INDEX

 001 instrument…

 002 instrument short names…

 003 instrument symbols…

 004 safety…

 005 multimeter…

 006 relay & contactor…

 007 twowire & four wire transmitter system…

 008 temperature…

 009 pressure…

 0010 level…

 0011 flow…

 0012 I to p converter…

 0013 control valve…

 0014 loop diagram,safety barrier and loop checking…

 0015 HART communicator…

 0016 interview questions for process control instruments…

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 001 instrument

---: INSTRUMENT :---

1. What is instrument ? (v.imp)

 Measurement.
 Monitoring.
 Controlling.
 Display.

Defination :- instrument is a device which is used for measurement, monitoring, controlling &
display of process variables.

2. What is instrumentation ?
 Instrumentation is a branch of engineering which deals with Measurement, Monitoring, Controlling
& Display of process variables.

 Process ( of oil and gas)..

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 001 instrument

3. What are the process variable ? (v.v.imp)

 Temperature.
 Pressure.
 Level.
 Flow.

 Process variables and their units

 Temperature : - “ it is to be measure hotness and coldness of process medium. ”

Units of temperature :-

Degree Celsius ( 0C )

0
Degree Fahrenheit ( f )

Degree Kelvin ( 0K )

Degree Rankin ( 0R )

 Pressure :- “ force acting per unit area. ”

Units of high Pressure :- kg/cm2

Bar

PSI (pounds per square inch)

Units of low Pressure :- pascal (kpa = killo pascal )

mm h2o

mm Hg

Inch h2o

Inch Hg

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 001 instrument

 Level :- “ difference between two heights of liquid in tank or vessel. ”

Units of level :- percentage (0 to 100%)

Meter

Feet

Inch

Cm

 Flow :- “ quantity of gas or liquid moving through pipeline with in standard time is in
minutes or hour. ”

Units of liquid Flow :- Litre per minute (LPM).

Litre per hour (LPH).

Gallons per minute (GPM).

Gallons per hour (GPH).

Barrel per day (BPD). (1 Barrel === 158.98 Liter)

Units of GAS and AIR Flow :- m3min (meter cube per minute).

M3hour (meter cube per hour).

CFM (cubic feet per minute).

CFH (cubic feet per hour).

Units of steam Flow :- Kg/min.

Kg/hour.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 002 instrument short names

---: INSTRUMENT SHORT NAMES :---

1. ISA = Instrument society of america.

2. DCS = Distributed control system.
3. PLC = Programmable logic controller.
4. SCADA = supervisory control and data acquisition.
5. HMI = Human machine interface.
6. HART = Highway addressable remote transducer.
7. LRV = Lower range value.
8. URV = Upper range value.
9. I/P = I to P converter.
10. FF = fundation field bus.
11. Profibus = process field bus.
12. ILD = Instrument loop diagram.
13. P & ID = Piping & Instrument diagram.
14. IP = Ingress protection.
15. AI = Analog Input.
16. AO = Analog output.
17. DI = Digital Input.
18. DO = Digital output.
19. I/O = Input output.
20. ESD = emergency short down.
21. PPE = Personal protective equipment.
22. SCBA = Self containing breathing apparatus.
23. TT = Temperature transmitter.
24. PT = Pressure transmitter.
25. LT = Level transmitter.
26. FT = Flow transmitter.
27. DPT = differential pressure transmitter.
28. TIC = Temperature indicating controller.
29. PIC = Pressure indicating controller.
30. LIC = Level indicating controller.
31. FIC = Flow indicating controller.
32. TCV (TV) = Temperature control valve.
33. PCV (PV) = Pressure control valve.
34. LCV (LV) = Level control valve.
35. FCV (FV) = Flow control valve.
36. TE = Temperature element.
37. RTD = Resistance Temperature detector.
38. T/C = thermocouple.
39. FE = Flow element.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 002 instrument short names

40. TW = Thermowell.
41. C/V = Control valve.
42. CV = Coefficient value.
43. AS = Air supply.
44. FC = Fail to close.
45. FO = Fail to open.
46. SOV = Solenoid valve.
47. SDV = Short down valve.
48. PSV = pressure safety valve.
49. MOV = Motor operated valve.
50. LSC = Limit switch close.
51. LSO = Limit switch open.
52. TY = I to P used for Temperature control valve.
53. mmwc = milli metter of water coloumn.
54. PSI = Pounds per square inch.
55. PV = Process valve.
56. SP = Set point.
57. PTW = Permit to work.
58. PID = Proportional + integral + derivative.
59. FBM = Field bus module.
60. PG = Pressure Gauge.
61. LG = Level Gauge.
62. TG = Temperature Gauge.
63. JB = Junction box.
64. TB = Terminal block.
65. ZB = Zener Barrier.
66. TAH = Temperature alarm high.
67. TAHH = Temperature alarm high high.
68. TAL = Temperature alarm low.
69. TALL = Temperature alarm low low.
70. NPT = National pipe thread.
71. BSPT = British standard pipe thread.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 003 instrument symbols

---: INSTRUMENT SYMBOLS :---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 003 instrument symbols

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 003 instrument symbols

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 003 instrument symbols

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 004 safety

---: SAFETY :---

 What is PPE ? OR What are the PPE?
 PPE is a personel protective equipment..
 Helmet.
 Safety shoes.
 Safety goggles.
 Ear plug (>80 db).
 Hand gloves.
 Mask.
 Cover all.

 What are the type of work permit?

1. Hot work permit.
2. Cold work permit.
3. Confined space entry permit.

HOT WORK PERMIT

“ The work which creates smoke,heat,spark and flame that work is called hot work. ”

EXAMPLE OF HOT WORK :- welding.

cutting .

drilling.

grinding.

COLD WORK PERMIT

“ The work which does not creates smoke, heat and flame but there is possibility
of creating spark that work is called cold work..”

EXAMPLE OF COLD WORK :- instrument instrallation.

field calibration.

loop cheking.

function test.

trouble shooting (fault finding).

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 004 safety

CONFIND SPACE ENTRYPERMIT

“ The space which having only one entry but there is no exist that space is
called Confined space. “

EXAMPLE OF CONFINED SPACE ENTRY :- Tank or vessel.

Well or sump.

Tower.

Inside Pipeline.

 What is hazardous area? Or Interinsically safe area?

 Hazardous area means it’s a danger area.oil and gas area is called hazardous area.where an
explosive gas is mixed with air in atmosphere.

 What is Zone? What are the types of Zone?

 Zone are used to define the pressence of explosive gas in atmosphere.

THERE ARE THREE TYPES OF ZONE

1. Zone 0 (Zone zero).
2. Zone 1 (Zone one).
3. Zone 2 (Zone two).

ZONE 0 :- an explosive gas mixed with air in atmosphere is continuosly presents . OR

Where there is explosive gas to atmosphere above 1000 Hrs. per year.

ZONE 1 :- an explosive gas mixed with air in atmosphere in normal condition . OR

Where there is explosive gas to atmosphere from 10 to 1000 Hrs. per year.

ZONE 2 :- an explosive gas mixed with air in atmosphere for short time. OR

Where there is explosive gas to atmosphere is less then 10 Hrs. per year.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 005 multimeter

---: MULTIMETER :---

 COMPANY :- Fluke, USA (normally used in gulf).

Rishabh max.
Mika.

UNITS OF MEASUREMENT:-

MEASUREMENT UNIT SYMBOL

 Voltage volt V
 Current ampere A,I
 Resistance ohm Ω
power walt w
Frequency Hertz Hz
capacitance ferade F

 What is multimeter?
 Multimeter is a device which is used to measure voltage(AC&DC),current(AC&DC),resistance,
milli ampere(mA), milli volt (mV), cable continuity.

 MULTI METER PROBE :-

RED PROBE

BLACK PROBE

Voltage is always measured in parallel.

Current is always measured in series.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 005 multimeter

AC VOLTAGE DC VOLTAGE

RED BLACK
N + L = 230 V AC
E + L = 230 V AC
N+E=0V

 HOW TO MEASURE VOLTAGE & CURRENT :-



 Voltage is always measured in parallel.

