therefore the atmospheric
most of the confusion comes in is to find out
pressure at sea level any place on earth is
from what platform someone is refering to and the specs refer to absolute pressure,
when they talk about absolute pressures. your pressure switch will not trip your
What you are suppose to do is to always stay application on 200mmHg(a) but only
on the platform of gauge pressure, since this
on 560mmHg(a). The same when you work
is the world standard we work on in
on a absolute pressure
instrumentation, and then refer to absolute
pressure from there. This means you will transmitter. Try to stay on the gauge platform
refer to absolute pressure in the negative like where
- 30Kpa or -200mmHg. In this case it is in
reference to gauge pressure so you do not possible since it makes life a bit easier and

add the (a). Should you put yourself on the less confusion

absolute pressure platform you would refer

will occur.
to the same pressure as +70Kpa(a) and

+560mmHg(a). Most of the time people refer

to absolute pressure in mercury but you may Absolute pressure transmitters are normally
use any UOM you feel comfortable with. In used on vacuum applications or applications
mercury, absolute pressure is -760mmHg where you work in gauge pressure most of
standing on the gauge pressure platform or the time, but with a possibility of negative
0mmHg standing on the absolute pressure pressures that could occur.
platform. NB!!!
Referring now only to smart transmitters, we
Be careful with this since there is a big calibrate a normal smart pressure
difference to calibrate a pressure switch for transmitter for example to something like
instance to 200mmHg(a) and this, LRV = 0Bar and URV = 2Bar. The
calibration of a smart absolute pressure
-200mmHg(g).
transmitter will look something like this, LRV

200mmHg(a) is equal to -560mmHg(g) and = -1Bar and URV = 0Bar, or LRV = -760mmHg

-200mmHg(g) is equal to URV = 0mmHg, again saying on the gauge

to 560mmHg(a), so by calibrating the switch platform. It is not recommended but you

for -200mmhg(g) can, if you need to, calibrate your tx to

absolute pressures as well but then you need
to chance your units of measure on the transmitters as well.So as a final word from
transmitter to absolute pressure. That is if me, don't make things complicated. Before
your transmitter have the facility to do so, you start your absolute pressure calibration
otherwise the transmitter will work with the on a smart transmitter, open it up to
measured pressures as if it is gauge atmosphere and do a zero trim on it and
pressures and your transmitter will not work. then just add your -1Bar to +1Bar or
Try and stay on the gauge platform to avoid whatever the calibration should be in with
confusing yourself and others. Watch out for the HART and give it back to production.
the following as well. With the previous era Simple as that. It will work perfectly, just
of pressure transmitters where we had to make sure the calibration values are the
use hand pumps and zero and span pots to same as on the DCS faceplate.
calibrate the pressure transmitters we also
Question difference b/w single acting
had to install absolute pressure transmitters.
and double acting actuator by using
The golden rule when working with these
application only?
transmitters was that you NEVER do a zero
calibration on them since they have already Answer Normally a control valve is
been calibrated by the manufacturer for as refer to by it's fail position. This means "what
close to absolute zero as possible. So when position will the valve move to should the
you install the transmitter it will immediately supply air or control signal to the valve falls
indicate atmospheric pressure and all you away". This is important to safe guard the
need to do is to pump the transmitter up and process at various places so some valves will
adjust the span pot to where the max be fail open and some fail close. In order to
pressure should be. Remember span have valve as a fail open or close the valve
adjustments do not affect your zero but a the actuator have to be spring loaded. So by
zero adjustment will affect your span having the spring on top or bottom of the
calibration. Now based on this you will find actuator piston, will determine if it will be a
that someone will blow a casket if you tell FO or FC valve. This kind of valve is also
them you have done a zero trim on a smart called single action since it will only have one
absolute pressure transmitter. This is a joke output from its positioner to either the top
since all smart pressure transmitter can or bottom of the actuator. The positioner on
measure up to -1Bar so all smart pressure the valve is also setup as a single acting
transmitters are really all absolute pressure positioner since it will only give a single
action to the actuator, the reverse action will Call it a extra fail safe if you want. In theory
be done by the spring. The problem with this not needed since a single acting valve should
setup is that it is possible that the process do the trick just as well,but in practice you
might be so strong or the pressure so high are at time very glad you did it especially if
(during a blow down or ESD shutdown in the you look at the kind of pressures the valves
plant) that the spring might in certain are working on. With those kind of flows and
instances be to week to push the valve into pressures you don't want to leave anything
the fail position quick enough, due to the to chance.
back pressure from the process and can
Question purpose of absolute
cause damage to the plant or even a
ppressure transmitter applcation?
explosion. To make sure that the valve will go
to the fail position we install a double action Answer You first need to understand
positioner with two outputs. One goes to the what pressure is. Without a thorough
top of the actuator and one to the bottom. understanding of pressure you will never
This is also very helpful to do very accurate understand some of the basic concepts of
and stable control on a high flow line since instrumentation. Air have weight. This can
the pressure from the position do the actual be proven by a simple primary school
control and not spring control one way and experiment of taking a balancing beam and
positioner control the other way as in single attached two balloons to it. With the two
acting control valves. It is also solving the balloons deflated the balancing beam hangs
problem that the valve will now be forced exactly horizontal and the weight is
into the fail position by the spring as well as obviously equal on both sides of the beam. If
the positioner supply pressure during a you now inflate one balloon the balancing
emergency. In shutdown valves (open/close beam will drop down on the inflated end
ESDV's) the same is true and sometime at proving that air have a definite and specific
critical and high pressure points we use weight, since the volume of air on the one
hydraulics instead of pneumatics as the side is now more than on the deflated side
double acting agent to make sure the valve and therefore the weight is more. Pressure is
will close during a emergency. So to measured on the surface of the earth as the
summarize the double acting action in ESD weight of the air from space pushing down
and control valve is just there to make sure on the surface of the earth. The reason air
the valve will do what it was designed for. and any other body have a weight is due to
the earth's gravity. Since the gravity of the of air pressure and is therefore referred to as
earth pull less the further you move away the atmospheric air pressure pushing down
from the earth's surface, the atmospheric onto the surface of the earth. This
pressure changes as well and become less atmospheric pressure is a specific amount of
since the weight of air from that point to pressure and is the same all over the world
space is less. Therefore on top of the at sea level. The amount is 101,3 Kpa (a) or
Himalayas the atmospheric pressure is much 14,7 PSI.(a) or 760mmHg(a). You should
less than at sea level. It takes a lot of years to memorize these values. These values is also
get use to the low density of the air up there refer to as the ABSOLUTE pressure or 1
and us normal people that are use to higher atmosphere.
density air find it difficult to breath up there.
Note the (a) on the end?
The reason is the lower atmospheric
pressure or the lower density of the air due If you write atmospheric pressures down you
to the shorter distance from space to that have to add the (a) to indicate to other
height. We all know that water is always at people that you are referring to atmospheric
the same level due to the earth's gravity pressure and not gauge pressure. Gauge
being the same all over the world, so pressure is very simply what we call zero
therefore if we look at the level of the sea it pressure at 1 atmospheric pressure at sea
will be at the same level in Canada as it is in level. Just makes life a bit easier to work in
Africa and the same at the coast in China. It gauge pressure than trying to work in
is therefore accurate to use the sea as our atmospheric pressure all the time. So to
reference point when we measure the summarize, zero gauge pressure is equal to 1
atmospheric pressure. So we therefore atmosphere or 14,7 PSI atmospheric or
always refer to world standard atmospheric absolute pressure. Be aware you will find
pressure as it is at sea level and is therefore that some people will also write it like this:
a standard throughout the world. In simple 14,7PSIA or 101,3KpaA. NB!! Zero pressure
terms the distance from sea level to space at absolute, is a complete vacuum and a
any place on the surface of the earth is complete vacuum is impossible to achieve on
exactly the same. Therefore the atmospheric earth. The closest you will ever get is
pressure at sea level any place on earth is -0,99999Bar but never -1,013bar. Where
the same. This atmospheric air weight is the most of the confusion comes in is to find out
reason why we have a measurable amount from what platform someone is refering to
when they talk about absolute pressures. normally used on vacuum applications or
What you are suppose to do is to always stay applications where you work in gauge
on the platform of gauge pressure, since this pressure most of the time, but with a
is the world standard we work on in possibility of negative pressures that could
instrumentation, and then refer to absolute occur. Referring now only to smart
pressure from there. This means you will transmitters, we calibrate a normal smart
refer to absolute pressure in the negative like pressure transmitter for example to
- 30Kpa or -200mmHg. In this case it is in something like this, LRV = 0Bar and URV =
reference to gauge pressure so you do not 2Bar. The calibration of a smart absolute
add the (a). Should you put yourself on the pressure transmitter will look something like
absolute pressure platform you would refer this, LRV = -1Bar and URV = 0Bar, or LRV =
to the same pressure as +70Kpa(a) and -760mmHg to URV = 0mmHg, again saying
+560mmHg(a). Most of the time people refer on the gaugeplatform. It is not
to absolute pressure in mercury but you may recommended but you can, if you need to,
use any UOM you feel comfortable with. In calibrate your tx to absolute pressures as
mercury, absolute pressure is -760mmHg well but then you need to chance your units
standing on the gauge pressure platform or of measure on the transmitter to absolute
0mmHg standing on the absolute pressure pressure. That is if your transmitter have the
platform. NB!!! Be careful with this since facility to do so, otherwise the transmitter
there is a big difference to calibrate a will work with the measured pressures as if it
pressure switch for instance to 200mmHg(a) is gauge pressures and your transmitter will
and -200mmHg(g). 200mmHg(a) is equal to not work. Try and stay on the gauge platform
-560mmHg(g) and -200mmHg(g) is equal to to avoid confusing yourself and others.
560mmHg(a), so by calibrating the switch for Watch out for the following as well. With the
-200mmhg(g) and the specs refer to absolute previous era of pressure transmitters where
pressure, your pressure switch will not trip we had to use hand pumps and zero and
your application on 200mmHg(a) but only on span pots to calibrate the pressure
560mmHg(a). The same when you work on a transmitters we also had to install absolute
absolute pressure transmitter. Try to stay on pressure transmitters. The golden rule when
the gauge platform where possible since it working with these transmitters was that you
makes life a bit easier and less confusion will NEVER do a zero calibration on them since
occur.Absolute pressure transmitters are they have already been calibrated by the
manufacturer for as close to absolute zero as Control and PID Control. Where some
possible. So when you install the transmitter confusion can come in, is when you look at
it will immediately indicate atmospheric he various CONTROLLER modes available on
pressure and all you need to do is to pump a DCS. PID controllers are also sometimes
the transmitter up and adjust the span pot to linked together like in cascade or feed
where the max pressure should be. forward control configuration, but the
Remember span adjustments do not affect control modes is still PID control. Look at
your zero but a zero adjustment will affect On/Off control: You can have a open/close
your span calibration. Now based on this you control valve in the field that is controlled by
will find that someone will blow a casket if the ESD or DCS system that will either open
you tell them you have done a zero trim on a or close this valve. The ESD system do not
smart absolute pressure transmitter. This is a do any control but it can open or close a
joke since all smart pressure transmitter can valve during a emergency as a step in it's
measure up to -1Bar so all smart pressure blow down or shut down sequence. This is in
transmitters are really all absolute pressure general not consider as
transmitters as well. So as a final word from
control just a action. You can also have
me, don't make things complicated. Before
another open/close control valve in the field
you start your absolute pressure calibration
that is controlling the level in a tank. In this
on a smart transmitter, open it up to
case it is connected to a Decap controller in
atmosphere and do a zero trim on it and
the DCS. a Dcap controller have a set-point
then just add your -1Bar to +1Bar or
that can be set to control the level of the
whatever the calibration should be in with
tank, but if a on/off valve is used as is, this
the HART and give it back to production.
valve will open and close all the time to try
Simple as that. It will work perfectly, just
and keep the level on the set-point. So to
make sure the calibration values are the
prevent this the controller have a small dead
same as on the DCS faceplate.
band around the set-point that can be
Question How many types of Control adjusted. This will then prevent the valve
Modes in process control, plz tell me from opening and closing until it reaches the
all.....? dead-band threshold position. Normally
about 5% over and under the set-point. It is
Answer There is only two modes of
still on/off control. Looking at PID control:
control if you really think about it. On/Off
Any mode in conjunction with proportional relevant process or application. The readings
control is possible on a PID controller it just of these sensors are then send to a central
depends on the application. For example control room via a world standard 4 to 20
PID, PI, PD, P. You can see them each as mA signal and 24VDC, where a monitoring
individual control modes if you want, but I supervisory system displays the information
prefer to just stick to PID or on/off control on a computer screen. Control room
modes since there is a definite and distinct operators interact with these computer
control mode difference between the two. I screens and stop and start pumps in the field
see Dcap, PI, PD and P modes as sub by clicking with the mouse on a small
divisions on the two main control modes. drawing on the screen of the relevant pump.
How this is done is with SCADA or DCS
P = Proportional
software normally programmed by the

I = Integral instrument technician as well.

Instrumentation consists of only two
D = Derivative sections, the field side and the software side.
Most instrumentation technicians can do
Answer There are Two basic mode
both. Electrical work is done by a electrician
ON/OFF mode and PID control. but in PID
and is all about main power supply and
mode there are also three mode ONE MODE
distribution to the complete plant either by
P=proportional D=derivative
using power from the main grit or local
I=intrgral TWO MODE power generators on the plant. Normally
PI=proportional+derivative THREE MODE instrument technicians will work on up to
PID=proportional derivative intrgral maximum 110VAC, a electrician can work on
any kind of power low or high. Only qualified
Question What is the deffernce bet.
high voltage electricians are allowed to do
Instrumentation and Electrical Enginerring?
high voltage switching since this can be very

Answer Instrumentation is all about dangerous to to.

measurement and control of industrial

Question what is the diffrence between
processes like flow, pressure, level, density,
plc&dcs
viscosity and so on. This is done with various
sensors in the plant that are calibrated by Answer simply plc is a controller we
instrument technicians according to the can control analog and digital i/o s but i/0
limit is there in plcs.dcs is nothing but A 25%open, B-75%open.. For 100%, Valve A
networking of plcs.EX plc1+plc2+smart fully closed & valve B Fully Open.. Like this, d
instruments+mc baesd instruments all are controller output action can be set
controlled by dcs at a time .ic has depending upon the application...
redundancy also
Answer In addition wt ANS.1- in split
Answer yes ur rite but i want to range control the control signal is split in two
addition first plc also has redundancy. ranges according to the application .for eg,4-
20MA.signal can be used as 4-12 MA. FOR
Answer the difference between is that
VALVE A OPEN i.e.50%.& 12-20MA for vlv b
we can detect the error in plc
open.vice-versa.

but in dcs we can find the exact point of

Answer Split range is as per answer 2
error. where the actual problem is. we can
and not answer 1.
also control the different error at different
Answer 1 using two valves, one is a fail open
Answer Actually in todays world there
and one is a fail close. The 4 to 20mA control
is a very thin line between a DCS and a
signal is then controlling the two valves but
PLC,in simple words when the plant process
in opposite directions. This can also be done
is controlled with the help of a computer(all
by calibrating the one positioner as a direct
the processing done by the server) is called
acting and the other as a reverse acting. Yes
a DCS and when the process control is done
this is 100% correct and can be done and the
with the help of stand alone contollers then
two valves will work perfectly and in exactly
it is called a PLC.
opposite directions to each other. In a case

Question Explain Split Range Control In like this the two valves will have to be

Control Valve Briefly. identical as well otherwise the balancing act

you are trying to perform with this setup
Answer split range control is which the might not work. Never seen a application
output of a controller is split to two or more where you would need this but if it needs to
control valves. For eg, For 0% controller work like that, it can be done. Split range
output,valve A fully open & B fully closed. means you are splitting a 4 to 20mA control
For 25%, Valve A 75% open,B 25% open For signal in two. This is very useful in
50%, Valve A& B- 50% open, For 75%, Valve applications where the product flow
increases very rapidly and then falls away signal of 4 to 12 mA. We then calibrate the
again. second bigger valve to open from fully close
to full open with a signal of 12 to 20 mA. In a
example will be before a slug catcher where
situation where you use identical valves you
the incoming product from the well heads is
can take the signal from one controller and
coming in suddenly very fast and then falls
send it to both valves but in the above
away again after a couple of minutes.
application it is better to use two controller
Another application is to control the steam
but with the same input from one pressure
from a boiler. At times you need a lot of
or flow transmitter. Each valve will then be
steam and other times you only need a small
controlled individually from its own
amount. How do you size the valve needed
controller and on it's own PID tuning set. I
to control these very big changes. a Small
am sure you can see that it will be quite
valve is needed to control the normal flow
impossible to find a PID tuning set that are
but if the flow increases the small valve will
appropriate for both the big and the small
open fully and it will still be to small to
valve and it is therefore better to use two
control the now very high flow or pressure. If
controllers but with the same input. During
you install a big valve to control the big
normal operations the small valve will
pressure or flow the valve will only open 2 to
control the process without any problems
5% most of the time and it will be impossible
based on the input from the pressure or flow
to do stable control with such a valve
transmitter, and the bigger valve stays close
opening. Say nothing about the plug and
all the time. If the process changes to
seat that will only last a couple of days. To
something bigger than what the small valve
control these very high variance in flow and
can handle the second bigger valve needs to
pressures of the process we install two
help, and will start opening up, once the
valves in parallel in the samen line. Normally
small valve is fully open. Once the demand
the one is a small valve and the other is
falls away the big valve will start to close and
about twice the size of the small valve. The
then the smaller valve until the process is
design and process engineers will decide
back to normal operating conditions.. Both
what minimum, normal and maximum
valves receive a full 4 to 20mA signal from
conditions are and do the valve sizing
it's owncontroller, but will only react based
accordingly. We calibrate the small valve to
on the 4 to 12 or 12 to 20mA calibration that
open from fully close to fully open with a
was done on each valve's positioner. In other
simpler applications you can use two Question What is the formula to know
identical vales and set their positioners as the error of weighfeeder after having drop
above and send the one controller output test.
signal to both. One PID tuning set will also
Answer Error=Actual value- counter
work for both valves and conditions. The
valuve/counter value Error %=(Actual value-
valve sizes will depend on what the
counter value/counter value)100 Actual
conditions are so they can be the same or
valuve is the referance got from
they might need to be different sizes.
Weighbridge Counter valuve is the value
Question what is the difference from weighfeeder.
between the microcontroller and PLC?
Question What is the formula To
convert Degree centigrade to foranhight.
Answer A PLC is a special
microcontroller designed for industrial use, Answer C=(F-32)(5/9)
that is for controlling machinery or
Answer C/5= (F-32)/9,
processes. Usually a PLC is programmed
using Ladder diagrams and specialized i.e., C= (F-32)5/9 & F= (9C/5)+ 32
control software. A microcontroller is a
F = Foranhight C = Centigrade
microprocessor that can be used for any type
of application, but there some for special
Question which type of rtd is good for
applications, like a PLC.
any system,2wire,3wire or 4 Wire?

Answer micro controllers used for

Answer If the distance between
specific task only and it cant accept analog
transmitter and RTD is not long,Any rtd (2,3
inputs directly.using plc we can control more
or 4 wire)is suitable.
micrcontrolled based control loops.
Answer But Generally 3 wire RTD only
Answer micro controller is used for
preparred for Industrial purpose. Most of
only particullar programming but plc
the Industires & Design document suggest 3
reprogrmmable device very easy to handle
wire RTD is suitable for any application.
very easy to reprogram it.
Answer depend on distance if distance comparatively high.Thus in using 4-20
too short its should be two wire 3 and 4 wire mamps signal is distortionless.
used for long distance
Question How to ensure vibration
Answer Balance two wires are used sensor functioning accordingly.With
for compensation, if no. of compensation
out using an other sensor.
cable increases ie compensation resistance
becomeaverage. Answer sensor use in prevented
functiion. sensor use in fire syes team
Question how flame detectors sense
the flame. Answer By using Vibration Transmitter
calibration equipment,fix the sensor on the
Answer the flame sensor is working
calibration equipment.Gap voltage shhould
depend upon the ultravilot rays
be adjusted as per requierd.Power on the
Answer There are 2 types of flame calibration equipment and vibration
detectors in market viz: IR (infra red ) and UV transmitter and increase the vibration as per
(ultravoilet ray). range.check the output of the transmitter in
milli amps across millivolts generated as per
Question in instrumentation why we
vibration.
are using 4-20mA , why not voltage ? if
somebody design a instrument which works Question WHAT IS A CALLIBRATION?
on voltage then can we use that WHAT IS MEEAN BY LOOP CHECKING
instrument?
INCLUDES PRESURE,
Answer no, because voltage makes THERMOCOUPLE,TT,DT?
fluctuation & current remains constant.
Answer I NEED TO SEND THE ANSWAR
Answer because there is voltage drop ABOUT INSTRUMENTAION
as per the length of conducting wire. but
Answer Calibration is nothing but
current has no drop
comparisonof an unknown standard with an
Answer 4-20 mamps is best choice known standard or in other words it is
because interference level is minimum in known as checking the output is
current application where as in 0-10 V it is proportional to the input or not. Loop
checking is nothing but the instrument Question d/p flow transmitter LP side
installed in the field must give the signal to give to pressure.what you geting out put ?
the control room without any break. First in how you get(ma)?
this the continuity of the cable will be
Answer yahh for DP-transmitter we
checked from inst to JB in field side and from
will be having the two taps at the side or at
the JB to control room.
the bottom side ,but to know the working of
Answer LOOP CHECKING MEANS the transmitter or for the calibration purpose
CHECKING THE CABLE LOOP FROM THE INST we have give/apply the pressure at LP-side
TO MARSHALING PANEL AND TO PLC. WHEN tapping & the HP-side it should be kept open
INST GIVING O/P SIGNAL TO CONTROL for the atmosphere ,,,,,,,,,hence by the
ROOM-PLC CHECKING WHETHER THE SIGNAL difference of the pressure we will get the
GOING TO CORRECT PLC CHANNEL. MA-output.,,i,e with respect to the applied
pressure
Answer Loop check used to check the
Field Instruments activity and continuity Answer Dp- transmitter workes on
from Field to DCS/PLC. Field Instruments Differential pressure.the pressure difference
forced/simulated from filed and value will between low and high pr. side.for eg,
be confirmed with DCS/PLC. For Valves,value pressure on high side is 2Kg/cm2 & on low
simulated from DCS/PLC and position will be side is 1.5Kg/cm2 then D.P. will 0.5 KG/CM2.
confirmed from the field. in conterol terms the diaphragm element
senses this 0.5 KG/cm2 & generate output
Answer Calibration of an instrument is
curresponds to signal.The input of
a comparison to a known standard. Eg. if i
transmitter is 24 V DC signal .& is converted
need to calibrate a weighing scale, then we
to 4-20 MA output according to the
need a known weight for comparison. A
callibration range.
known standard have to be certified by
certfying body like NIST. Loop check is a Question what should be the distance
continuity test coming from/to field to of vibration sensor & to the
junction box and junction box to/from
point where vibration to be measured Ex
Control system.
turbine axial

displacement
Answer The distance of vibretion Answer Plc stands for programmable
sensor and the piont where the vibretion is logic controller. Its a solid state device which
to be measured is should be 1.5 mm. works on boolean algebra.\Dcs is distributed
control system which consists of associated
Answer The philosophy is different for
plc's and remote i/o devices
Axial and Radial measurment. For radial
measurement the AC component voltage is Question which is the best type to
directly proportional to the magniture of measure level of a Tank(water). Displacer or
vibration so the gap is fixed based on the Differential Pressure method?
probe linearity (usually
Answer If you have the money buy a
10vdc for bently nevada probes).For axial DP Transmitter, they are much easier to work
measurement the AC component voltage is with and more accurate, Dis placers are old
not important and only the DC component is technology get rid of it. If you are measuring
considered which varies proportional to the clean water you can use stainless steel
distance between the probe and the shaft. tubing and a 5-way manifold. Here are some
Conversely, the shaft is centered and the more info to do the calibration. We use
probe voltage is adjujsted to 10Vdc and the these configurations during the calibration of
same voltage is also referenced in the system a Differential Pressure Transmitter (in short
for shaft zero position. While the DP Cell) in a level calibration of a closed
unit/turbine is running the position of the pressurized vessel. This can only be used
shaft is proportional to the dc component when you are making use of a Diff Press
measured. Transmitter that is piped to the high and low
tap off points on the vessel with stainless
Question what is the principle of
steel piping. You cannot use it on any other
vibration
type of level measurement device, even if it

Answer it works on the principle of is also a Diff Press Transmitter with capillary

electro-magnetic flux tubes and pad cells installed on the H/L tap
off points and not stainless steel piping.
Question what is the difference When you use capillaries you need to do the
between dcs & plc calibration completely differently from
normal, so be careful when using capillaries
in level applications. Ok back to wet and dry
leg calibrations. The dry leg is the most filling up with condensate and there goes
common and the easiest to do. This is much your calibration because the calibrated diff
the same as the basic open tank level press (your calculated Zero and 100% values)
calibration. The transmitter is mounted begins to chance. To resolve this problem we
anywhere below the HP (bottom) tap off fill the LP leg with a buffer solution like
point and it's HP leg is connected via S/S diesel,glycerin, glycol or even the same liquid
tubing to the HP (Bottom) tap off point on you have in your vessel can work as well, in
the vessel. The LP side of the transmitter is non critical applications. I prefer glycol since
connected to the LP (Top) tap off point on it's density is higher than water so if the gas
the vessel. The HP side will always be in starts to condensate it will just lie on top of
contact with the liquid in the vessel and the the glycol buffer solution and run back into
LP side will always be in contact with gas the vessel from the LP leg and not mix with
since it's is tapped of from the top of the it. The mixing of the wet leg liquid with the
vessel. You obviously can only achieve this if gas condensate could also cause problems
you have a 5-way manifold (isolation, vent and inaccuracies, since this could chance the
and equalization valve piece)installed on the buffer density over a period of time. To
transmitter. You will start your calibration by calibrate the transmitter will depend on the
opening up the transmitter to atmosphere type and era of transmitter you are using.
and make sure that when equal press is The following calibration is for smart
applied to HP and LP side the transmitter transmitters only. The smart transmitters
shows zero and 4 mA. After this zero check it that we use today can measure in the
is a simple matter of measuring where your negative (-1Bar) and you can do your
Zero and 100% positions are on the vessel in calibration as normal. The final result will be
relation to the transmitter and multiply something like this, LRV = -1230mmH2o
these with the density of the liquid you are (4mA), URV = +125mmH2o (20mA). I know it
measuring and and install these Z AND 100% looks a bit strange when you see it for the
values in the transmitter. Ok this is very easy first time but here is how it works. Before
so far but what happens when the liquid is you can do this calibration you need to know
hotter than the ambient temperature and it's the ATM value for the installation. The
vapor in the top half of the vessel starts to atmospheric value (ATM) can be read
condense and run into the dry LP leg? In a directly from the transmitter by
very short time this dry leg is going to start disconnecting the HP side(Bottom) and open
it up to atmosphere, so the only pressure on transmitters cannot measure in the negative
the transmitter is on the LP side and this will so you need to change the HP and LP sides
obviously push the transmitter into the around so that the HP side goes to the top of
negative. Maximum negative differential the vessel and the LP side goes to the
pressure for a instalation = ATM pressure. bottom tap off point on the vessel.You now
Make sure the LP line is filled to the position need to do you calibration in the reverse as
where it will start to run back into the vessel, well. Again find the ATM value first, in other
then read off the displayed value on the words max positive differential (HP wet leg
transmitter. This is your ATM value. In this filled and LP open to atmosphere) on the
example it might be something like transmitter will now be your ATM value. Will
-1350mmH2o. This value is determined by, be say +1350mmH2o.Actual zero will now
where you have installed the transmitter and be 20mA and not 4mA and will be
what you use for a buffer solution. To determined by makind use of the ATM value
calculate the actual zero and 100% positions minus the actual zero measured value,
on the vessel you do the same as before and multiplied by the liquid density. The actual
just measure from the transmitter to you 100% value will be determined by making
zero and 100% positions on the vessel, use of the ATM value minus the actual 100%
multiply them with the density of the liquid measured value, multiplied by the density.
you are measuring and add them to the ATM You should end up with something like this,
value. You can then input these values to this zero = +1250mmH3o = 20mA and 100% =
transmitter's LRV and URV and the +150mmH20 = 4mA. Finally the display on
calibration is done. So assuming you have you remote level indicator needs to be
installed the transmitter slightly below the changed as well otherwise it will read in the
lower tap off point the above LRV and URV is reverse. If you use a pneumatic DP
about right in relation to the ATM value in Transmitter just substitute 4 and 20 mA with
this example. Be sure to understand the 20 to 100Kps or 3 to 15 Psi the principle stays
difference between the ATM value and the the same. There you have it, wet and dry leg
LRV it will in most cases not be the same. calibrations used ONLY in PIPED DP Cell level
The more accurately you can determine your calibrations.
ATM value the more accurate the calibration
Answer differential pressure method
will be. Now the calibration of the 4to20mA
and the pneumatic DP transmitters. These
Question What is DCS and PLC scanning Answer Instrumentation is the branch
time? of engineering that deals with measurement
and control of process paramiters.
Answer Scan time is time required for
checking i/p,to executive program and give Answer Instrumentation is the branch
out put.generally 5msecfor plc of engineering that deals with measurement
and control.
Question What unit is used for
measuring comp. outlet flow. it is Answer Instrumentation is a branch of
engineering which deals with the application
CFM, M3/hr or NM3/hr. ?
of other Engineering subjects. In a broader

Answer Compressor outletflow is way we can say it as APPLICATION

measured in terms of Nm3/hr. ENGINEERING. The basic objective of

instrumentation is measurement & control.
Question How to define the size of But this can only be achived with the help of
control valve? many different engineering departments.