 Current is always measured in series.

FLUKE MULTIMETER

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 006 relay & contactor

---: RELAY :---

C = COMMON NO = NORMALLY OPEN NC = NORMALLY CLOSED

 WHAT IS RELAY?
 Relay is an electromechnical device.which is used to change over contacts from normally open(NO)
to normally close(NC) and normally close (NC)to normally open (NO)..

GENERALLY 24V DC RELAY IS USED

 HOW TO CHECK COIL OF RELAY,CONTACTOR AND SOV?
 Keep multimeter in resistance (Ω)mode..

If coil is ok ===== 150 Ω to 2000Ω

If coil is not ok ===== open (0L) & short (0Ω)..

SIMPLE CIRCUIT DIAGRAM USING RELAY WITH BULB

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 006 relay & contactor

---: CONTACTOR :---

SYMBOLE OF CONTACTOR

In industry normally used 24VDC & 230AC contactors

SIMPLE CIRCUIT DIAGRAM USING,RELAY & CONTACTOR AND MOTOR..

C = COMMON NO = NORMALLY OPEN NC = NORMALLY CLOSED

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 007 twowire & four wire transmitter system

---: TWO WIRE TRANSMITTER SYSTEM :---

 What is transmitter?
 Transmitter is a device which is used to measure process variables that is temperature, pressure,
level and flow..

STANDARD COMPANY :-

NAME OF COMPANY COUNTRY COLOUR OF INSTRUMENT

Emerson Usa Blue
Rosemount Usa Blue
Yokogawa Japan Dark green
Endress + Houser (E+ H) Switzerland Blue + White
Krohne Germany Dark blue
Foxboro Usa Grey
ABB Switzerland White
Siemens Germany Green

TO WIRE CIRCUIT DIAGRAM :-

 Transmitter supply voltage = 24 V DC (world wide)

 Transmitter output = 4 to 20 mA DC (world wide)

NOTE :-

 Generally all transmitter works on two wire transmitter system..

 Here transmitter supply voltage is 24V DC, so that it is applied to transmitter in parallel. transmitter
output is 4 to 20 mA DC that is current output and we know that current is always measured in
series.so from sbove circuit (-) to (-) line is standard servies line. So using multimeter in series we can
measure output is 4 to 20 mA DC and from this signal we can get process variable..

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 007 twowire & four wire transmitter system

Figure :--

INDICATOR ,DCS, PLC,& CONTROLLER ARE ALWAYS CONNECTED IN SERIES

 WHY 4 TO 20 mA DC SIGNAL IS USED FOR SIGNAL TRANSMITSSION?

0 to 20 mA

4 to 20 mA

IMP POINT NOTE:-

 Voltage will drop for long distance so that voltage signal will not used.
 Using 0 to 20 mA DC signal we can not differentiel that actual process value is zero or there is open
circuit .
 Liner graph we can get (4,8,12,16 and 20)..
 4 mA is called “live zero” ..

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 007 twowire & four wire transmitter system

---: FOUR WIRE TRANSMITTER SYSTEM :---

HOW TO CONNECTED IN TERMINAL

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

--: TEMPERATURE :--

Temperature : - “ It is to be measure hotness and coldness of process medium.”

Units of temperature :-

Degree Celsius ( 0C )

0
Degree Fahrenheit ( f )

Degree Kelvin ( 0K )

Degree Rankin ( 0R )

 Conversion from 0C to 0f and 0f to 0C

Formula :-

Example = 1 Example = 2

1000f = ? 0C 100 0C =? 0f

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

Example = 3 Example = 4

150 0C =? 0f 1000f = ? 0C

150 0C = 302 0f 1000f = -12.22 0C

Example 5

-400C = ? 0f

-400C = -40 0f

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

--: RTD :--

(SENSING ELEMENT = RESISTANCE BULB)

 WHAT ARE THE TEMP. SENSING ELEMENTS ?

 RTD & thermocouple..

 RTD ----- Resistance Temperature Detector.

1. RTD is Temperature sensing elements.
2. RTD is used to mesure low Temperature.
3. Range of RTD is -500C to 3500C.
4. Output of RTD is Resistance in ohm.
5. RTD works on the principle of “ changes in Resistance “.
6. When Temperature changes, Resistance is also changes.
7. When Temperature increase, Resistance is also increase. so that is called positive Temperature
coefficient (PTC).

When temp. is 0 0C , Resistance is 100 Ω..

0 0C ------->> 100 Ω

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

 What is PT 100 formula ?

 1STFORMULA :-
RT = R0 * (1 + )
Where,
RT = Resistance of temp. to be measure.
R0 = Resistance at 0 0C = 100Ω
= temp. cofficient = 0.00385
T = temp. to be measure.

Example 1 Example 2

30 0C ------>>> ? Ω 100 0C ---->>> ? Ω

RT = R0 * (1 + ) RT = R0 * (1 + )
R30 = 100 * (1 + (0.00385 * 30)) R100 = 100 * (1 + (0.00385 * 100))
= 100 * (1+ 0.1155) = 100 * (1+ 0.385)
= 100 * 1.1155 = 100 * 1.385
= 111.55 Ω = 138.5 Ω

Example 3

200 0C ------>>> ? Ω

RT = R0 * (1 + )
R200 = 100 * (1 + (0.00385 * 200))
= 100 * (1+ 0.77)
= 100 * 1.77
= 177 Ω

10-3 = 0.001
10-7 = 0.0000001
 2ND FORMULA 2002 = 200*200 = 40,000
A = 3.9083*10-3 (standard velue )
200 0C ------>>> ? Ω B = -5.775*10-7

RT = R0* (1 + AT + BT2)
R200 = 100*(1+(3.9083*10-3*200) + ( 5.775*10-7*2002))
= 100*(1+0.78166 – 0.0231)
= 100*1.75856
= 175.856 Ω

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

 WHAT ARE THE TYPES OF RTD ?

 There Are Three Types Of RTD
1 Two wire RTD
2 Three wire RTD
3 Four wire RTD

TWO WIRE RTD :-

1. It is used for short distance.

2. Not accurate for long distance.
3. Can be used up to 100 meters.

THREE WIRE RTD :-

1. It is used for long distance.

2. accurate for long distance.
3. Can be used up to 500 meters.
4. 3rd wire is used to cancel the resistance of cable. OR 3rd wire is used for “ compensation of
resistance”

FOUR WIRE RTD :-

1. It is used for very long distance.

2. Can be used up to 1000 meters. (1km)

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

--: TEMPERATURE TRANSMITTER :--

Temp.transmitter is a used to measure temp. with output 4 to 20 mA DC.

 WHAT IS CALIBRATION ?
 “Compairing measuring instrument with standard instrument for its best accuracy.”
OR
 “calibration means the instrument under test is being compared with more accurate(standard)
instrument which includes adjustment of instrument to show correct reading.”

CALIBRATION - 1 :-

Company = Rosemount
Model number = 244R
0
Range = 0 to 200 C
output = 4 to 20 mA DC
Supply = 24V DC
input = PT100 (RTD)

CALIBRATION TABLE :-

0
mA OUTPUT RANGE IN C RESISTANCE IN Ω
(Z) 4.00 0 100 Ω
8.00 50 119.4 Ω
(L) 12.00 100 138.51 Ω
16.00 150 157.33 Ω
(S) 20.00 200 175.86 Ω
( measuring value) (standard value)

CALIBRATION CIRCUIT DIAGRAM :-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

RESISTANCE SOURCE :- 1st

RESISTANCE SOURCE :- 2nd

 How to calibrate temp.transmitter with RTD input ?