Answer BY SEEING BODY SIZE AND Question what is dry leg and wet leg in
NAME PLATE transmeter calibration?

Answer we can seeing valve size and Answer We use these configurations
valve tubing and valve colour during the calibration of a Differential
Pressure Transmitter (in short DP Cell) in a
Question what is instrumentation?
level calibration of a closed pressurized
vessel. This can only be used when you are
Answer The shortest answer would be
making use of a Diff Press Transmitter that is
measurement, control and monitoring of
piped to the high and low tap off points on
various control processes and machinery.
the vessel with stainless steel piping. You

Answer Instrumentation is a branch of cannot use it on any other type of level

engineering which deals with measurement measurement device, even if it is also a Diff

and control of process variables like Press Transmitter with capillary tubes and

pressure, temperature, flow and level. pad cells installed on the H/L tap off points
and not stainless steel piping. When you use
capillaries you need to do the calibration
completely differently from normal, so be the top half of the vessel starts to condense
careful when using capillaries in level and run into the dry LP leg? In a very short
applications. Ok back to wet and dry leg time this dry leg is going to start filling up
calibrations. The dry leg is the most common with condensate and there goes your
and the easiest to do. This is much the same calibration because the calibrated diff press
as the basic open tank level calibration. The (your calculated Zero and 100% values)
transmitter is mounted anywhere below the begins to chance. To resolve this problem we
HP (bottom) tap off point and it's HP leg is fill the LP leg with a buffer solution like
connected via S/S tubing to the HP (Bottom) diesel,glycerin, glycol or even the same liquid
tap off point on the vessel. The LP side of the you have in your vessel can work as well, in
transmitter is connected to the LP (Top) tap non critical applications. I prefer glycol since
off point on the vessel. The HP side will it's density is higher than water so if the gas
always be in contact with the liquid in the starts to condensate it will just lie on top of
vessel and the LP side will always be in the glycol buffer solution and run back into
contact with gas since it's is tapped of from the vessel from the LP leg and not mix with
the top of the vessel. You obviously can only it. The mixing of the wet leg liquid with the
achieve this if you have a 5-way manifold gas condensate could also cause problems
(isolation, vent and equalization valve and inaccuracies, since this could chance the
piece)installed on the transmitter. You will buffer density over a period of time. To
start your calibration by opening up the calibrate the transmitter will depend on the
transmitter to atmosphere and make sure type and era of transmitter you are using.
that when equal press is applied to HP and The following calibration is for smart
LP side the transmitter shows zero and 4 mA. transmitters only. The smart transmitters
After this zero check it is a simple matter of that we use today can measure in the
measuring where your Zero and 100% negative (-1Bar) and you can do your
positions are on the vessel in relation to the calibration as normal. The final result will be
transmitter and multiply these with the something like this, LRV = -1230mmH2o
density of the liquid you are measuring and (4mA), URV = +125mmH2o (20mA). I know it
and install these Z AND 100% values in the looks a bit strange when you see it for the
transmitter. Ok this is very easy so far but first time but here is
what happens when the liquid is hotter than
the ambient temperature and it's vapor in
how it works. Before you can do this difference between the ATM value and the
calibration you need to know the ATM value LRV it will in most cases not be the same.
for the installation. The atmospheric value The more accurately you can determine your
(ATM) can be read directly from the ATM value the more accurate the calibration
transmitter by disconnecting the will be. Now the calibration of the 4to20mA
HPside(Bottom) and open it up to and the pneumatic DPtransmitters. These
atmosphere, so the only pressure on the transmitters cannot measure in thenegative
transmitter is on the LP side and this will so you need to change the HP and LP sides
obviously push the transmitter into the around so that the HP side goes to the top of
negative. Maximum negative differential the vessel and the LP side goes to the
pressure for a instalation = ATM pressure. bottom tap off point on the vessel. You now
Make sure the LP line is filled to the position need to do you calibration in the reverse as
where it will start to run back into the vessel, well. Again find the ATM value first, in other
then read off the displayed value on the words max positive differential (HP wet leg
transmitter. This is your ATM value. In this filled and LP open to atmosphere) on the
example it might be something like transmitter will now be your ATM value. Will
-1350mmH2o. This value is determined by, be say +1350mmH2o. Actual zero will now
where you have installed the transmitter and be 20mA and not 4mA and will be
what you use for a buffer solution. To determined by makind use of the ATM value
calculate the actual zero and 100% positions minus the actual zero measured value,
on the vessel you do the same as before and multiplied by the liquid density. The actual
just measure from the transmitter to you 100% value will be determined by making
zero and 100% positions on the vessel, use of the ATM value minus the actual 100%
multiply them with the density of the liquid measured value, multiplied by the density.
you are measuring and add them to the ATM You should end up with something like this,
value. You can then input these values to this zero = +1250mmH3o = 20mA and 100% =
transmitter's LRV and URV and the +150mmH20 = 4mA. Finally the display on
calibration is done. So assuming you have you remote level indicator needs to be
installed the transmitter slightly below the changed as well otherwise it will read in the
lower tap off point the above LRV and URV is reverse. If you use a pneumatic DP
about right in relation to the ATM value in Transmitter just substitute 4 and 20 mA with
this example. Be sure to understand the 20 to 100Kps or 3 to 15 Psi the principle stays
the same. There you have it, wet and dry leg Question why flow transmitter showing
calibrations used ONLY in PIPED DP Cell level 2.2ma?
calibrations.
Answer If there is zero error, the
Answer Dry leg pertain to the impulse output will be minimum peak of 3.1 mA. If it
line tubing of the transmitter which does not like 2.2mA, the transmitter electronics may
have any filled fluid, and the wet leg has. be problem. Interchange with good
transmitter and check.
Question How Control valve sizing is
done? Answer it might have given the over
range pressure at the time of
Answer Cv=q/[[change in
measurement /calibration, hence due to this
pressure/specific gravity]^0.5]
it has moved to the some different
value ,,,,,,,,,,,

Question when the instrument tapping Question in pressure gauge inside why

on pipe line is located below and we are using the glasarin oil?

transmitter is located above the tapping

Answer we are using glasarin oil inside
point for liquid service transmitter, what
the pressure gauge to use the gauge in
should we do, is there any additional drain
vibrating area
valve is required?
Answer for damping we are using the
Answer Cannot answer your question
glycerine in the pressure gauges
if you cannot clearly ask the question. What
are you referring to level, press? Answer To allow for its usage in areas
subjected to vibration. The oil acts like a
Question what is the name of
damper.
thermocople element cable from field to
pannel end? Question how to convert transmitter
milliamps output to like temp,pressure etc
Answer this cable is known as extion
cable of themo couple Answer Milliamps output can be
converted to temperature or pressure, by
Answer compensating cable.
means of converting the amps to volt by Answer using the hart ....we give the
placing a 250ohm resister across the circuit. temp.

Answer i am giving here the formula Question wHAT IS BURST MODE IN

for the same, temp/ pressure = (ma - 4)* TRANSMITTER?
span / 16 where, ma = what you measured
Answer it is a high-speed transmission
by multimeter span = max range of the
mode in a communications or computer
transmitter.
channel. Under certain conditions, the
Answer with the help of transducer system sends a burst of data at higher speed
we convert (temp,pressure) in outputs for a limited amount of time. high frequency
milliamps signals. of dat transfer from the transmitter.

Answer the sensor in the transmitter Question what is difference between

sense the physical effect profibus and field bus?
(pressure/level/flow) in the transducer this
Answer Fieldbus (or field bus) is the
effect is converted to electrical effect where
name of a family of industrial computer
we can measure 4 -20 ma for example that
network protocols used for real-time
on the transeducer and the sensor part,but
distributed control, now standardized as IEC
to answer the above question it is mainly as
61158.PROFIBUS (Process Field Bus) is a
answered by Nitin Patil it is merly calculation
standard for field bus communication in
as the forumla provided by Nitin.
automation technology. The Profibus in his
Question what is the input of Process versión (Profibus PA) is two wire
conductivity sensor and meter during (Twisted pair) for data and power. fieldbus
foundation is only for process (Mainly for
the calibration time and what is the output?
instruments), Profibus is for process and

Answer 4 to 20 mA automation (instruments, drives, I/O, motor

controllers to PLC, PLC to PLC etc.).
Question what is the input to be given
digital temp controller during the the Question why full bore ball valve is not

calibration time? used in steam applications?

Answer Thermocouple or RTD

Answer Rotary valves like Ball, meters of cable. This applies equally to
butterfly valves are called as high recovery balanced bridge and fixed bridge system. In
valves. High recovery means less pressure order to minimize the effects of the lead
drop ofcourse compare to Globe valves. The resistances a three wire configuration can be
biggest problem with high recovery valves is used. Using this method the two leads to the
that they are prone to Cavitation. In case of sensor are on adjoining arms, there is a lead
Globe valves the path is quite torturous and resistance in each arm of the bridge and
hence less prone to cavitation. In case of therefore the lead resistance is cancelled
ball valves flow is starigh through the ball. out.
Cavitation occurs when pressure at the vena
contract drops below the liquid vapour
presure. In case of ball valves the vena Answer Serious lead-wire resistance
contracta pressure and inlet pressure have errors can occur when using a two-wire RTD
marginal difference ( thats why high (see Fig. 3A), especially in a 100Ω
recovery). When inlet pressure and vena sensor. In a two-wire circuit, a current is
contract pressure are clsoe to each other passed through the sensor. As the
valve is definetely to cavitate . Hence Ball temperature of the sensor increases, the
valves are not used in applications where resistance increases. This increase in
cavitation is likely to occur. resistance will be detected by an increase in
the voltage (V = I•R). The actual resistance
causing the voltage increase is the total
Question WHAT IS DIFFERENCE resistance of the sensor and the resistance
BETWEEN TWO WIRE RTD AND THREE WIRE introduced by the lead wires. As long as the
RTD? lead wire resistance remains constant, it can
be offset and not affect the temperature
Answer The simplest resistance
measurement. The wire resistance will
thermometer configuration uses two wires.
change with temperature, however, so as the
It is only used when high accuracy is not
ambient conditions change, the wire
required as the resistance of the connecting
resistance will also change, introducing
wires is always included with that of the
errors. If the wire is very long, this source of
sensor leading to errors in the signal. Using
error could be significant. Two-wire RTDs are
this configuration you will be able to use 100
typically used only with very short lead
wires, or with a 1000Ω element. In a 3- Answer The temperature indication
wire there are three leads coming from the does not increase so significantly that it is
RTD instead of two. L1 and L3 carry the worth the effort to use a 3 or 4 wire RTD. It
measuring current, while L2 acts only as a might increase with something like 0,001Deg
potential lead. Ideally, the resistances of L1 C so that is so small you might as well say
and L3 are perfectly matched and therefore there is no difference in the accuracy of a 2,3
canceled. The resistance in R3 is equal to the and 4 wire RTD, using a local or smart
resistance of the sensor Rt at a given transmitter. In the old days we use to use a 2
temperature—usually the begining of the wire RTD in the field and then run a cable say
temperature range. At this point, V out = 200m to the temperature indicator. By the
zero. As the temperature of the sensor time it gets to the indicator the temperature
increases, the resistance of the sensor is completely different from what it was in
increases, causing the resistance to be out of the field due to the cable resistance that add
balance and indicated at V out. Resistances itself the the RTD resistance.We
L1 and L3 in leads up to tens of feet long compensated for that by installing a 3de wire
usually match well enough for 100 ohm for the sole propose to measure the
three-wire RTDs. The worst case is resistance resistance of the cable itself and deduct that
offset equal to 10% of single-lead resistance. from the total resistance measured at the
The optimum form of connection for RTDs is temperature indicator. So the actual
a four-wire circuit (see Fig. 3C). It removes resistance of the RTD as measured at the
the error caused by mismatched resistance temperature indicator is RTD - RLine1.(or
of the lead wires. A constant current is [(Rline1/2)x2]if you want) With the 4 wire it
passed through L1 and L4; L2 and L3 makes it more accurate in that you can now
measure the voltage drop across the RTD. measure line one and line 2. The theory is
With a constant current, the voltage is that the one line might have a small
strictly a function of the resistance and a difference compare to the other line. So the
true measurement is achieved. This design is actual RTD resistance at the temperature
slightly more expensive than two or three- indicator is measured RTD - [(RLine1/2)+
wire configurations, but is the best choice (RLine2/2)] But since we all use the small
when a high degree of accuracy is required. compact local and smart temperature
transmitters these days, 3 and 4 wires are no
longer needed since the distance from the
RTD to the transmitter is only from about 50 if the fourth wire is connected, new errors
to 500mm and but it seems it have stayed will be introduced. Connecting a 3-wire RTD
due to some design engineer always saying, to a 4-wire instrument can cause serious
why buy a 2 wire if you can get the 3 and 4 errors or simply not work at all, depending
wire for just about the same price. It will on the instrument circuitry.
make the indication just more accurate, but
Answer Your maths is not right but
they never say by how much (0,001Deg C)
actually you are right, and the temperature
Question what is full form of NAK? indication does not increase so significantly
that it is worth the effort to use a 3 or 4 wire

Answer NAK is negative RTD. It

acknowledgment or not acknowledged. It is

might increase with something like 0,001Deg
a signal used in digital communications to
C so that is so small you might as well say
ensure that data is received with a minimum
there is no difference in the accuracy of a 2,3
of errors. Sometimes the NAK signal is called
and 4 wire RTD, using a local or smart
REJ (for rejection or rejected).
transmitter. In the old days we use to use a 2
wire RTD in the field and then run a cable say
200m to the temperature indicator. By the
Question what is the si unit of time it gets to the indicator the temperature
pressure? is completely different from what it was in
the field due to
Answer pascal(pa)

the cable resistance that add itself the the

Question what is the difference
RTD resistance. We compensated for that by
between 3,4 wire RTD sensor?
installing a 3de wire for the sole propose to
Answer RTD is inherently a 2-wire measure the resistance of the cable itself
device, A 2-wire RTD can be used with either and deduct that from the total resistance
a 3 or a 4 -wire instrument by jumping the measured at the temperature indicator. So
appropriate terminals.3-wire instrument, a the actual resistance of the RTD as measured
4-wire RTD will not provide any better at the temperature indicator is RTD - RLine1.
accuracy. If the fourth wire is not connected, (or [(Rline1/2)x2]if you want) With the 4
the device is only as good as the 3-wire RTD; wire it makes it more accurate in that you
can now measure line one and line 2. The earth wire (about 4 to 6mm is fine). This
theory is that the one line might have a small earth wire is then attached to the outside of
difference compare to the other line. So the the instrument at the earth connection point
actual RTD resistance at the temperature on it's housing. Every instrument will have
indicator ismeasured RTD - [(RLine1/2)+ this earth connector on the outside of it's
(RLine2/2)] But since we all use the small housing. From there you attached another
compact local and smart temperature earth wire to the earth boss nearby. This
transmitters these days, 3 and 4 wires are no boss is normally just a piece of round bar
longer needed since the distance from the about 40mm in diameter and about 30mm
RTD to the transmitter is only from about 50 long and tapped in the middle that is welded
to 500mm and but it seems it have stayed to the structure close by, specially for this
due to some design engineer always saying, earthing of the instruments. Again it is better
why buy a 2 wire if you can get the 3 and 4 to use copper washers. If noboss is available
wire for just about the same price. It will you can use some other point on the
make the indication just more accurate, but structure as well like a stainless steel cable
they never say by how much (0,001Deg C) tray for instance but the earth boss should
really be part of the design. On the other
Question What standards are used for
side of the instrument cable at the RTU the
earthing of field instruments?
internal screen in attached the

Answer The internal screen is always instrumentation clean earth. The dirty earth

floating at the instrument. This means we is used only for electrical equipment.

just put some heat shrink on it to seal it and

Question What is the difference
then tie it off inside the instrument and just
between Analytical instruments and other
let it lie there. The overall screen (braiding
instruments?
surrounding the cable just below the pvc
outside)will be in contact with the gland Answer Yes, I see what you mean it
once you have installed the gland. On the can be a bit confusing.Instrumentation is a
gland thread you install a copper gland ring very wide field so the easiest to explain
and a red IP washer, and the gland then are would be to classify all the various areas in
attached to the instrument. From the gland different categories, but they are all part of
ring you use a six mm bolt and nut with the instrumentation field. Process measuring
copper washers to attached a small diameter instrumentation, like pressure, temperature,
flow, density, level, viscosity, conductivity, lie there. The overall screen (braiding
PH, redox, distance, angle ext. Process surrounding the cable just below the pvc
control instrumentation, like control valve, outside)will be in contact with the gland
on/off valve, solenoids valves, valve once you have installed the gland. On the
positions, feedback positioners. Monitoring gland thread you install a copper gland ring
and control instrumentation, like the DCS, and a red IP washer, and the gland then are
SCADA, PLC's and relay control systems. attached to the instrument. From the gland
Pneumatic instrumentation, like pneumatic ring you use a six mm bolt and nut with
valve positioners, electromagnetic copper washers to attached a small diameter
positioners, DP transmitters, level trolls, earth wire (about 4 to 6mm is fine). This
switches and pneumatic relays and pistons. earth wire is then attached to the outside of
Hydraulic instrumentation, like hydraulic the instrument at the earth connection point
control systems, pneumatic/hydraulic on it's housing. Every instrument will have
solenoid valves, hydraulic control valves, this earth connector on the outside of it's
feedback positioners and pistons. Fire and housing. From there you attached another
gas instrumentation, like flame, gas, smoke, earth wire to the earth boss nearby. This
heat detectors and the addressable boss is normally just a piece of round bar
monitoring and control systems. CO2, foam, about 40mm in diameter and about 30mm
440VAC foam control valves and deluge long and tapped in the middle that is welded
systems and their pneumatic and solenoid to the structure close by, specially for this
control systems will also fall in this category. earthing of the instruments. Again it is better
Analytical instrumentation, like oil in water, to use copper washers. If no boss is available
gas chromatographic, oxygen content, you can use some other point on the
chlorine content, florescence, dew point structure as well like a stainless steel cable
analyzers. tray for instance but the earth boss should
really be part of the design. On the other
Question what are the standards used
side of the instrument cable at the RTU the
for earthing instruments in the field?
internal screen in attached the

Answer The internal screen is always instrumentation clean earth. The dirty earth

floating at the instrument.This means we just is used only for electrical equipment.

put some heat shrink on it to seal it and then

tie it off inside the instrument and just let it
Question Please explain about FAT? Question What is difference between
What is the difference between FAT and flame retardant & flame resistance cable?
SAT?
Answer T here is a vast difference
Answer FAT = Factory acceptation test between cables that are rated flame
retardant and those that have earned the
SAT = Site acceptation test when any
rating fire rated or fire resistive. Flame
company going to install new instrument
retardant cables resist the spread of fire into
control
a new area, while fire rated cables maintain

system,they have to test how its working ? In circuit integrity and continue to work for a

the FAT shop they will do configuration specified time under defined conditions. Fire

setting for all instrumet loops. according to rated cables continue to operate in the

configuration the system providor will do presence of a fire and are commonly

function test by simulating signals.but during referred to as circuit integrity cables. The

the SAT they will check all function with real differences between the two ratings are

Input signals. significant for the critical circuits required

for life safety or a safe and immediate plant
shut down. Additionally, fire rated cables can
be used to replace expensive fire rated
Answer FAT: It will be conducted at
structures, blankets or wraps and the
System Supplier's place with presence of EPC
difficult to install MI cable. Flame retardant
and End user.They will check the
cables are not rated to continue to operate
functionality of Control loops and logics with
in a fire, and in all probability will not
use of Simulators.Third part devices will also
maintain circuit integrity during a fire.
physically connected to the system supplier
and functionality will be checked and Question What is the difference
corrected. between pneumatic and electro

SAT: It will be conducted at End user's pnematic positioner?

place.Here field to system will be checked
and corrected.Back to Questions Page Answer The only difference between
Pneumatic Positioner and Electropneumatic
Positioner is the electropneumatic (i/p)
converter unit in the electropneumatic
positioner to convert the electric signal from given, we have to follow ASME 31.3 code to
the controller into a proportional pneumatic find the required thickness for the design
signal.These positioners use a flapper-nozzle pressure and temperature.
system, which operates according to the
Answer Clarification:
force-balance principle. They can be

There are four end connections:

Applied for both normal and split-range
operation. 1. Butt weld

Question What is pipe schedule? What 2. Socket weld

are all effects its having in the valve? how
do we take care of pipe sch in case if the 3. Threaded end

customer dint specify in the data

4. Flanged end
sheet.What we need assume and in what
basis?

Answer Thickness of the pipe is For butt welded and socket welded end
normally spelled in Schedule valve, schedule is important. For other no
need.But while connecting a pipe and a
example 1/2" Sch 40S,
flange, schedule is needed.For joining any
two components (a pipe with a valve)

Generally, ID (Inside diameter) of the pipe through butt welding, ID of both should be

will vary by varying the thickness but OD match.Pipe is designated by a "Nominal Pipe

(Outside Diameter) remains constant. But it Size" based upon the ID (inside diameter) of

is vice versa when we speak about tube, the most common wall thickness. Tubing is

where ID remains onstant and OD will designated by the measured OD (outside

change by varying thichmess.For a valve diameter).

with welded end connection ,schedule of the

Question How to check range of DP
valve is needed, so that while joining valve
Transmitter
with the pipe, both ID of valve and pipe shall
be matched. For that most of cases schedule Answer With the help of Hart
is important.In case when pipe sch is not communicator u can check or change
the range of DP transmitter. and thermocouple linearity is increase so it
used mostly.
Brif Procedure:-
Answer resistance
1) connect The communitor in series wt
transmitter Question Please anyone answer my
question, what is the difference between
2)start communicator.if connection ok then
single acting and double acting control
it will
valve, in what condition we better choose

transmitter. single acting rather than double acting

3)prsee ok.
Answer Normally a control valve is

4)it will show all the transmitter data ,such refer to by it's fail position.This means "what

as position will the valve move to should the

supply air or control signal to the valve falls
range,zero ,span etc.
away". This is important to safe guard the
process at various places so some valves will
5) you can change zero and span for better
be fail open and some fail close. In order to
resolution.
have valve as a fail open or close the valve
Question Can we place a Control Panel the actuator have to be spring loaded. So by
in Hazardous area Group IIC ? If 'yes' then having the spring on top or bottom of the
is there any approval required? actuator piston, will determine if it will be a
FO or FC valve. This kind of valve is also
Answer 1)yes you can put in Group IIC
called single action since it will only have one
2)IEC-60059 code should follow 3)minimun
output from its positioner to either the top
IP-65 reqiured
or bottom of the actuator. The positioner on

Question In Increasing temperature the valve is also setup as a single acting

why thermocouple used and RTD is not positioner since it will only give a single

used. Both RTD and Thermocouple have in action to the actuator, the reverse action will

Range of uses. be done by the spring. The problem with this

setup is that it is possible that the process
Answer Because of Linearity.
might be so strong or the pressure so high
Increasing Temp. Linearity is decrease of RTD
(during a blow down or ESD shutdown in the
plant) that the spring might in certain are working on. With those kind of flows and
instances be to week to push the valve into pressures you don't want to leave anything
the fail position quick enough, due to the to chance.
back pressure from the process and can
Question I have one DP transmitter of
cause damage to the plant or even a
range 0-500mmWC i have to
explosion. To make sure that the valve will go
to the fail position we install a double action calculate its range in M3/hr for flow
positioner with two outputs. One goes to the measurement so whats
top of the actuator and one to the bottom.
This is also very helpful to do very accurate the formula.

and stable control on a high flow line since

Answer DP transmitter are used for
the pressure from the position do the actual
flow measurement in combination with flow
control and not spring control one way and
obstructing devices such as
positioner control the other way as in single
venturi,orifice,nozzle or aerofoil,which have
acting control valves. It is also solving the
tested characteristics i.e. pressure drop
problem that the valve will now be forced
across them for a perticular flow.This
into the fail position by the spring as well as
characteristic is then used with DP
the positioner supply pressure during a
transmitter to measure flow.
emergency. In shutdown valves (open/close
ESDV's) the same is true and sometime at Answer range of dp tx and range of
critical and high pressure points we use output is entirely different. first of all to
hydraulics instead of pneumatics as the measure flow, we need primary elements
double acting agent to make sure the valve like ventury tube, flow nozzle, annubar
will close during a emergency. So to which will restrict the flow and so that dp
summarize the double acting action in ESD will create. from the manufacture of the
and control valve is just there to make sure primary element itself the constant value
the valve will do what it was designed for. should be noted. then only we can calculate
Call it a extra fail safe if you want. In theory the flow using dp tx.
not needed since a single acting valve should
Answer You first need to have a flow
do the trick just as well,but in practice you
element like a orifice plate installed in order
are at time very glad you did it especially if
to get a differential pressure across the
you look at the kind of pressures the valves
orifice. You then need to measure this remote location. Good example of a all in
differential pressure with the differential one unit is the Coriolis meter. You can read
pressure transmitter or a u-tube or two the flow, the density or the mass flow
pressure gauges at various flow rates. If this directly from it and configure its output to
is not possible the orifice plate manufacturer give you whatever you need to be displayed
will give you the minimum and max diff on your supervisory system. The principle it
pressure across the orifice plate for various works on is vibration tubes. The variance in
flow rates and liquids. You should already vibration is a direct and proportional result
have the pipe size, the orifice plate details due to the variance in flow. So the frequency
and the liquid you will use in this application. of the vibration is monitored and converted
Once you have this minimum and maximum into the output signal obviously with some
diff pressures for the minimum and max flow calculations inside to get the density and
rates you can see on the transmitter range if massflow as well.
it will be big enough to measure these diff
pressures. The signal can be send from the
transmitter directly to the DCS and the
squire roof extraction can be done there or
you can do the SQ extraction on the Question what is the resource block

transmitter itself by modifying it's mode in foundation field but ? what is

configuration to measure flow. advantages for this

Answer simply measure dp at max Answer This block provides the

flow. caliberate dptx to that value. select common shared use withe other two

output sqrt in dptx. if its out of range of blocks.i.e transducer block and analog input

dptx. adjust orifice and try. block.also called functional blocks.rersource

block in otherway it manages nonvolatile
Question What is the working principal memeory
of Mass flow transmitter?
Question i am working in thermal
Answer It is a combination of a flow power plant .if temperature transmitter is
meter and a density meter combined either not showing reading in dcs then how can
as one unit or two separate instruments and we rectify the problem?
the final mass flow calculation gets done at a
Answer SEE THE FIRST ALRM Answer check the millivolts output of
CONDITION ON TRANSMITTER BECAUSE thermocouple.then multiply with the
MOST PROBABILITY IN PRIMERY ELEMENT standard values depends on the type of
PROBLE. thermocouple.if the value is ok,check the
temparature trnsmitter,then check the mA
Answer Go to the field and check the
o/p of TT.
local indication in the transmitter.(normally it
is in either engg. units or as percentage) If it
is zero ,then the problem is in the sensor or
Question how we can check level probe
terminal connection, because most of the
and controller
current generation transmitters are highly
accurate and have longer stability Answer if it is digital ie NO/NC touch
the probe with hand then relay with switch
periods.Suppose local reading is ok,then
over,
check the DCS analog input card for any
fault condition and clear it.Normally this if it is analogue keep sliding with hand on the
situation is rare. probe from bottom to top then controller
indication will vary
Answer Check the Sensor properly. if it
is ok, then Question What is the Flow rate ?