1. Connect 24V DC supply to transmitter.
2. Connect transmitter in series.
3. Connect resistance source at sensor input terminal of transmitter.
4. Apply Resistance From Resistance Source And Check Zero, Span And Linearity.
5. Check Zero (4.00mA), If It Is Disturbed Than Adjust Using Zero Pot OR Push Button.
6. Now apply Resistance according to range (URV).
7. Check span (20.00mA), If It Is Disturbed Than Adjust Using Zero Pot OR Push Button.
8. Check linearity (12.00mA) by applying 50% input temperature.
9. If Zero, Span And Linearity ok transmitter calibration is ok.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

CALIBRATION - 2 :-

Company = Rosemount HART SMART Family.

Model number = 644
0 0
Range = -200 C to 850 C
output = 4 to 20 mA DC
Supply = 10.5 to 42v DC (24V DC)
Sensor type PT100 type (RTD)

 NOTE :- in this temp. transmitter range and unit can be change by using HART communicator.
Range limit for this transmitter is -2000C to 850 0C so we can change any range in between
-2000C to 850 0C..

TRANSMITTER TERMINAL AND INPUT CONNECTIONS.

CALIBRATION RANGE = -50 to 150

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

FORMULA :-

CALIBRATION TABLE :- .

0
mA OUTPUT RANGE IN C RESISTANCE IN Ω
(Z) 4.00 -50 80.31 Ω
8.00 0 100 Ω
(L) 12.00 50 119.4 Ω
16.00 100 138.51 Ω
(S) 20.00 150 157.33 Ω
( measuring value) (standard value)

CALIBRATION CIRCUIT DIAGRAM :-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

--: THERMOCOUPLE :-
( SENSING ELEMENT = TWO DIFFERENT METAL )

1. Thermocouple is Temperature sensing elements.

2. Thermocouple is used to mesure High Temperature.
3. Output of Thermocouple is millivolts (mV) in DC.
4. Thermocouple works on the principle of “ Seeback Effect “.
5. Thermocouple WAS FIRST introduced in the year of 1821 by german scientist called T.J.Seeback
(Thomas John Seeback).

 Construction of T/C.

 WHAT IS SEEBACK EFFECT ?

 When heat is applied at hot junction , millivolts is genrated at cold junction.

 WHAT ARE THE TYPE OF THERMOCOUPLE ?

1. E type T/C
2. J type T/C
3. K type T/C
4. R type T/C
5. S type T/C
6. T type T/C

 WHICH TYPE OF THERMOCOUPLE IS MOSTLY USED IN INDUSTRIES ?

 K Type Thermocouple.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

 WHAT IS THE RANGE,MATERIAL OF METAL AND COLOUR CODE OF K TYPE THERMOCOUPLE ?

 RANGE = -1800C TO 12600C
 METAL = Chromel Alumel
(+) (-)
 COLOUR = Yellow Red

 TYPES OF T/C,METAL WITH COLOUR AND RANGE

Types Of T/C Positive Metal Nagative Metal Range
With colour With Colour
0 0
E Type T/C Chromel Constantan -180 C TO 870 C
(purple) (red)
0 0
J Type T/C Iron Constantan -180 C TO 760 C
(white) (red)
0 0
K Type T/C Chromel Alumel -180 C TO 1260 C
(yellow) (red)
0 0
R Type T/C Platinum with 10% rhodium (Black) Platinum 0 C TO 1480 C
(red)
0 0
S Type T/C Platinum with 13% rhodium (Black) Platinum 0 C TO 1480 C
(red)
0 0
T Type T/C Copper Constantan -180 C TO 350 C
(Blue) (red)

 WHAT IS THE DIFFERENCE BETWEEN RTD AND T/C ?

RTD THERMOCOUPLE
 RTD is used to mesure low Temperature.  T/C is used to mesure High Temperature.
 Output Of RTD Is Resistance.  Output Of T/C Is millivolts. (mV)
 Principle of RTD Is “ Changes in Resistance “  Principle of T/C Is “Seeback Effects”
 RTD Having Resistance Bulb to sence  Thermocouple Two Different Metal to sence
Temperature. Temperature.
 Any cable (lead wire) can be used.  Special purpose cable (lead wire) is used.
OR
 Same Metal Material Of T/C Cable is used.

 Calibration of Temperature transmitter (T/C input).

While calibrating Temperature transmitter millivolts is to be applied from millivolt source
according to range and chart velue but chart velue is given at reference junction (cold junction) 00C
but our cold junction is at room temp. so here room temp. millivolts is to be minus from chart
millivolts than actual mV is to be apply from mV source to Temperature transmitter.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

For Example :-

Room temp. = 300C

300C ------>> 1.203mV

Formula :- Actual mV= Chart mV – Room Temp. mV

0
For 100 C = 4.096 mV - 1.203mV

= 2.893 mV

Actual mV= Chart mV – Room Temp. mV

0
For 200 C = 8.138mV - 1.203mV

= 6.935 mV

0
For 300 C = 12.209mV - 1.203mV

= 11.006 mV

0
For 500 C = 20.644mV - 1.203mV

= 19.441 mV

0
For 600 C = 24.905mV - 1.203mV

= 23.702 mV

0
For 1000 C = 41.276mV - 1.203mV

= 40.073 mV

CALIBRATION :- 1

Company = Rosemount HART SMART.

Model number = 644
Range = -1800C to 13720C
output = 4 to 20 mA DC
Supply = 24V DC
Sensor type = T/C “K” Type
Calibration Range = 00C to 12000C

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

CALIBRATION TABLE :-
0 0
mA OUTPUT RANGE IN C mV AT 30 C
(Z) 4.00 0 -1.203
8.00 300 11.006
(L) 12.00 600 23.702
16.00 900 36.123
(S) 20.00 1200 47.635
0 mV ------>>> Room Temp. (300C)

CALIBRATION CIRCUIT DIAGRAM :-

 HOW TO CHECK TEMP. TRANSMITTER WITHOUT CONNECTING THERMOCOUPLE OR MILLIVOLT

SOURCE?
OR
 HOW TO GET ROOM TEMP. IN TEMPERATURE TRANSMITTER ?


Connect short link at (+) and (-) sensor terminal of TT, T T show room temp, if TT shows room
temp. when we can say that TT is ok.

0
 If T/C Is On Table, Room Temp. Is 70 c.Than What Will Be The millivolts O/P Of T/C ?
 Actual mV = Chart mV – Room Temp.

= 2.851mV – 2.851mV

= 0 mV
0 0
 If T/C is in tank measuring tank temp. temp. of tank is 100 c Room temp. is 30 c than what will be the mV
Output of Thermocouple ?
 Actual mV = Chart mV – Room Temp.

= 4.096mV – 1.203mV

= 2.893mV

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

CALIBRATION :- 2

Company = Honeywell, USA

Model number = STT 3000 SMART
0 0
Range = 0 C to 1000 C
output = 4 to 20 mA DC
Supply = 24V DC
Sensor type = T/C “K” Type
0 0
Calibration Range = 0 C to 1000 C

CALIBRATION TABLE :-
0 0
mA OUTPUT RANGE IN C mV AT 30 C
(Z) 4.00 0 -1.203
8.00 250 8.95
(L) 12.00 500 19.44
16.00 750 30.01
(S) 20.00 1000 40.07

CALIBRATION CIRCUIT DIAGRAM :-

Zero & Span Adjust Using HART

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

--: TEMPERATURE SWITCH :--

( SENSING ELEMENT = BELLOWS )

Company = Danfoss
= Indfoss
HOW TO IDENTIFY NO -NC & COMMON IN TEMP.SWITCH

 Temp. switch is a device which is used to change over contacts from NO to NC And NC to NO. When
Temp. Reaches to set point.
 Genrally capillary type mercury/gas filled temp.switch is used.
 If we set temp. of 700C on temp.switch so when actual temp. comes 700C then switch will change its
contects from NO to NC And NC to NO.
 Temp. Switch Is Used For Heater Control,Alarm Purpose And Tripping Circuits.

 WHAT IS THERMOWELL ?
 Thermowell is used to protect temp. sensor against damage,corrosion and high pressure process.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 008 temperature

 HOW TO CALIBRATE RTD,THERMOCOUPLE AND TEMP. SWITCH ?