1)check continuity between the sensor Answer Flow Rate is usually used in
cables industries working on hydraulic and
pneumatic areas to specify the amount of
2)tight the cables properly
working fluid passed across a fixed cross-
3)check the transmitter supply (24vdc) section areas in fixed time. Mostly, we
describe flow rate in Litre Per Minute means
if it is not ok, then check the DCS analog i/p
how much litres of working fluid has been
cord.
passed through a given cross-section area in
One minute.Flow Rate is independent of
pressure in hydraulic i.e liquid. but is
Answer check wiring in i/o dependent on pressure in gases as gases are
compressible at pressure. Hydraulic is also 4. S type. (platinium/10%platinium,aradium)
compressible but at higher pressure. upto 1700c

Answer flow rate is besed on the 5. B type.

terms ie, Turndown and Rangeability
6. E type.
turndown means ratio of full scale range to
minimum scale Rangeability means ratio of 0 Amsal Zaman
maximum rane to min range thats the flow is
based on the two terms and i studied from
PATRANBIES author

Question what is basic working

Answer total more than 8 types of
principle of Governer in power plant?
thermocouple is there.mostely

Answer Auto regulation of steam

used k,t,j,r,s,b...
pressure/flow with respect to speed of the
turbine. 0 All

Answer it controls the MW generation

according to the steam flow,pressure.

Question how many types 0f

Answer Thermocouple Standards and
thermocouples?
Scales
Answer these are the types of
Thermocouple Type Standard Scale
thermocouples.

J, K, T, E, R, S, B NIST 175 ITS-90

1. K type. (chromal/alumal) upto
1150c L (J-DIN), U (T-DIN) DIN 43710 IPTS-68

2. J type. (iron/constantun) upto Thermocouple Properties

1300c
Thermocouple
3. R type. (platinium/13%platinium,aradium)
upto 1700c Type
Temperature 1°C or °F

Ranges B 600 to 1800°C

Display Resolution 1112 to 3272°F

J -200 to 1200°C, 1°C or °F

-328 to 2192°F L -200 to 900°C

0.1°C or °F -328 to 1652°F

K -200 to 1370°C 0.1°C or °F

-328 to 2498°F U -200 to 600°C

0.1°C or °F -328 to 1112°F

T -200 to 400°C 0.1°C or °F

-328 to 752°F 0 S.k.kamalakannan I&c Engin

0.1°C or °F

E -200 to 950°C Question HOW TO CALCULATE WAKE

FREQUENCY FOR THERMOWELL?
-328 to 1742°F
Answer wake frequency
0.1°C or °F
Fw = 2.64 x Fluid velocity(feet/sec) / Dia. of
R -20 to 1750°C
well tip (inch).

-4 to 3182°F
Refer to ASME PTC

1°C or °F
Question what is relation between

S -20 to 1750°C electronics&instrumentation

-4 to 3182°F Answer Electronics is t back bone of

instrumentation to get better contol
actons .Eletronics playing a vital role in parameters(Kp,Ki,Kd) so as to obtain desired
instumentation.Eg. Take a transmitter to performance of the controller.
convert The physical quantity in to elecrical it
needs electronic components...

different tyes of tunning:-

Question Tell me about PID Tuning and
what is PID. 1. Zigler-Nicholes method

Answer pid is proportional integrative 2. Cohen Choon

derivative pid is a closed loop system which
is used for error checking of analog devices 3. 1/4 decay ratio

only, it cant used on digital devices.

0 Karthika

pid consistes of

kp proportional

ki integrative
Answer by the help of P we calculate

kd derivative the error signal Error signal=SP-PV (How

Much)in the timming of pid tunning. By the
in pid tuning first kp,ki,kd is taken as any help of I we Remove the offset error-it will
integer and then error is checked by the pid decide how long the error exit in the cycle
formulae inthe timming of pid tunning. And by the
help od D we fasten the control action-it will
if there is error then the values of kp ki kd
decide how fast the control action to remove
can be changed to give the error 0
the error without any overshoot for failure
0 Sumit Sharma cycle.at last

P=How Much(present)

I=How Long(past)

Answer Tunning is a process in which D=How Fast(future)

we adjust the controller
Question what is the basic working Answer Leakage class does not
principle of I/P and Positioner in depend upon any process parameter.It
depends upon user/process
any control valve.
requirement.required Shut-off condition is

Answer I/P is basiclly working on the the parameter and selected trim type and

flapper and nozzle principle.And the MOC

positioner is working on the Forced balance

are parameter upon which leakage class
principle.
depends.For detail refer hand book on

Answer I/P is input (requirement of Control valve by fisher.It is available on

process/operator) at which valve needs to be internet.

operated.Positioner gives output (feedback)

Question what is differnace between
to control loop about actual position of
radar level tranmitter & hart
valve.Conclusively-I/P-requirement,
Positioner-job done conformation type tranmitter?

Answer I/P Converter , converts 4-20 Answer radar is the non contact type
mA signal from controller to .2 to 1.0 Kg/cm2 level transmitter which works on the
pneumatic signal.Positioner consist of air principle of electro-magnetic waves of
supply port , signal input port, out put frequncy in the range of 3Ghz to 25 Ghz.Hart
port.When positioner get in put signal ,it is the protocol for digital
compare with stem position and output is communication.Radar is available with HART
generated and signal boosted sufficiently to protocol.
operate the valve . It uses force balance
Answer Radar type level transmitter
system.
works on the principle of FMCG (frequency
Question can any one tell leakage class modulated continious wave system) & hart
in control valve depend on transmitter works on the principle highway
adressable remote transducer the data is
which parameter and there is any specific
transmitted from the sensor to the requred
table or chart for
system through the hart adress

selection of valve leakage class

Question what is the difference varies with weather or atmospheric
between RTU & MTU in SCADA system? conditions.

Question An electronic p controller has

Answer RTU is Remote Terminal Unit.
an input range of 1-5v, and
RTU is the basic component of SCADA that
converts analog signals (either from some output range of 4-20mA, while testing a
level sensor, temperature sensor) to digital step change of 0.4
signals that can be accepted at the PLC end.
was applied at the input , the PB setting
MTU is Maximum Transmission Unit. It is the
was 50% ,what
maximum size of a data block that can be
transmitted through any of transmission should be the change in the output ?
protocol e.g. IP protocol.
Answer as PB is given 50%, so Prop
gain would be (100/PB)..in this case it is
twice(prop gain)...now as we know for the
Answer I think MTU is also known as
change of 1 v in input we get 4ma change in
Master terminal unit.And its main purpose is
output..so for 0.4 the change will be 1.6ma
to accept the diffrent inputs from the
WITHOUT using P controller...BUT we have
Remotely connected devices and transmitt
Prob gain is 2 so change in output will be
them over the network
1.6*2=3.2ma hence change in output is
*** 3.2ma

Question what is an ambient Question Why we use 4 to 20 mA, (This

temperature? is International Standard)

Answer ambient temperature means instaed of this can we use 4-16, or 4-24 or 3-
generally we r called room temp. ok 15 or any
approx.25-27degree centigrade
other range
Answer Ambient temperature is
Answer 4-20 mA signals are possible
nothing but the atmospheric temperature
to divide equally, 0-4 mA as close loop
which surrounds us.Ambient temperature
checking.
Answer We use 4-20 mA range as a to give a calibration points for 0-25-50-75-
standard bcoz we know very well when there 100%. Because the start point is 4 the steps
is no input i.e. output must be 4 mA are 4mA.
otherwise instrument is giving wrong
Answer First the question is why can't
output(i.e. instrument not having proper
we use 3~15mA or other range, here also we
calibration).
can check live zero and also we can go step
Answer There are basically 2 reasons current like 3,6,9,12,15(i.e
of using 4-20ma 0%,25%,50%,75%,100%).ok The reason is
the transmitter voltage is 24Vdc , here we
1. we can know whether the instrument is
can load max of 600 ohms, for this voltage &
working properly or not. we can distinguish
load better
"live zero" and "dead band". if there is
problem in instrument then also it is going to range is 4~20. Why 4 ~ 20 is better since we
show zero and if there is no supply then also can convert easily 1~5Vdc by put 250
it will show zero so we can differentiate this ohms.All the controllers and DCS , PLCs are
two. operated by the input of 1~5Vdc (external or
Internal convertion)
2. 4-20ma is linear with 3-15psi .
Answer Answers 5 & 6 are totally
correct.. just adding another point. 20 mA as

Answer We use 4-20 mA range as a upper value is used to keep electrical

standard bcoz we know very well when there components intrinsically safe at hazardous

is no input i.e. output must be 4 mA area.

otherwise instrument is giving wrong output

Answer Answers 5, 6 & 7 are correct.

Answer the 4mA zero is termed a "live just want 2 add that why cant we use 3 mA

zero". If 0mA was the zero point there would current as lower value. The reason is that

be no way of telling if the transducer was there are many small noise signals that can

reading zero or in a fault condition eg. an be picked up by our signal wire which has

open loop. with a 4mA zero an open loop the potential of providing upto 3 mA current.

would drive the indicator eg. a recorder into So to be on the safe side to distinguish

a minus figure (-25%). The 4 - 20mA scale is between our proper field signal and the
noise pick-ups we use 4 mA as our lower HART is a digital device, so this digital signal
value will superimpose on the analog transmiiter
signal without disturbing it.
Answer ans. 5,6,7 & 8 r correct.only
two points add. Answer HART Communicator - is a
device used to communicate with the HART /
1.in ancient time,niddle type galvanometers
SMART family transmitters, used in the
are used,only if we pass 4mA current it
process control.
shows deflection.therefore 4mA.
* To monitor the PV, Current mA value,
2.if 21mA current will pass through our
Sensor Temperature,
body,man can goes dead.therefore 20mA. &
4-20 mA can divided into 5 equal %. * It is used to re-range the transmitter,

Question plz give me the logic for how * damping adjustment,

a pushbuttoon can be worked
* trimming the sensor of zero/lower/upper
as atoggle switch ranges.

Answer use latch after pushbutton * create the tags/messages of the

and then output transmitter.

or * Review the complete details of the

transmitter.
give memory in or to pushbutton and then
output. * Loop testing the control loop
(Indicator/Controller), etc.Whereas the 4-20
Question what is the difference about
mA source is used for the following:
HART, and 4-20mA signal?
* To simulate the 4-20 mA signal (For
Answer normally in industries we use
calibration of control valves, loop testing of
4-20mA signal to transfer the signal from a
the closed/open loop).
transmitter to the control system.nowadays
the trasmitters are smart type. so a HART is a * Using the high accuracy 250 ohms resistor,
device used to communicate with this smart we can get 1-5vdc as the output which is
transmitters to get the data online or offline. useful for the DCS input.
Answer HART=higely addresaable (conventila wiring) b/ HART HART use the 4
remote tranduer which works on high -20 ma but the communication is done via
frquency modulatition tech. to calbirate
digital this why we can view many of the
smart transmitter and 4-20ma signal
transmitter parameters,this base on PKS
std.linear signal
(phase hey shifting)refer to modulation
Answer HART is a tecniques in communication.
communicator/device works on RF Signal
Answer The HART Protocol is an
whereas 4-20 mA is a Electrial Analog Signal
acronomy of Highway Adressable Remote
not a Device/Instrument.
Transducer,it uses the frequancy shift
Answer HART is a protocol and not a koeying standard to impose digital
device.It is protocol for digital signal communication on top of the 4-20mA
communnication. signal.this enables a two way field
communication to take place, making it
HART compatible transmitter transmits
possible for additional info rather than the
digiatl signal super-imposed on analog 4-20
process variable only. Hart protocol is a
mA signal and gives many useful
Master/Slave protocol, the HART protocol
infoarmation about the transmitter and
can be used in different modes like point to
process parameter other than output.You
point or multidrop for communicating info
can configure the HART based transmitter
from/to smart fiel device and the controller,
using HART configuator withou removing the
the field device and the controller should be
trasnmitter from its
HART enabled.In general HART protocol

location/process.4-20mA is simple low opens two communication channels: the first

current signal which is propotional to one is the 4-20mA normal signal for the

calibration range. measured value using the 4-20mA current

loop. And the second chanel is the digital
Answer ANSWER NO 5 IS GOOD,the signal whic is imposed on the analog one.The
question about communication prtotocol, digital signal gives additional info about the
how we trassfer the signal from transmitter field device such as device status, diagnosis,
to the DCS,Many ways let us compare and other types of info
between two of them.a/ 4 - 20 ma
Question How to make position qualified applicants. By faking it you will only
transmitter feedback reverse i.e at recruit people who know no better.

valve close i want 20ma output and at full Question What is instrumentation
open 4ma.for the amplifier?