 RTD,Thermocouple And Temp. Switch Is Calibrated By Using Temperature Bath.
 Temperature Bath Company :- Ametak, (Norway)
Sika (USA)
Nagman (chennai)

1. Keep RTD,T/C & Temp.Swich In Temperature Bath.

2. Connect multimeter at sensor terminals.
3. Set Temperature on temp. controller in Temperature Bath.
4. Check Resistance And millivolts in multimeter according to Temperature set.
5. For RTD,if set Temperature is 1000C then check Resistance at multimeter 138.51Ω.
6. For T/C, if set Temperature is 1000C then check millivolts at multimeter according to room temp.
and chart velue.
7. For Temp.Swich, if temp. reaches to set point switch should change its contacts from NO to NC And
NC to NO.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

---: PRESSURE :---

 Pressure :-
“ force acting per unit area.”

Units of high Pressure :- kg/cm2

Bar
PSI (pounds per square inch)

Units of low Pressure :- pascal (kpa = killo pascal )

mm H2o

mm Hg

Inch H2o

Inch Hg

 1 kg/cm2 = 14.223 PSI

 1 Bar = 14.504 PSI
 1 kg/cm2 = 0.9807 Bar
 1 Bar = 100000 pascal (100 killo pascal)
 1 kg/cm2 = 10018 mm H2o
 1 PSI = 704.332 mm H2o
 1 Bar = 1000 milli Bar

 Convert Following Values :-

1. 25 PSI = ? BAR 2. 3.45kg/cm2 = ? PSI

14.504 Psi = 1 Bar 1 kg/cm2 = 14.223 Psi

25 Psi = ? Bar 3.45 kg/cm2 = ? psi

1.7225 Bar 49.00 Psi

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

 What Are The Pressure Sensing Elements ?

 There are three types :--

1. BOURDON TUBE :- (Pressure Gauge)

 ‘C ’ type Bourdon Tube..
 Helical
 Spiral
2. BELLOWS :- (Pressure switch)
3. DIAPHRAGM :- (Pressure Transmitter , DPT)

Pressure Sensing Elements Works On “ SHAPE CHANGE “ Principle.

‘ C ’ type bourdon tube :-

Bourdon Tube was first introduced in the year of 1852 by “ Eugene Bourdon “
Range = 0 to 1,00,000 PSI

Bellows :-

Diaphragm :-

 Diaphragm Is used for low pressure measurement.

 Diaphragm Is very sensitive to small change in pressure.
 Diaphragm Is Used For Pressure Transmitter And Differential Pressure Transmitter (DPT).

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

--: PRESSURE GAUGE :--

( SENSING ELEMENT = “C” TYPE BOURDON TUBE )

 Pressure Gauge is used to measure process pressure.

 Pressure Gauge works on the principle of “ Hook’s law “.
 Hook’s law states that “ measuring pressure in elastic medium”.

 What Are The Parts Of Pressure Gauge ?

1. ‘C ’ type Bourdon Tube.
2. Connecting link .
3. Hair spring.
4. Zero & Span Adjustment.
5. Pointer.
6. Scale.
7. Gear Sector & Pinion Arrangement.
8. Fitting.

 Bourdon Tube Materials :-

1. Stainless steel (for high pressure measurement).
2. Copper ( for low pressure measurement).
3. Bronze.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

 What Is Oil Filled Gauge ?

 When There is Vibration Presents Then Oil Filled Gauge Is Used.

 What Is Siphon ?
 Siphone Is Used To Protect Pressure Measuring Instruments From Suddenly Increase In Pressure.
 Siphone Is Used To Protect Pressure Sensor From High Temperature Medium Such As Steam.
 When Siphone Is First Instralled It Shoud Be Filled With Water OR Same Other Suitable Material.

 What Is Compound Gauge ?

 Compound Gauge Is Used To Measure Both Gauge Pressure And Vacuum Pressure.

 What Is Vacuum Pressure ?

 Any pressure below atmospheric is called vacuum pressure it is called negative pressure.

 What Is maximum Vacuum ?

 -760 mm Hg

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

--: PRESSURE GAUGE CALIBRATION :--

1. Dead Weight Tester And Oil Comparator Is Used For Pressure Gauge Calibration.
2. Dead Weight Tester And Oil Comparator Is Works On The Principle Of “ Pascal Law “.
3. Pascal Law States That “ Pressure Applied On The Liquid Will Be Remains Same In All Direction “.

OIL COMPARATOR :-

DEAD WEIGHT TESTER :-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

--: PRESSURE SWITCH :--

(SENSING ELEMENT = BELLOWS)

Company = danfoss , indfoss & switzer.

C = COMMON NC = NORMALLY CLOSED NO = NORMALLY OPEN

1 = COMMON 2 = NORMALLY CLOSED 4 = NORMALLY OPEN

 What Is Pressure Switch ?

 Pressure switch is a device which is used to change over contacts from NO to NC And NC to NO.
When Pressure Reaches to set point.
There are two setting for Pressure switch.
1. Cut In = Set
2. Cut Out = Reset

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

Example = 1

CUT IN = 4.0 BAR CUT OUT = 3.0 BAR DIFFRENCE = 1.0 BAR

 How To Calibrate pressure switch ?

 Connect pressure switch and standard gauge at pressure source.
 Connect multimeter at pressure switch contact (Common & NO).
 Set cut in (set) and cut out (reset) setting.
 How apply pressure and check NO to NC and NC to NO according to settings.
 If not then adjust it according to standard gauge.

Application (use):-

 Pressure switch is used for pump protection,it can stop pump when there is no flow and it can start
pump when ther is flow.
 When flow stop it can generates alarm.

 PUMP PROTECTION AND ON – OFF WITH PRESSURE SWITCH : -

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

--: PRESSURE TRANSMITTER :--

( SENING ELEMENT = DIAPHRAGM)

Pressure Transmitter Is Used To Measure Process Pressure With Output 4 To 20 mA.

 CALIBRATION : - 1
 Company = Tecsis, Malasia
 Range = 0 To 4 Bar
 Output = 4 To 20 mA Dc
 Supply Voltage = 24v Dc
 Sensor = Diaphragm.
 CALIBRATION TABLE:-

mA OUTPUT Range in BAR

(Z) 4.00 0.0
8.00 1.0
(L) 12.00 2.0
16.00 3.0
(S) 20.00 5.0

 CALIBRATION CIRCUIT DIAGRAM:-

 What Are The Pressure Source/Calibrator Is Used ?

 There Are Two Types Of Pressure Source Pneumatic (AIR) and Hydraulic (OIL).
1. Druck Calibrator. (DPI 610)
2. Oil Calibrator.
3. Dead Weight Tester.
4. Protable Pneumatic Hand Pump.
5. Protable Hydraulic Hand Pump.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

 What Will Be The mA Output Of Transmitter When Pressure Applied Is 2.88 BAR ?
Range = 0 To 4 BAR
 FORMULA:-

Example:-

 What Will Be The mA Output Of Transmitter When Temp. Is 1250 C ? (Range = 0 To 3000 C )

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

 CALIBRATION : - 2
Company = Rosemount HART SMART Family.
Model number = 3051 / 3051S
Range = -1 to 55.2 BAR
output = 4 to 20 mA DC
Supply = 10.5 to 55v DC (24V DC)
IP (Ingress Protection) = 66
6 = Protection Against Entry Of Dust.
6 = Protection Against High Pressure Water Jet From All Direction..
Diaphragm Material = SS 316 L
Flange Material = SS 316 L

 FIELD CONNECTION :-

PWR = power supply (24 v DC)

COMM = HART communicator
TEST = output 4 to 20 mA DC
 ZERO AND SPAN SETTING:-

CALIBRATION RANGE:- 0 TO 10 BAR

mA output Range In BAR

(Z) 4.00 0
8.00 2.5
(L) 12.00 5
16.00 7.5
(S) 20.00 10

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 009 pressure

 HOW TO CALIBRATE PRESSURE TRANSMITTER IN FIELD ?



1. Take Loop In Menual.

2. Isolate Pressure Transmitter From Process Pressure, Close Isolation Valve And Open Drain Valve.
3. Connect Multimeter At Setpoint (Series).
4. Check Zero (4.00mA),If It Is Disturbed Than Adjust It Using Zero Pot Or Push Button.
5. Connect Pressure Source/Calibrator And Standard Gauge At Drain Point Of Manifold And Apply
Pressure.
6. Apply Maximum Pressure According To Range (URV).
7. Check Span (20.00mA),If It Is Disturbed Than Adjust It Using Span Pot Or Push Button.
8. Check Linearity (12.00mA) By Appling 50% Input Pressure.
9. Reduce Pressure To Zero,Remove Pressure Source. Close Drain Valve And Open Isolation Valve Of
Manifold.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

---: LEVEL :---

 LEVEL :- “Difference Between Two Heights Of Liquid In Tank Or Vessel.”

 UNITS OF LEVEL :-
1. Percentage (0 To 100%)
2. Meter
3. Feet
4. Inch

 What are the types of instruments used for LEVEL MEASUREMENT ?

1. Leveltrol OR Displacer Type Level Transmitter
2. DPT Type Level Transmitter OR Hydrostatic Head Type Level Transmitter
3. Radar Type Level Transmitter OR Non Contact Type Level Transmitter

 SIGHT GLASS :-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

---: LEVEL SWITCH :---

 Level Switch Is Used To Control Liquid Level Of Tank Using Pump Logic.
 Level Switch Having Two Contacts NO & NC And Common (C).
 Level Switch Is Directly Mounted In Tank At Which Point Liquid Level Is To Be Maintain.
 When Level Reaches At Switch Contact Will Change Over From NO to NC and NC to NO.
 For Industrial Application Mostly Float Type Level Switch Is Used.

There are two type of level switch:-

1. Float Type Level Switch.
2. Vibrating Fork Type Level Switch.

DIAGRAM OF PUMP ON – OFF WITH LEVEL SWITCH:-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

---: LEVELTROL/DISPLACER TYPE LEVEL TRANSMITTER :---

( SENSING ELEMENT = DISPLACER )

COMPANY = Fisher(U.S.A),Masoneilan,Mobrey.

 Leveltrol Works On The Weightloss Principle Of “ Archimedes Low”.

 Archimedes Low States That :-

“When body is immersed in the liquid,the weight of the body will be get loss.”
 DIAGRAM OF DISPLACER

 DISPLACER :-
It Consists Of Cyllindrial Shape Pipe Scaled And Filled Inside With Sand Or Some Weight.The
Purpose Of This Is To Convert Change In Level To Primary Motion.
The Change In mA Output Depends On Change In Liquid Level Which Varies The Net Weight
Of Displacer Increasing Or Decreasing The Load On Torque Arm. The Change Is Directly Proportional
To The Change In Level And Specific Gravity Of Liquid.
 NOTE :-
1. Using Leveltrol Maximum Level Measurement Can Be Done Up To 72” Only.
2. Minimum Hight Of Displacer Is 14”.
3. Maximum Hight Of Displacer Is 72”.
4. Other Available Height Is 32”,48” And 72”.

 What is the limitation of leveltrol ?

 Limitation of leveltrol is that it can measure level up to 72” only.

 What Will Happen, If Displacer Has Fallen Down, While In Live ?

 Output will be Maximum (20.00mA)

 What Will Happen, If Displacer Has Hole In It, While In Live ?

 Output will be Minimum (4.00mA)

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

 SPECIFIC GRAVITY OF LIQUIDS :- (1 Inch = 25.4mm)

1. Water = 1.0
2. Oil = 0.84
3. Kerosene = 0.82
4. Petrol = 0.73722
5. Mercury = 13.570
6. Silicon & glycol = 0.94
7. Sulphuric asid = 1.83
8. Hydrochloric asid = 1.64
9. Sea water = 1.023
10. Glycol = 0.94

 LEVELTROL RANGE CALCULATION :-

Example no = 1

Process Liquid = Water

Displacer Height = 14” = 355.6mm
Specific Gravity Of Water = 1.0

Range = Hight Of Tank * Specific Gravity Of Process Liquid

= 355.6mm * 1.0

= 355.6 Mm

Calibration range =

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

Example no = 2

Process Liquid = Oil

Displacer Height = 14” = 355.6mm
Specific Gravity Of Oil = 0.84

Range = Hight Of Tank * Specific Gravity Of Process Liquid

= 355.6mm * 0.84

= 298.70 mm

Calibration range =

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

 How To Calibrate Leveltrol In Field ?



 Take Loop In Menual.

 Isolate Tank From Displacer Chamber, Close both Isolation Valve And Open Drain Valve.
 Check Zero (4.00mA),If It Is Disturbed Than Adjust It Using Zero Pot Or Push Button.
 Connect Transparent PVC Tube At Drain Point And Make Making On The Tube For 0%,50%And
100% According To Range And Center Point As Shown In Diagram.
 Fill Liquid Up To 100% Marking That Is Top Of Displacer (Fill Valve).
 Check Span (20.00mA),If It Is Disturbed Than Adjust It Using Span Pot Or Push Button.
 Drain Liquid Up To 50% And Check Linearity (12.00mA).
 Reduce Transparent PVC Tube,Drain Liquid From Chamber, Close Drain Valve And Open Both
Isolation Valve.
 Take Loop In Auto.

 What Is Interface Level ?

 When tank is filled with two different specific gravities of liquid than that level is called interface
level.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

--: DPT TYPE LT or HYDROSTATIC HEAD TYPE LT :--

NOTE:-

Here All Pressure Will Be Same It Only Depends On Hight And Sg (Specific Grevity),
It Does Not Depends On Diameter Of Tank..

DPT type LT Works On Basic Principle Of “PRESSURE PRODUCED BY THE HEIGHT OF LIQUID
WHICH IS TO BE MEASURE IN TERMS OF LEVEL”.

 WHAT IS DPT ? (DIFFERENTIAL PRESSURE TRANSMITTER)

 DPT is used to measure Differential Pressure.

 How to install DPT in open tank ?



Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

Example = 1
Process Liquid = Water
Specific Gravity Of Water = 1.0
Tank Hight (100%) = 2000mm = 78.74inch.

Range = Hight Of Tank * Specific Gravity Of Process Liquid

= 2000mm * 1.0

= 2000mmH2O (mmwc)

CALIBRATION RANGE =

Example = 2
Process Liquid = Oil
Specific Gravity Of Water = 0.84
Tank Hight (100%) = 2000mm = 78.74inch.

Range = Hight Of Tank * Specific Gravity Of Process Liquid

= 2000mm * 0.84

= 1680mmH2O (mmwc)

CALIBRATION RANGE =

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

Example = 3 (BEHRAIN PETROLIUM WRITTEN TEST QUASTION)

 Sketch a simple DPT to measure level in open tank.

Tank height = 2540mm
Process Liquid = Water
Find out calibration range with drawing.
 Tank height = 2540mm (100 inch)
Process Liquid = Water (SG = 1.0)

Range = Hight Of Tank * Specific Gravity Of Process Liquid

= 2540mm * 1.0

= 2540mmH2O (mmwc)

CALIBRATION RANGE =

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

Example = 4 (BEHRAIN PETROLIUM WRITTEN TEST QUASTION)

 What Will Be The Calibration Range Of Transmitter In Inch Of Water Colomn (Inwc Or InchH2O) For
Example No=3 ?

Example = 5 (BEHRAIN PETROLIUM WRITTEN TEST QUASTION)

 Calculate Head Pressure Of Liquid In Vessel,25 Inch In Diameter And 60 Inch In Height,The SG Of
Liquid Is 0.6 ?