NELES positioner,model:ND8261/TS1. Answer an instrumentation amplifier

may be defined as conversion of any
Answer removed link from actuator
physical quantity into an electrical
than fix back which condition you need you
quantity at the output.hence it is coupled
will get other wise if you have HART base
at the output of the transducer and used
change your counter (first read counter )
as an data acquisition system
than increased from potentio meter you
can? i donot have idies about same your Answer A type of differential amplifier
positioner model but you can try with high input impedance and low output
impedance.Mostly used in all Transducers
Question i want interview questions
because of its common mode rejection ratio
about PROCESS CONTROL
property so that noise can be eliminated

INSTRUMENTATION , from signal produced by primary sensing

element.
Answer karumudi , start reading basic
books abt instrumentation. As such you will
not get any ready questionaire anywhere.
Question How can we measure the

Answer first of all u study basics of the level of a closed system like drum

instrumentation regarding with

Answer We can measure the level of
measurement parameters and their
the closed tank usingDifferential pressure
measuring methods also the equipments
measurement system, or ultrasonic level
used for that ,,
measurement, or using displacer level

Answer Qualified applicants will know measurement system, etc.

instantly that you are faking it. If this

Answer We can measure the level of
knowledge were this easy to obtain you
closed tank usingDP-tx ,,,,,,,,,,,even we can
would not have a difficult time finding
use the level switches for the NO & NC point
,by which we can consider the HIgh level & Answer Lead-wire resistance in two-
Low level measurement wire measurements causespotentially large
temperature measurement errors.Other
Answer We can measure level of
types of resistance measurements include
closed system by
three-wire

1. Radar type level transmitter

and four-wire resistance measurements.

2. Ultra sonic type Level transmitter Four-wire measurements are preferred in

temperature applications because they
3. Differential pressure transmitter eliminate lead wire resistance from the
measurement.
4. Leveltrols (displacement type)

5. float type level transmitter

Answer 3rd wire is used as

compension and if we use 4 wire RTD it
for Local indication we can use different type
elemeneted more resistence as compere to 3
of level gauge like glass type or float type
wire.4 wire is
**
more perfect
Question what is difference between 3
wire and 4 wire RTD sensor?

Answer three wire RTD FOR

RESISTENCE COMPENSETION FOR TWO WIRE Answer 3 wire rtd sensor have a 1
HAVE INTERNAL COMPENATED WITH postive(red) and 2 negative(white).whenever
WHISTEN BRIDGE CIRCUIT 3 wire rtd used for long distance that means
10 meter wire..that time wire resistance also
Answer In 3 wire , 2 wires supply
increased.(r=pl/a).in 4 wire rtd sensor have
power and 1 give the o/p
a 2 postive(red) and 2 negative(white).4 wire
Whereas in 4 wire , 2 2 wires supply power rtd used for long distance that time the red
and 2 for o/p and red wire have short.so the resistance
variation is equal.
Question what is difference between Answer RTD & Thermocouple are
wheatstone bridge, pirani gauge and strain positive temp. Coefficeint and thermistor is
gauge ? negative temp . Coff..

Answer WHEATSTONE BRIDGE IS Answer with t/c we can measure upto

INVENTED BY WHEATSTONE.PIRANI GAUGE 1700deg. but with RTD 600 degree is
AND STRAIN GAUGE ARE INVENTED BY accurable. in t/c only the tip is sensing point
PIRANI AND STRAIN wihre in RTD the average value will be taken.
RESPECTIVELY.WHEATSTONE BRIDGE IS A
Question what is difference between
BRIDGE WHEREAS PIRANI GAUGE AND
total flow and flow rate in
STRAIN GAUGE ARE GAUGES.

general ?? explain it with daily life example.

Answer wheat stone bridge is used for
measuring resistance and pirani gauges are
used for measuring small pressures and Answer TOTAL FLOW= AREA OF ANY

strain gauge is depends on the principle of CONTAINER X HIEGHT WILL BE TOAL FLUID

when strain is applied to conductor the GOT INTO CONTAINER

length increases and resistance increases

FLOW RATE= D.V.A

Question how bolometer is used in

temperature measurement ?
WHERE D= DIA OF PIPE
Answer bolometer is just a strip of
metal having positive alpha...it can be used V= VELOCITY OF FLUID
as any other resistive transducer
A= AREA OF PIPE
Question what is difference between
Answer Total flow is the total quantity
RTD , thermo couple and
(in mass or volume)passed through a flow
thermistor in general ?? (except meter.Flow rate is the quantity of flow (in
temperature co-efficient ) mass or volume)in a unit time.

Answer in general RtD and thermister Answer Suresh has given right answer
is passive transducer and thermocouple is but it must be total Fluid as flow will depend
active transducer on velocity of fluid.
Question what is the difference Where as DC stands for Direct Current.It has
between DELTA-V & FOUNDATION FIELD zero frequency and has one positive and one
BUS? negative.Infact Dc is much powerful than AC.

Answer delta-v it's from emerson and Answer amplitude of an ac voltage

foundation field is fron yokogawa so there is continiously with time it has a frequency
no diffrance infact delta-v new verson so
dc voltage does not have frequency the
there some configuration is littel diffrent but
amplitude does not vary with time
basically it is same as well as field bus.

Question why we use negative 24vdc to

Answer Delta v is the DCS offered by
a proximeter
Emerson.Foundation feildbus is protocol for
dgital signal Answer in vibration senseor we give
-24 v in proximitor becoz it have vaild reason
transmission.FF is next level of digital
communication after HART. and reason is that becoz we have to take o/p
of proximitor is -10 to 0 and why we have to
Answer THE SECOND ANSWER BY
take the voltage o/p -10 to 0 is that becoz
vaibhv vt is accurate, my advice is that we
and the distance b/w shaft and and sensor
only can compare apple to apple u can
get less rf signal is absobed by the meatal
compare communication protocol like
and voltage gets down ,,,but acc to human
FF,PROFIBUS AND HART.BESIDE u can
mind setup as gap decrease singla amount
compare DCS from different vendors.
shoukld increase (as in case of 4 to 20
Question What is mean by AC voltage ma ),so we -ve volatage o/p becoz as -ve
and DC voltage voltage decrease it means vale is increasing
(acc. to math -4<-3)
Answer AC stands for alternating
current.It has frequency in it.It flows in
single,dual or 3 phase as per
Answer In -ve voltage the rate of
requirement.Thus it has phase and neutral
distabance is lesser than +ve voltege.So we
i.e return...also it has pulses and follows sine
using -10vdc(some time-9.7 to -9.8vdc is
graph.
acceptable ).
Answer we r not using negative supply CV -flow coefficient
but the 0utput is set negative and this is ony
Q -flow of liquid
the company monopoly

P-pressure drop across the flow

Question what is the function of a
diaphragm? SG-specific gravity of the liquid

Answer Function of a Diaphragm is to

convert a pressure signal to Displacement
CV=1.17KV => KV=.86CV
Question WHAT IS CV OF CONTROL
VAVLE

Answer The Cv is actualy the Flow KV is metric unit of CV

Coefficient of control valves. It actually

measures the friction experienced by a fluid
as it moves through some pipe / valve. The the flow of water through a valve at 60
standard definition oF in US

of Cv is:"the flow of water through a valve at gallon/minute at a pressure drop of 1 lb/in2.

60 oF in US gallon/minute at a pressure drop
of 1 lb/in2."

Question i have one absolute pressure

Answer coefficient valve
transmitter for the range is
one cv equal the flow of one u.s galleon(3.8
-400mmhg to 400mmhg. If i do the zero
litter)per minutes of water at 60 F under a
trim at atmosphere the
pressure drop of value of 1psi.

transmitter should be give 4ma or 12ma?

Answer flow coefficient of control
which one is correct?
valve.its calculated by the given below
formula: Answer Your transmitter has a range
of 800mmhg. The LRV is -400mmhg and URV
CV = Q/(P/SG)^1/2
is +400mmhg. So at atmosphere you will get
where:
12mA. All the time, because atmosphere is working like a DCS. Although PLC is Better for
Zero gauge pressure Sequincial Operation, Because its Scan Time
is less than DCS & DCS mostly used for
(perfectly mid value in between the LRV and
Continues Process.If You see todays PLC, Its
URV).If you do zero trim at atmosphere, it
IO Capacity is near to DCS IO handling
will take "ZERO" with the atmospheric
Capasity. Yaa, one Big Advantage of DCS
pressure. The range of the transmitter will
System is that Logic of whole process is Split
not change. The range will remain
in Defferent different CM's. So that when
800mmhg. But your LRV will change to
change in one CM do not affect other
0mmhg and URV will change to +800mmhg.
Proccess.
So in that case, without any process
connection it will give 4mA.

Answer -400mmhg= -0.53bar Answer DCS is distributed control

system,in which we can control many
400mmhg = +0.53bar
process in case of any sefe-failure

if u do zero trim by opening the valves with operations,there wont be any problem in

respect to atm controlling it,But according to plc it cant

control mutiple functions.In case of any
the output of the transmitter is 12ma problem,the entire process which it controls
gets affected.i thnk like ths......it may be
without any process connection the output
wrong
is 4ma

Question Can anyone explain in a

simple way the difference between Question what is intools software

DCS and PLC?

Answer Intools is the popular Software
Answer number of I/Os is high in DCS
in industries used for the process control
compare than PLC
using Graphics & is Nothing but the SCADA
software
Answer These question is very difficult
in todays Automation system, Because
Answer The INtools is the
Today's PLC is much more upgraded &
instrumentation design and engineering
software.It suite includes integrated modules Answer the density is wrong. It must
for instrument indexes, specifications, be specific gravity 0.9.range is specificgravity
process data, calculation, wiring, loop x hight in inches ( the answer is in inches of
drawings, hook-ups, calibration and water column) the range varies from 0 to
maintenance... 300*0.9/2.54 " w.c

Question what is the best method to Answer 3000 mm * .9 = 2700 mmwc

measuring level in high pressure
Question what r all the type of
and temperture thank? viberation measurement measuring in

Answer In a tank with high Pressure turbin? what's the output of viberation
and high temperature the best suited liquid sensor?
level measurement technique is using a DPT.
Answer proximeter type based on
But in this case density compensation is a
eddy current principal and its o/p in milli
must. Because
volts.
with the increase of Temperature and
Answer The answer No 1 given by
pressure in a closed tank, the density varies
Mr.Amit is absolutely correct. You may need
for every liquid.For level measurement of
some more details.The vibration sensors
solids in tanks with high pressure and
used in turbine, generator etc are all same
temperature the best way of level
type i.e proximity type of sensors. The
measurement is using a ultrasonic level
sensor are mounted at the proximity of the
transmitter. Though in case of solids,
Turbine and generator rotor.
temperature and pressure does not hamper
much in the readings. From the sensors one coaxial cable runs to
the proximiter,which is mounted in a
Answer RADAR Type Also Ok
seperate JB nearby. From TSI Monitors,this
Question calculate the rane of level use Vibration probes gets +24 Volts DC. The
of this values, h=3 meter proximeter gives a signal 0 to -22.4 Volts DC
depending upon the vibration measured by
density=0.9 , whats the rang?
the sensor. Generally the diatance between
the probe tip and the rotor is maintained
such that it gives -10 Volts DC when the Answer As the Generator output
turbine is not running. frequency remains constant usually 50Hz, so
we have to control the speed of the turbine
The sensor works on eddy current principle.
in constant speed. Govorner takes the signal
As the rotor vibration increases, the eddy
from Magnetic
current generation remains contant, but the
absorption of power in terms of eddy Pickup Unit (MPU) and operates the
current increaes. This loss of power is sensed govorning valve so that the turbine rotates in
by the proximeter and DC voltage signal is constant speed.
transmitter to TSI monitor for Measurement,
The magnetic pickup unit is mounted on
Controlling & Indication purpose.
turbine front, facing the gears of the gear
Question what r all the closed loop wheel. Generally there remains 2 or 3 nos of
used in boiler? sensors which measure the speed
simultaneously. As the turbine rotor rotates,
Answer drum level control system,
the number of gear teeth cutting by the
Master pressure control system, de aerator
sensor increases. This is counted at the
level control system r imp closed loops
sensor itself. According to this the sensor

Answer The following are the closed sends an mA signal to the govorner. And thus

loops used in boiler... with respect to this, the govorner takes

action to open or close the Govorning valve
1) Three Element Drum Level Control to regulate the flow of steam entering into
turbine.
2) Super Heater Steam Temperature Control

Question THE OUTPUT OF A CURRRENT

3) Deaerator Level Control
TRANSMITTER OR A PNEUMATIC
4) Deaerator Pressure Control
TRANSMITTER HAS A LIVE ZERO?EXPLAIN
5) Soot Blower Pressure Control

Answer ANSWER SHOULD BE IN 5

6) Soot Blower Temperature Control
LINES
Question what u mean by speed
control in turbin? how it was working?
Answer 3 psi & 4mA is termed as live for a specific application and it controls
zero Because they will indicate 0 . through its IO blocks.DCS covers a wider
aspect and it gathers information form many
PLCs and perform operations as per the

Question what is the difference Machine Operator instructions.

between PLC & DCS

Answer DCS consist many PLC or other

Answer PLC-- PROGRAMMABLE LOGIC control device. Means PLC is sub part of DCS.

CONTROLLER DCS--DIGITAL CONTROL

SYSTEM
Answer PLC - is programmable logic
BOTH ARE USED IN field AUTOMATION BUT
controller DCS - Distributed control system
MAINLY DIFFER IN THEIR APPLICATION.........
The main difference between the two is
Answer PLC can control only one
there size i.e. in market PLC is available in
system at a time where as DCS can control
wide range of size from few IO's to as large
multisystem at a time DCS has its own
as you require,DCS is not.PLC was earlier
database while PLC does not. it has to use
used to control sequential operation
SCADA or MMI. scan time for PLC is less than
only,whereas the DCS was for loop
10ms where as scan time for DCS is less than
control.Scanning time of PLC is very fast then
100ms.
that of DCS so where the fast control is

Answer Number input/output(Field required the PLC is preffered as in grid

tags) quantity can be used in DCS are control system.DCS comes with its graphis

high.but Plc it does not. system where as in PLC additional MMI

softwere is require.