Example = 6 ( PRACTICAL WITH WATER IN OPEN TANK)

 Process Liquid = Water
SG Of Water = 1.0
Tank height = 600mm

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

Example = 7 ( PRACTICAL WITH PETROL IN OPEN TANK)

 Process Liquid = Petrol

SG Of Petrol = 0.73722
Tank height = 600mm

Example = 8 ( PRACTICAL WITH SEA WATER IN OPEN TANK)

 Process Liquid = Sea Water

SG Of Sea Water = 1.023
Tank Height = 600mm

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

 WHAT IS SUPPRESSION ?
 “ Compensation Of An Unwanted Pressure At High Side Of Level Transmitter”.
OR
“ To Cancle The Unwanted Pressure At High Side Of Level Transmitter”.

Example = 9 ( EXAMPLE FOR SUPPRESSION)

SG Of Process Liquid = 0.8

SG Of Seal Liquid = 0.9

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

Example = 10

SG Of Process Liquid (Petrol) = 0.73722

SG Of Seal Liquid (Water) = 1.0

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

 What Is Elevation ?
 “ Compensation Of An Unwanted Pressure At Low Side Of Level Transmitter”.
OR
“ To Cancle The Unwanted Pressure At Low Side Of Level Transmitter”.

Figure Of Elevation :-

 THERE ARE TWO TYPES OF LEG :-

1. WET LEG
2. DRY LEG

 WET LEG :-
1. When Process Vapour Is Condensable Than Wet Leg Is Used.
2. Wet Leg Can Be Filled With Seal Liquid Or Process Liquid.
3. When Using Wet Leg The Liquid In The Leg Must Be Remains At Constant Level Under All
Process Condition.

 DRY LEG :-
1. When Process Vapour Is not Condensable Than Dry Leg Is Used.

 What Wii Be The mA Output Of Level Transmitter When Level Of Tank Is 48% ?

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

 What Wii Be The % Of Level When Output Of LT Is 17.85 mA ?

Example = 11 (WITH ELEVATION USING DRY LEG)

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

Example = 12 (WITH ELEVATION USING WET LEG)

SG Of Process Liquid = 0.8

SG Of Seal Liquid = 0.9
SG Of Wet Leg Seal Liquid = 0.9

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

 How To Calibrate DPT (LT) In Field ?



 Take Loop In Menual.

 Isolate DPT From Process Liquid By Using 3 Way Manifold. Close Both Isolation Valve And Close
Drain Pot Of Manifold..
 Connect Multimeter At Setpoint (Series).
 Check Zero (4.00mA),If It Is Disturbed Than Adjust It Using Zero Pot Or Push Button.
 Connect Pressure Pneumatic Source(Calibrator ) At High Side Of Drain Pot And Low Side Open To
Atmosphre Apply Pressure At High Side.
 Apply Maximum Pressure According To Range (URV).
 Check Span (20.00mA),If It Is Disturbed Than Adjust It Using Span Pot Or Push Button.
 Check Linearity (12.00mA) By Appling 50% Input Pressure.
 Reduce Pressure To Zero,Remove Pressure Source. Close Both Drain Pot And Open Both Isolation
Valve Of Manifold.
 Take Loop In Auto.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

Example = 13 (CALIBRATION WITH DPT)

NORMAL FIGURE OF DPT (IN LEB)

ROSEMOUNT = 3051 (DPT)

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

--: RADAR TYPE LEVEL TRANSMITTER (LT) :--

(SENSING ELEMENT = MICRO WAVE)

 COMPANY :-
1. Rosemount Model No – 5401 , 5402
2. Endress + Houser (E+H) = FMR 245
3.Krohne Model No - BM 702

 Radar Type LT is also called non contact type LT.

 Radar Type LT Works on the principle of “ Time Of Flight System “ or “FMCW = frequency
modulated continous wave” which measures distance from top of the tank to the surface of
process liquid.

Figure :-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0010 level

--- TYPES OF RADAR ---

 EXAMPLE

Company = Krohne
Model Number = BM 702
Out Put = 4 To 20 mA DC HART
Supply Voltage = 17 To 32 V DC
Measuring Range Limit = 30 Meter
Tank Height =
20 mA Height =
4 mA Height =
Antenna :-
1. wave stick
2. standard
Still Well :-
1. yes
2. no
Height Unit :-
1.mm
2.cm
3. feet
4.inch
5.meter

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

--: FLOW :--

 FLOW :-
“quantity of gas or liquid moving through pipeline with in standard time is in
minutes or hour.”

 Units of liquid Flow :- Litre per minute (LPM).

Litre per hour (LPH).

Gallons per minute (GPM).

Gallons per hour (GPH).

Barrel per day (BPD). (1 Barrel === 158.98 Liter)

 Units of GAS and AIR Flow :- M3min (meter cube per minute).

M3hour (meter cube per hour).

CFM (cubic feet per minute).

CFH (cubic feet per hour).

 Units of steam Flow :- Kg/min.

Kg/hour.

 What Are The Types Of Instruments Used For Flow Measurement ?

1. DPT Type Flow Transmitter (Air Or Gas Flow)
2. Mass Flow Transmitter (Oil Flow)
3. Magnetic Flow Transmitter (Water Flow)
4. Vortex Flow Transmitter
5. Turbine Flow Transmitter
6. Ultrasonic Flow Transmitter
7. Rotameter OR Variable Area Flowmeter

( ROTAMETER IS NOT FLOW TRANSMITTER, IT IS A SIMPLE INDICATOR)

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

---: DPT TYPE FLOW TRANSMITTER :--- (AIR OR GAS FLOW)

(SENSING ELEMENT = ORIFICE PLATE)

DPT TYPE FT :-

1. DPT Type flowmeter works on the principle of Bournoli ’s theoram.

2. DPT Type flowmeter works on the principle of “ when there is restriction (flow sensor) in pipeline
flow produces Differential Pressure (DP) across the restriction ”.
3. Flow is not a linear.
4. Flow is always measured in square root (√).
5. Flow is directly proportional to the square root(√) of Differential Pressure (DP).

 What Difference Has To Be Change While Using DPT For Level And Flow ?

1. While using for level DPT should be in linear mode.

2. While using for flow DPT should be in squre root mode.
3. Linear and squre root is to be change by using HART communicator.

 What Are The Flow Sensing Elements ?

 There are five types of flow sensing elements..
 Orifice plate
 Venturi tybe
 Pitot tube
 Flow nozzle
 Annubar

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

---: ORIFICE PLATE :---

 What Is Orifice Plate ?

 Orifice Plate Is Used To Produce Differential Pressure (DP) In The Pipeline.

 What Are The Types Of Orifice Plate ?

 Concentric Orifice Plate.
 Ecentric Orifice Plate.
 Segmental Orifice Plate.
 Quadrant Edge Orifice Plate.
 Integral Orifice Plate.

 Concentric Orifice Plate :-

 This orifice plate has hole in centre so that it is called concentric orifice plate.
 USED :- 1. Ideal Liquid Flow
2. Gas Or Air Flow
3. Dry Steam Flow

 Ecentric Orifice Plate :-

 This Orifice Plate Has Hole In Ecentric So That It Is Called Ecentric Orifice Plate.
 USED :- 1. Liquid Containing Solids
2. Oil Containing Water
3. Wet Steam
4. Viscous Liquid
5. Slurry Liquid

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

 Segmental Orifice Plate :-

 This Orifice Plate Has Hole In From Of Segmental Of Circule So That It Is Called Segmental Orifice
Plate.
 USED :- 1. Liquid Containing Solids
2. Oil Containing Water
3. Wet Steam
4. Viscous Liquid
5. Slurry Liquid
6. Colloidal Liquid

 Why quadrant edge orifice plate is used ?

 Quadrant edge orifice plate is used for viscous flow measurement.

 Why integral orifice plate is used ?

 Integral orifice plate is used for low flow measurement.

 How to identify High side of an orifice plate ?

 Marking of INLET on the tab is high side of an orifice plate.

-: INSTRALLATION OF ORIFICE PLATE IN PIPELINE :-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

 Why ORIFICE TAB is Provided ?

 Indication of orifice plate in pipeline.
 Marking of inlet (High side) of orifice plate in tab.
 Tag number marked on it.
 Orifice hole diameter marked on it.
 Material used for orifice plate marked on it.

 Why there is small hole sometimes above and below of an ORIFICE HOLE ?

 small hole above and below of an orifice hole is called weep hole or breath hole.

LIQUID FLOW :-
Weep hole will be in the top of the orifice hole to pass out any air or gas or vapour
particles in liquid.

AIR or GAS FLOW :-

Breath hole will be in the bottom in the orifice hole to pass out any water particles
presents in air or gas.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

 How to instrall DPT in pipeline with using 5 way manifold ?

 If process person tells you that flow is showing more,less or fluctuating than how how will you
start chcking ?......(maintenance most imp. Question)
 First drain or Flush the DPT.
 Check Choking if there then flush both impulse line .
 Check Leackage at both impulse line.
 Check Zero of DPT,if disturbed then adjust it.
 Check 24 V DC Supply voltage it shouldnot drop to minimum supply voltage of transmitter.
 Check Calibration Of DPT.
 Interaction between two cables that is high voltage cable and signal cable 4 To 20 mA DC.

 How To Check Zero Of DPT ?.... (maintenance question)

 Close isolation valve of manifold either high side or low side then open equilisation valve dpt output
will be zero (4.00mA).
OR
 Close isolation valve of manifold and open both drain pot output of dpt will be zero(4.00mA).

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

 What Are The Tappings Used For Orifice Plate ?

 Flange Tapping.
 Corner Tapping.
 Radius Tapping.
 Vena Contracta Tapping.
 Pipe Tapping.

-: FLANGE TAPPING :-
Flange tapping is used on line size 2” or larger.they are locked in the orifice flange 1” from
upstream and 1” from downstream from face of the orifice plate.

 How To Do Tubing For Impulse Line For DPT For Liquid Line,Gasline And Steam Line ?

 Liquid Line:-
For Liquid Line, DPT Is Mounted Below The Orifice Plate Because Liquid Has A
Property Of Self Draining.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

 Air or Gas Line:-

For Air Or Gas Line, DPT Is Mounted Above The Orifice Plate Because Air And Gas Has A
Property Of Self Venting.

 Steam Line:-
For Steam Line, DPT Is Mounted Below The Orifice Plate with condensate pot.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

 How To Calibrate DPT (FT) In Field ?



PROCESS:-

 Take Loop In Menual.

 Isolate DPT From Process Medium By Using 5 Way Manifold. Close Both Isolation Valve And
Open Drain Pot Of Manifold..
 Connect Multimeter At Setpoint (Series).
 Check Zero (4.00mA),If It Is Disturbed Than Adjust It Using Zero Pot Or Push Button.
 Connect Pressure Source (Pneumatic ) At High Side Of Drain Pot And Low Side Open To Atmosphre
Apply Pressure At High Side.
 Apply Maximum Pressure According To Range (URV).
 Check Span (20.00mA),If It Is Disturbed Than Adjust It Using Span Pot Or Push Button.
 Check Linearity (12.00mA) By Appling 50% Input Pressure.
 Reduce Pressure To Zero,Remove Pressure Source. Close Both Drain Pot And Open Both Isolation
Valve Of Manifold.
 Take Loop In Auto.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

PRACTICAL NO :- 1

FORMULA FOR SQUARE ROOT OUTPUT :-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

 How To Convert Linear To Square Root Output ?

 FORMULA :-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

---: MORE FLOW SENSING ELEMENTS :---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

---: ULTRASONIC FLOWMETER :---

( SENSING ELEMENT = MICRO WAVE)

Ultrasonic Flowmeter Works On The Principle Of “ Change In Frequency Of Sound Wave “

OR
“ Shift In Frequency Of Sound Wave”

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

---: MAGNETIC FLOWMETER :---- (WATER FLOW)

(SENSING ELEMENT = MAGNETIC COIL WITH ELECTRODE )

COMPANY :-

1.Rosemount Model 8712 SMART

2. Endress + Houser Model PROMAG 30F
3.Krohne Model OPTIFLUX 4000

 Magnetic Flowmeter Is Used For “Conductive Liquid.”

 Magnetic Flowmeter Works On The Principle Of “ Faraday’s Law Of Electromagnetic Induction.”
 Faraday’s Law States That “ Whenever Conductor Moves In Electromagnetic Field Voltage Is
Generated In Conductor ” Which Is Directly Proportial To The Density Of Electromagnetic Field (B),
Velocity Of Conductor (B) And Diameter Of Pipe (D).

---: MAGNETIC FLOWMETER INSTRALLED IN THE FIELD :---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

---: MASS FLOWMETER :---- (OIL FLOW)

(SENSING ELEMENT = OSCILLATING TUBE)

COMPANY :-

 Emerson Model CMF 100

 Endress + Houser Model PROMASS 80F
 Krohne Model OPTIMAS 7000

 Mass Flowmeter Works On The Principle Of “ Corioli’s Effect.”

 Mass Flowmeter Is Also Called As “ Corioli’s Flowmeter.”

-: FIGURE OF OSCILLATING TUBE :-

CORIOLI’S EFFECT STATE THAT :-

“ When There Is No Flow Through Oscillating Tube It Does Not Twist But When There Is Flow
Through Oscillating Tube, The Tube Will Twist.”

---: MASS FLOWMETER INSTRALLED IN THE FIELD :---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

---: VORTEX FLOWMETER :---

(SENSING ELEMENT = BLUFF BODY/SHREDDER BAR)

COMPANY :-

 Rosemount MODEL 8800

 Yokogawa Model DY 025, DY 100
 Endress + Houser MODEL -72F
 Krohne Model OPTISWIRL 4070

 Vortex Flowmeter Works On The Principle Of “ Karman Vortex Street”.

 Vortex Flowmeter Having Small Sensor Inside Flowmeter Called “ Bluff Body ” Or “ Shredder Bar ”
Which Is Placed Vertically In Flowmeter.
 When Flow Passes Through Bluff Body It Will Produss Series Of Vertices.
 Generated Series Of Vertices By Bluff Body Produces In Vibration Sensor Which Is Placed In
Flowmeter.
 The Vibration Is Directly Proportional To The Flow.

-: HOW TO WORK :-

-: HOW TO INSTROLLED IN PIPELINE WITH 2 WIRE TRANSMITTER POWER SUPPLY : -

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0011 flow

---: FLOW SWITCH :---

COMPANY :-

 HONEYWELL
 DANFOSS

 Flow Switch Is Used To Change Over Contacts From NO To NC & NC To NO In Response To The Flow
Of Process Liquid.
 Flow Switch Is Directly Mounted In Pipeline Occording To Direction (Arrow) And Online Setting.
 Generally Paddle Type Flow Switch Is Used.
 Flow Switch Is Operates Through Paddle Which Gets Displaced Due To The Force Of Process Liquid
Moving Through Pipeline.

-: FIGURE OF FLOW SWITCH :-

o APPLICATION (USE) :-
 Flow Switch Is Used For Pump Protection ,It Can Stop Pump When There Is No Flow.
 Flow Switch Is Used For Alarm Purpose, It Can Generates Alarm When Flow Stops.
 Flow Switch Is Used For Tripping Circuits.

-: CIRCUIT DIAGRAM PUMP PROTECTION WITH FLOW SWITCH :-

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0012 I to P converter

---: I TO P CONVERTER :---

(CURRENT TO PRESSURE CONVERTER)

Company :-

 Fisher
 ABB
 Foxboro
 Control Air

DCS -----> I/P CONVERTER -----> CONTROL VALVE

 I To P Converter Is Used To Convert Input 4 To 20 mA DC To Output 3 To 15 PSI..

 3 To 15 PSI Is A Master Signal For Control Valve.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0012 I to P converter

 How To Calibrate I To P Convertor ?

 Connect mA source at (+) and (-) terminal of I to p convertor.