Answer less weight,storage high

Answer plc is mainly used for on-off
control dcs is used for distributed cotrol or Answer PLC- it is a sequential control

continuous control system.where as DCS- it is a closed loop

control system.
Answer PLC is Programmable Logic
Controller DCS is Distributed Control System Question dear friends pls tell me how

PLC is just a monitoring/controlling device temperature compensations are

done in bourdoun tube of pressure guages 4.open the vent caps of both HP and LP
leadlines near the rootvalves.
Answer Compensation is achieved by
inserting a bimetallic bar into 5.fill the lead lines completely with water.

the linkage between elastic element and the 6.obviously LP side , more pressure acts and
gauge movement. current goes below 4mA. So elevate the Zero
Potentiometer to 4 mA(this is for analog
standard dp transmitter).

Question tell me about Woodward505

7.first of all you have to calibrate the dp
Function as a point of Instrument Engineer.
transmitter for the required range, then only
Answer woodward 505 best governer
you can do this elevation zero checking.
to control only inlet steam to the to turbine
Answer close the hp and lp valve and
woodward 505E for control inlet steam and
drain the water then open the vent valve it
extractions of steam turbine
should show the zero value.

Answer WOODWARD 505 IS

Question what is watch dog in PLC
BASICALLY SPEED CONTROLLER FOR
Answer A timer that monitors how
TURBINE. SENSE INPUT FROM SPEED
long it takes the CPU to complete a scan.
SENSOR, COMPARES IT WITH SETPOINT AND
Watchdog timers output an error message if
GENERATES THE OUTPUT WHICH OPERATES
the CPU scan takes too long.
THE STEAM CONTROL VALVE.
Answer watch dog is the timer used
Question How can we check Zero of DP
for measuring scan time of cpu.If scan time is
type Level Transmitter onside?
more PLC will not give required result.Scan

Answer 1.close the both HP and LP time increases due to much rungs in ladder

rootvalves diagram

2.open the both HP and LP drain valves to Answer A timer that monitors how

drain the service completely. long it takes the CPU to complete a scan.It
output an error message if the CPU scan
3.Close the drain valves. takes long.
Answer it watches the timing of the Answer We can use 0-10 volt also for
scan cycle(fetch, decode and execute)of the signal. But while signal transmission voltage
cpu, if it is out of the predefined time limit it drop will occur on lead wires. Also voltage
give the error message,, will have noise due to this we may loose
signals at receiving end. To overcome this we
are using current (4-20mA) for signals.

Question Which standard is used for

Question What is the difference calibration of Control Valves ?

between Pressure Safety Valve and Pressure

Answer 0.2 to 1 bar or 3 to 15 psi
Relieve Valve, in what condition we prefer
choose Pressure Safety Valve rather than Answer 0.2 bar - 0%, 0.4 - 25 %, 0.6 -
Pressure Relieve Valve? 50 %, 0.8 - 75% and 1bar - 100%

Answer pressure safety valve is Question how to calibrate ph meter?

automatic relieves the static pressure on a
gas..usually it opens completelly ..while relief Answer ph meters are calibrated using
valve relieve the static pressure in a liquid buffer solutins which are at known ph levels.
filled ,its opens proportionally with Make sure the probe is cleaned before
increasing pressure...PSV is used in case of imerging it in the solutions.
gas and PRV is used in liquid.
Answer YOU CAN CALIBRATE IN THREE
Question Why 4-20mA SIGNAL IS PHASE 4/7/9 PH BUFFER SOLUTION
PREFERRED OVEA A 0-10v signal?
NORMALLY WE ARE CALIBRATING WITH 4 &
Answer Generally in a transistor some 9 PH BUFFER THAT MEAN 4PH--4MA/9PH--
amount of voltage is required for turning it 20
on. This voltage is the cut in voltage. Up to
this voltage the exists a nonlinearity in its Answer the Ph calibration is done by

characteristics. Beyond this cut in voltage the using the buffer solutions,with the one

char. of transistor is linear. This nonlinear probe i,e the reference electrode and the

region lays between 0-4ma, beyond 4ma it measurement electrode ,,,,,,,,,,,,,

linear. This is why 4-20 ma range is used.

Question Tell me about the controllers are mounted in the AHU's. All the
synchronization panel. controllers are linked with one anoter. While
sensing devices such as temprature and
Answer First Know the
humidity sensors are connected to each
Synchronization.We have to check 4
specific controller. Main panel is attached
parameter in sequence listed below.
with a computer.Then all the controllers are

1. Phase Secquence.(this has to be 1 programmed and their parameters can be

time.basicly this is the rotation of the phase.) viewed by the computer attached to the
main panel.
2.Voltage has to be equal.(but in practical
case votlage difference not more than 2%) Answer no BMS mean burner
managment system specially this system
3.Frequency has to be equal .(but in practical using in boiler & furnace
case Frequency difference not more than
2%) Question what will be the output of a
temperature transmitter if temperature is
4.Phase angel difference must be zero(but in 120 degree celcius?
practical case phase angel difference not
more than 7*) Answer Hi mydear friend,Transmitter
output depends on the transmitter
so we required in Synchronization Panel.2 calibrated range.With out knowing the
volt meter,2 frequency meter,Phase angel transmitter calibrated range diffucalty to tell
check Relay(CSQ) the output of the transmitter.If u calibrated
the transmitter 0-120deg.The transmitter
in case you dont have the csq you can use
ouput will be 20ma at actual temp 120 deg.If
the dark lamp mathod.
u calibrated the transmitter 0-480deg,the
Question What is BMS (Building transmitter ouput will be 8ma at 120deg
Managment System)& is AHU / HVAC are actual temp.

in BMS. Answer The above ans it correct but it

will not be 20mA , it should be 16 mA.
Answer It contains two types of
controllers one is the main usually mounted
in the plant room while other sub main
Answer Lenin answer is correct. It will used for linearty and according to ohms law
be 20mA when the transmitter is calibrated to covert 1 to 5 volt dc,
to 0 - 120 DeG C
Question What is the Difference
Answer lenin answer is 100correct. between E/P Positioner and I/P

Question WHY WE NOT USE 2-20mA,1- positioner in a control valve?

20mA,3-20mA or 10-50mA SIGNAL?
Answer My understanding that the IP
INSTEAD OF 4-20mA. positioner would be that you are using a
current signal (I) and converting it to a
Answer because 4-20ma is a linear
pressure signal (P) in order to operate a
range compared to other ranges
positioner valve. I would call the signal

Answer Generally in a transistor some conditioner in this case an I to P converter.I

amount of voltage is required for turning it am not so sure about EP, but E can be used

on. This voltage is the cut in voltage. Up to to mean EMF

this voltage the exists a nonlinearity in its

which is measured in volts and so could ve
characteristics. Beyond this cut in voltage the
voltage to pressure signal conditioner in the
char. of transistor is linear. This nonlinear
same way as I to P in the example above.
region lays between 0-4ma, beyond 4ma it
linear. This is why 4-20 ma range is used. Answer Basically both are same. Here
letter I stands for Current & E stands for
Electric signal which is nothing but current

Answer I am not sure why the range of signal to operate control valve. It's all

16mA i.e 20 - 4, but the 4mA starting is so depends on legends we are going to use in a

that you have a posative value of current for particuler project.

all values that the loop current represents.

Answer I/p convertors converts a
This way, if you have no current at all, the
current input signal for eg. 4-20 ma to
loop is open circuit for some reason.
pneumatic siganl which controls the opening

Answer starting with 4ma is to know and closing of a control valve and e/p have

DEAD or LIVE of the transmitter,4 to 20 is simmiliar operations as those of i/p but it

can be either a voltage input based or Answer DDC MIS stands for Digital
current input based. Distributed control Monitoring and
Information System.The name itself is self
Answer i/p is a converter and e/p is a
explanatory.Generally used in Power Plants
positioner
Controls and Instrumentation.

0 Xyz
Answer earlier answer was just the full

Answer E/P is combination of I/P & form.digitally distributed control and

positioner i.e. the o/p pf E/P is directaly monitoring information system used in

given to the valve actuator.And in the case of thermal pwer plants to centrally control all

I/p 4-20ma is given to it & output of I/P is the functions without going to the location.

given to the positioner .

Question Which instrument used to

Answer I to p means input signal is 4- calibrate the pressure switch?

20MA E to p means input signal is 0 to 10

Answer pressure calibrator[druke]
VDC

Answer The "E/P" elector-pneumatic

positioner is used for operation of pneumatic Answer pressure calibrator or dead
rotary valve actuators by means of weight tester
electroller or control systems with an analog
Answer Answer 1 and 2 is absolutely
output signal of "DC4 to 20mA" or split
right .another way is to use comparison
ranges. I/P not sure yet.
tester.
Answer Basically both are same &
Answer druke and multimeter
there is no difference at all between
them.Both are used for controlling C valve. Question HELLO FRIENDS PLZ EXPLAINE
4-20mA input to the I/P (E/P) converter ME WHAT IS ORIFICE?AND HOW WE
converts the current signal to 3-15 psi which
either goes directly to CV actuator or thro ARE USING IT IN INSTRUMENTATION

positioner with or without booster(1:1 or

Answer orifice is nothing but a plate
1:2).
having hole at the centre.when it is placed

Question What is DDC-MIS? across a flow line a differential pressure is

created across the orifice due the diff. in the Question I want to measure
dia of orifice and pipe line.this diff pressure bidirectional steam flow? Kindly suggest
is directly proportional to the flow of the
me a suitable flow meter. steam is
liquid.this differential pressure is given to
superheated at 41kg/cm2,
the differential pressure transmitter.

350°C
Answer orifice is variable restriction
flow meter,it has two tapings befor Answer bi-directional Averaging Pitot
restriction and after restriction connect to Tube,Transit Time Ultrasonic Flow Meters.
differntial manometer this pressure head is
propotional to the flow rate,it is based on Question what is meant by calibration

bernuolis law and continutiy equation.

Answer the process of measuring the
Answer orifice is a used as a primary
response of an instrument to a particular
element for flow measurement.the
input and correcting the response to a
differential pressure created by the orifice is
predetermined value and repeating this in
propotional to the flow rate.it is very cheap
increasing and decreasing orders throughout
and easy to install
the range of the physical parameter to be

Answer oriface plate can be used a measured is called calibration.

primary sensing element for differential

Answer Calibration is matching of the
pressure transmitters.basic principle is to
standard value of instrumentation. Which
make restrictions in flow to obtain
gives Instrument society of America (ISA) in
differential pressure.which will be directly
1968. Or matching of the value of master
proposional to the flow rate.
(True) Instrument. 4 mA to 20 mA 3 PSI to 15

Question What is SLPC & MLPC? How it PSI, 0 % to 100 % etc.

works?
Question what are the levels of

Answer slpc is single line process automation?

controller mlpc is multi line process

Answer ...Unit Level
controller
Group control level(GC)
 subgroup control(SC) 2. RTD - Resistance Temperature Detector for
temperature measurement upto 600°C.
Question 1. How many output signals
do we have in process control? 3. O/P signal for pneumatic transmitter is
pneumatic signal 3 - 15 psi
2. Could you write down the names of the
pre-commissioning 4. O/P signal for electronic transmitter is
electrical signal 4 - 20 mA, 1 - 5 volt.
and commissioning stage test instruments
and explain them 5. Close loop having sensor, transmitter,
controller, and controlling element (like
(more than 5 items)?
control valve, on off valve, damper, servo

3. What is the first step to commission a motor). Open loop does not have controlling

transmitter on element. open loop is used for only

indication in control system.
service?
Answer 4. o/p signal of electronic
4. What is RTD? transmitter is 4-20 mA and 1-10 mV dc

5. Find the output value in MA of a Answer Answer of Ques No.5))

temperature transmitter Transmitter(Tx) o/p depends on calibration
range. If the Tx is calibrated in the range 0-
(RTD Type) at 120degree celius?
120degC. Then it will show 20ma when the
6. What is the O/P signal of a pneumatic actual temperature would be 120degC.
transmitter?
Question what is the diffrence between
7. What is the O/P signal of an elctronic mmwc and kg/cm2 for pressure
transmitter?
measurment when we are using mmwc and
8. What is the close loop and open loon? when kg/cm2 and why?

?? what is the reason

Answer 1. Two output signals are used
in process control - analogue and digital. Answer when we r measuring very low
pressure :: mmWC and measuring high pr.
:: kg/cm2/bar/psi... ok for example we r
measuring like boiler furnaces Answer why we require a 4-20 mamp
pressure(draft) i.e very low pr.(250mmWC) for transmission? the main reason behind it
so we r measuring in mmWC, and when we r because of electro magnetic interference the
calibrating the transmitters (flow voltage can get interfered very easily and we
can't get our desired o/p value.when we are
and level) that time also we r calling
using 4-20 mamp this problem is solved but
transmitters range also mmWC ok here note
since, PLC is a digital device it can
the point is 10,000 mmWC = 1 Kg/cm2 then
understand mainly High=5V or low so we

1mmwc=0.0001kg/cm2 ok design the sink to have a resistance as high

to get the desired voltage, the 4 mamp is
Answer 10000 mmwc equals to 1 also helpful to power the electronics at the
kg/cm2.For low ranges pressure is transmitter end. to have a 4-20 mv instead
mentioned in MMWC otherwise in any other can firstly : cause em interference and
pressure units. secondly we need to have a continuous level
monitoring for different voltages...which can
Question if the t/c o/p is 4-20mv then
increase the size of PLC . Also because of
how plc recognize it
change of impedance at the transmission
because we are dealing with the 4-20ma in line the voltage can drop below 4 volt
the ocassionaly then loop powering of field
instrument will not be possible.
plc ???
Answer There will be a Convector for
Answer we will convert mV in to the
mv to ma what ever the temperature Sens
ma....by connecting resistance
by the t/c that will convert to the ma and

in parallel signal goes to DCS.

Answer standard thermocouple Answer Voltage to current converter

output is 0 to 10 mV. There will be 4-20MA using op-amp

converter either in DCS in the

Answer There is different module in a
field(Transmitter)as the modules will accept
PLC . Out of which one is T/C module if you
only 4-20 MA output.
connect the o/p of T/C directly to this
module of PLC , then the PLC will recognise
it. T/C module is not inbuilt we have to select responselag compasator is suitable for
it seperately. There are many modules like systems having unsatisfactory transisnt
this such as RTD module, 0-10 volt module response but it provides only a limited
etc. improvment in steady state response.lead
lag compensator is used in unstable system
Question Describe all types and levels
to convert the stable system .
(4-20mA, 0-10V, mV, pulse, etc.)of analog
and digital I/O used in process control Answer A lead-lag compensator is a
application. component in a control system that
improves undesirable frequency response in
Answer all types and levels are 4-
a feedback and control system. It is a
20ma and 0-10mv v pule etc because in
fundamental building block in
industries somthing we assume in 0mA so
the control room is not understand outbut classical control theory. We are using it in
on the panel is not display so any signal are varied discipline such as robotics, satellite
come in panel and out put is uderstand so control, automobile diagnostics, laser
4ma any signal and it understand this frequency stabilization and many more. It
procees is any problem .so analo and digital can also be used in digital control.
I/O used in process controle application are
Question Give me best instrumentation
levels 4-20mA and 0-10v,mV
Books name..Ple...
Answer 4-20 mA is used to
Answer Instrumentation Engineering
discriminate between process 0 and
by A.K Shaney
instrument 0.

Answer HANDBOOK OF INSTRUMENTS

ENGINEERS BY B.G LIPTAK
Question what is lead lag compensator
Answer Handbook of instrument
and for wat v using that???
Engineering by Bela G Liptak
Answer THe lead compasator is
suitable for systems having unsatisfactory
transient response but it provides only a
limited improvment in steady state
Question Why Boiler Drum level 3.Individual.
transmitter (TX) or level transmitter rang
This Type ensures smooth communication of
always put -600 to 0 other -900 to 0. Mines
very Low level signal from transmitter to
range why use….?
control room & also effectively Cut the cross
Answer In boiler Drum level communication & noise.Back to Questions
transmitter or level transmitter range always Page
put -600 to 0 other -900 to 0.Because the
Question if the t/c o/p is 4-20mv then
pressur of LP side is always high aginst
how plc recognize it
pressure of the HP side in closed tank.

because we are dealing with the 4-20ma in

Question what r the different types of
the
instrumentation cables? give

plc ???
their specification?

Answer we will convert mV in to the

Answer Instrumentation cables such
ma....by connecting resistance
as Pair,Tried,Individual etc.All made up of
Aluminium polyester tape and ATC drain in parallel
having Tin-copper bridging, these wires are
available in armoured as well as unarmoured Answer standard thermocouple

cables. These Cables facilitate smooth output is 0 to 10 mV. There will be 4-20MA

communication of Low Level Signal from converter either in DCS in the

Electronics transmitters. field(Transmitter)as the modules will accept

only 4-20 MA output.
Answer IN Industry Instrumentation
Cables faciliate Smooth Communication Low Answer why we require a 4-20 mamp

Level Signal from Electronic for transmission? the main reason behind it

Transmitters.Hence they are speciliasied and because of electro magnetic interference the

the specificiation are voltage can get interfered very easily and we
can't get our desired o/p value.when we are
1.Triad using 4-20 mamp this problem is solved but
since, PLC is a digital device it can
2.Pair
understand mainly High=5V or low so we
design the sink to have a resistance as high etc.)of analog and digital I/O used in
to get the desired voltage, the 4 mamp is process control
also helpful to power the electronics at the
application.
transmitter end. to have a 4-20 mv instead
can firstly : cause em interference and Answer all types and levels are 4-
secondly we need to have a continuous level 20ma and 0-10mv v pule etc because in
monitoring for different voltages...which can industries somthing we assume in 0mA so
increase the size of PLC . Also because of the control room is not understand outbut
change of impedance at the transmission on the panel is not display so any signal are
line the voltage can drop below 4 volt come in panel and out put is uderstand so
ocassionaly then loop powering of field 4ma any signal and it understand this
instrument will not be possible. procees is any problem .so analo and digital
I/O used in process controle application are
Answer There will be a Convector for
levels 4-20mA and 0-10v,mV
mv to ma what ever the temperature Sens
by the t/c that will convert to the ma and Answer 4-20 mA is used to
signal goes to DCS. discriminate between process 0 and
instrument 0.
Answer Voltage to current converter
using op-amp Question what is lead lag compensator
and for wat v using that???
Answer There is different module in a
PLC . Out of which one is T/C module if you Answer THe lead compasator is
connect the o/p of T/C directly to this suitable for systems having unsatisfactory
module of PLC , then the PLC will recognise transient response but it provides only a
it. limited improvment in steady state response
lag compasator is suitable for systems having
T/C module is not inbuilt we have to select it
unsatisfactory transisnt response but it
seperately. There are many modules like this
provides only a limited improvment in steady
such as RTD module, 0-10 volt module etc.
state response.lead lag compensator is used
Question Describe all types and levels in unstable system to convert the stable
(4-20mA, 0-10V, mV, pulse, system .
Answer A lead-lag compensator is a Answer In boiler Drum level
component in a control system that transmitter or level transmitter range always
improves undesirable frequency response in put -600 to 0 other -900 to 0.Because the
a feedback and control system. It is a pressur of LP side is always high aginst
fundamental building block in classical pressure of the HP side in closed tank.
control theory. We are using it in varied
Question what r the different types of
discipline such as robotics,satellite control,
instrumentation cables? give their
automobile diagnostics, laser frequency
specification?
stabilization and many more. It can also be
used in digital control. Answer Instrumentation cables such
as Pair,Tried,Individual etc.All made up of
Question Give me best instrumentation
Aluminium polyester tape and ATC drain
Books name..Ple...
having Tin-copper bridging, these wires are
Answer Instrumentation Engineering available in armoured as well as unarmoured
by A.K Shaney cables. These Cables facilitate smooth
communication of Low Level Signal from
Electronics transmitters.

Answer IN Industry Instrumentation

Answer HANDBOOK OF INSTRUMENTS Cables faciliate Smooth Communication Low

ENGINEERS BY B.G LIPTAK Level Signal from Electronic

Transmitters.Hence they are speciliasied and
Answer Handbook of instrument the specificiation are
Engineering by Bela G Liptak
1.Triad
Question Why Boiler Drum level
transmitter (TX) or level transmitter 2.Pair

rang always put -600 to 0 other -900 to 0. 3.Individual.

Mines range why

This Type ensures smooth communication of

use….? very Low level signal from transmitter to

control room & also effectively Cut the cross
communication & noise.
*** after operat one sov to dicharge water after
high level.
Question what do we mean by hook up
drawing. what r the information we Answer TAKE TWO TAPINGS, ONE AT
5CM (HP SIDE)ONE AT 75 CM (LP SIDE). NOW
get from it?
CONNECT THE DPT AS PER HP AND LP

Answer hook-up drgs provides CONNECTION AND IN Tx. ALSO DEFINED THE

detialed information about how to install an LSV AND USV IN Tx. IT WILL GIVE U 4 MA AT

instrument in proper manner..it also includes 5 CM AND 20MA AT 75 CM OF THE TANK

the details of Bill Of Materials..It is necessary LEVEL.NOW THE SAME THING U CAN DO

document for project engineering as well as FOR THE COMP. MOISTURE LEVEL. TO

maintenance dpt.. OPERATE SOV U HAVE TO USE THE ANALOG

SIGNAL COMING FROM DPT AND WITH USE
Answer hook up drawing is refrence or OF THIS U HAVE TO GENERATE A DO
information engineering installation also COMMAND (24V). THIS COMMAND WILL
specification the equipment to be install. DIRECTLY GO TO SOV(24 V) WHEN LEVEL IS
HIGH.SUPPOSE DPT TAG IS (PI01)SET PI01.HH
Answer HOOK UP DRAWINGS: The
AT 75 CM.. AND USE THIS SIGNAL TO
process has hook up(transfer) or arrested
GENERATE THE DO FOR SOV USING A
into field instruments is called as hook
SWITCH LOGIC IN DCS
up.there are different types of hook up
depends upon the fluid properties. Question How will u convert the
mmh2o in mass or Volumetic flow rate
From the hook up drawing shows that How
to install the tubings in the process pipe line in DP Flow Transmitter.
to instruments, Bill of Quantity, Material
specification....all the detail information Answer Follow this link and open the

about the hook up including slops. calculator after downloading it.you will get
ready made flow calculator for that .You just
Question i have 80cm water tank.how have to put input pressure ,Differnatial
can i use DPT as level mesurment.pls give pressure ,fluid viscocity and other data and
specs for that..?We have air comp.from that calculator will give you the flow at that DP
moisture comeout to one tank.i want to Pressure....http://www.flowmeterdirectory.c
mesure level of water in that tank and then om/flowmeter_orif
Question what is the difference It also isolates the dcs panel from feild
between servo valve & proportional valve? control panel..

Answer A servomechanism, usually

shortened to just servo, is a device used to
provide mechanical control at a distance.A
Answer in addition to maulik points 3.
servo can be used at a remote location to
marshalling cabinets location-- if located
proportionally follow the angular position of
exactly will
a control knob. The connection between the
two is not mechanical, but electrical or save much cable cost and easy for
wireless.Servos are commonly electrical or maintenance people to trace out cable
partially electronic in nature, using an routing and fault finding
electric motor as the primary means of
Answer Marshalling means grouping
creating mechanical force, though other
of I/Os. Marshalling panel is placed between
types that use hydraulics, pneumatics or
the DCS system panel and field instruments.
magnetic principles are available. A
In marshalling panel grouping of I/Os like
proportioning valve is a valve that relies on
Analog Input, Analog Output, Digital Input,
the laws of fluid pressure to distribute input
Digital Output and Pulse I/O are done.From
forces to one or more output lines. A
marshalling panel the I/O signals are
proportioning valve can increase or decrease
communicated to the system
forces for each output, depending on the
CPU/Controllers through Isolation/Signal
cross-sectional surface areas of those output
conditioners.In marshalling panel we can
lines.
easily identify the Input or Output and easy
diagnosis can be done in case of fault
finding.
Question why we are using
MARSHALLING PANEL? what is the role? Question What is the diffirence
between Earth and Neutral and What is the

Answer marshalling panels are used as required normal voltage between earth and

interface between field junction box & dcs neutral?

control panel..
Answer jasmeet is true but in case of Question what is meant by calibration
sensitivity like PLC application, this
diffetrence MUST be less then 0.3V Answer Calibration means a
comparison of two certain components
Answer through earth current goes to
between the standard and the components
earth, but through neutralv current goes to
to be calibrated.
neutral point of supplier. voltage diff. is zero

Answer It is the process for

Answer A little more clarification in
determination by measurement or
Prahlads answer:While 'earth' is the
comparison with standard
universal ground, 'neutral' is the local ground
of a circuit or a loop.Secondly, 'neutral' Answer calibration means it is a
completes the circuit whereas 'earth' process of making the instrument gives the
predefined value.
is not meant for this.

Answer The voltage difference should

be idealy zero but practically it depends Answer it is the comparison of two
upon application. Normally it should not be components from which the primary is your
more than 5 Volts. standard (which is traceable to NATIONAL
INSTITUTE OF STANDARD AND
Answer Means group of neutral is
TECHNOLOGY) and your secondary
ground but not group of ground is neutral
component is the one to be calibrated.
Question what is the diffirence
Answer calibration is process in which
between Earth and Neutral?
we compare the operational element with
Answer Earth is a search current for the standard element.
dissipation Neutral is the reference point for
Answer The procedure laid down or
current also the return path for current
checking the absolute values on a measuring
Answer One more...Neutral is not instruments is called Calibration .
supposed to carry any current or
"&#2980;&#3007;&#2992;&#3009;&#2997;
voltage.Earth wire will carry current, voltage
&#3016;&#2991;&#3006;&#2993;&#3009;" -
in case of short circuit.
&#2997;&#3007;&#2965;&#3021;&#2985;& Answer Calibration is when you check
#3015;&#2999;&#3021; or modify the scale or instrument. As well as
&#2965;&#3009;&#2990;&#3006;&#2992;& in calibration you compare of two quantities
#3021; from which the primary is your standard and
your secondary piece is the one to be
0 &2997;&3007;&29
calibrated.

Answer The procedure laid down or

Question what is Micro-switch and
checking the absolute values on a measuring
where it is used......?
instruments is called Calibration
"&#2980;&#3007;&#2992;&#3009;&#2997; Answer Micro switch is a switch which
&#3016;&#2991;&#3006;&#2993;&#3009;" - change the contacts if the mechanical input
is given. there is no need of external power
&#2997;&#3007;&#2965;&#3021;&#2985;&
supply.
#3015;&#2999;&#3021;
&#2965;&#3009;&#2990;&#3006;&#2992;& Answer A micro switch is a generic
#3021; term used to refer to an electric switch that
is able to be actuated by very little physical
0 Tyrkrv83
force, through the use of a tipping-point

Answer in callibration primary mechanism.

standard is compared with another working

Question Is there devices to convert
standard
mechanical energy/rotational

Answer calibration is a technique

energy into electrical energy.......?
which a other(reference) instrument like txt
which are compared to std instrument or a Answer piezoelectric crystals convert
master piece mechanical energy(eg:pressure)to voltage..

Answer i would like to add up the Answer generator which converts

measured value with true value mechanical energy into electrical energy...

Answer tends to standard value is Answer windmill

called calibration
Answer tachometer
Question hi i'm an Instrumentation dealing mainly with field instrumentsand
student,i have one doubt that we their installation and maintenance.

can call- Question thermocouple output is AC

OR DC??
> computer science as CS
Answer thermocouple output is
> Information science as IS
mvDC..

> Electronics & communication as E & C

Answer thermocouple output is in MV

In the same way what is short term for which is in DC.

Instrumentation....?
Answer Out put is Mv and its DC

Answer instru.....
Answer its output is mV DC

simply..
Answer t/c o/p is dc and range is mv

Answer The short form of the

INSTRUMENTATION is IN

Answer In all companies we use INST

as short for instrumentation. Answer dc 33

Answer You can vry well E&I

Answer probably you will be called as

I&C Engr or C&I Engr in future

Answer I&C = Instrumentation and

Control, Instrumenation fielddealing mainly
with control systems such as PLC and
DCS,Programming, Etc.

I&E = Instrumentation and

Electronics/Electrical,Instrumentation field