 Apply 20 PSI of air supply to I to p convertor .
 Connect test gauge at output.
 Apply 4.00mA, and check output 3.0 PSI. if it is disturbed then adjust it using zero pot.
 Apply 20.00mA, and check output 15.0 PSI. if it is disturbed then adjust it using span pot.
 Apply 8.00mA, and check output 6.0 PSI.
 Apply 12.00mA, and check output 9.0 PSI.
 Apply 16.00mA, and check output 12.0 PSI.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0013 control valve

---: CONTROL VALVE :---

 COMPANY :-
Fisher
Masoneilan
Delma
Valtek
Samson

 What is control valve ?

 Control valve is final control element. which is used to regulate(control) material flow in the process.

 What are the types of control valve Depending on Body ?

 1. Single seated valve.
2. Double seated valve.
3. Angle valve.
4. Three way valve.
5. Butter fly valve.
6. Needle valve.
7. Ball valve.
8. Globle valve.
9. Pinch valve.

 What are the types of control valve Depending on Action ?

 1. Air to open. (fail to close = FC)
2. air to close. (fail to open = FO)

 What are the Parts of control valve ?

 1. Positioner 2. Actuator
3. Spring 4. Diaphragm (Material is RUBBER )
5. Yoke 6. Stem
7. scale (0 to 100%) 8. Indicating edge
9. Feedback link 10. Valve body
11. Plug 12. Plug seat
13. Bonnet 14. Gland packings ( Material is TEFLON)
15. Gland pusher 16. Gland nut
17. Three gaugs

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0013 control valve

---: DRAWING OF CONTROL VALVE :---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0013 control valve

 What is air to open ?

 3 to 15 PSI air pressure at the bottom of the diaphragm moves the stem upwords opening the valve.
The action is called air to open.
 When air pressure will fail valve will get close that is called air fail to close (FC).

 What is air to Close ?

 3 to 15 PSI air pressure at the top of the diaphragm moves the stem downwords closing the valve.
The action is called air to close.
 When air pressure will fail valve will get open that is called air fail to open (FO).

 What is CV of control valve ?

 CV = coefficient value.
CV is the capacity value.
 “ numbers of us gallons per minute (GPM) of water which passes through fully (100%) open control
valve is pressure drop of 1 PSI ”.

 What is the use of valve positioner ?

1. Zero and span can be adjust using valve positioner.

2. Quick action of control valve (opening and closing of control valve will be fast).
3. Valve hysteresis (error) will be zero.
4. Valve can be used for viscous liquid.
5. If line pressure change suddenly then also there will be no effect on control valve.
6. Reversing valve action from FO to FC and FC to FO.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0013 control valve

 How to CALIBRATE control valve ?

OR
 How to check STOCK of control valve ?
OR
 How to check loop from DCS to CONTROL VALVE ?

-----: LAB :-----

-----: FIELD :-----

 Take loop in manual from DCS.

 Enter 0% from DCS and check 0% at control valve. If it is disturbed then adjust it using positioner.
 Enter 100% from DCS and check 100% at control valve. If it is disturbed then adjust it using
positioner.
 Enter 25% from DCS and check 25% at control valve.
 Enter 50% from DCS and check 50% at control valve.
 Enter 75% from DCS and check 75% at control valve.
 Take loop in auto.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0013 control valve

 If process person tells you that control valve is stuck up (not working) then how will you start
checking ?

 Take work permit.

 Take loop in manual.
 Take control valve by pass from line using by pass valve.
 Check 4 to 20 mA signal at I to p convertor which is coming from DCS. Check air supply of positioner
and I to p convertor. Check output of I to p convertor that is 3 to 15 PSI.
 Check air signal from positioner to actuator.
 If possible the disconnect stem and plug.
 Give air signal to actuator and check actuator operates or not. If not then diaphragm may be got
punctured.
 If actuator operates then connect stem and plug then give air to actuator.
 If it is not operates then loose gland nut and hammer little bit and check it operates or not.
 If does not operates then control valve is to be remove from line and send to workshop for
repairing purpose.
 Install spare control valve and check stock.
 Take loop in auto..

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0013 control valve

---: SOLENOID VALVE :---

Company =
1. Rotex
2. Asco

 Solenoid valve is an electrically operated valve.

 Solenoid valve is used to control liquid and gas flow.
 Solenoid valve is controlled by electrical voltage which is applied to coil.
 When voltage is applied to coil magnetic field will generates. So that plunger inside the coil will
moveup and down.
 Depending on design of value plunger will open and close the valve.
 Generally 24 V DC Solenoid valve is used.

--- There are two types of valve ---

1. Normally open.
2. Normally close.

---: APPLICATION :--- (USE)

 To operate the ON-OFF control valve.

 For emergency shutdown (ESD) system.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0014 loop diagram,safety barrier and loop chceking

---: LOOP DIAGRAM :---

 What is loop ?
 The loop which having transmitter, DCS and control valve for measurement and controlling of
process variables.
 There are two types of loop :-
1. Open loop
2. Close loop

 What is open loop ?

 The loop which having only indication of process variables that loop is called open loop.
 Open loop which having transmitter and DCS for indication of process variables.

For example :-
 Pressure transmitter is measuring pressure of tank and DCS is indicating pressure in control room
(C/R).

---: OPEN LOOP DIAGRAM :---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0014 loop diagram,safety barrier and loop chceking

 What is close loop ?

 The loop which having both indication and controlling of process variables that loop is called close
loop.
 Close loop which having transmitter,DCS and control valve.

For example :-
 Pressure transmitter is measuring pressure of tank and DCS is measuring and controlling of pressure
using final control element that is control valve.

---: CLOSE LOOP DIAGRAM :---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0014 loop diagram,safety barrier and loop chceking

---: SAFETY BARRIER :---

 Company :-
1. MTL (measurement and technology limited) Englend.
2. Pepperl + Fuchs (P+F)

 What is safety barrier ?

 Safety barrier is used to protect instrument in hazardous area.
 Safety barrier is works as a fuse in loop.

 There are two types of safety :-

1. Zener safety barrier (ZB).
2. Diode safety barrier.

---: HOW TO CONNECTED IN FIELD :---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0014 loop diagram,safety barrier and loop chceking

---: LOOP CHECKING :---

 What is loop checking ?

 Loop checking is a process to check signal continuity from transmitter to DCS and DCS to control
valve.

 What are the types of loop checking ?

 There are two types of loop checking
1. Cold loop checking
2. Hot loop checking

---: COLD LOOP CHECKING :---

 Cold loop checking is done without appling power to the loop.

 In Cold loop checking cable continuity is to be check using multimeter from transmitter to DCS and
DCS to control valve.
 In Cold loop checking cable continuity checking starts from transmitter to junction box (JB) to
safety barrier (SB) to marshalling panel (M/R) to DCS.
After successfully checking of cold loop hot loop is to be check.

---: HOT LOOP CHECKING :---

 Hot loop checking is done with appling power to the loop.

 Hot loop checking is done using source or HART communicator.
 In hot loop checking we have to check readings on DCS.

 What are the instruments required for loop checking ?

 1. Multimeter.
2. Source / calibrator.
3. HART communicator.
4. Communication device (walkie - talkie).
5. Instrument data sheet.
6. Instrument loop diagram (ILD).
7. Piping & instrument diagram (P&ID).
8. Necessary tools.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0014 loop diagram,safety barrier and loop chceking

---: CONTROL LOOP DRAWING :---

--- FLOW CONTROL LOOP ---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0014 loop diagram,safety barrier and loop chceking

---: TEMPRETURE, PRESSURE, LEVEL AND FLOW CONTROL LOOP :---

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0015 HART communicator

---: HART COMMUNICATOR :---

H= Highway
A= Addressable
R= Remote
T= Transducer

Company :---

1. Emerson model 375 & 475

2. Yokogawa BT 200

 What is HART communicator ?

 HART communicator is a device which is used to communicate with SMART instruments that is
transmitter and positioner.

 Where to connect HART communicator ?

 HART communicator is connected at (+) and (-) terminal of 24V DC supply of transmitter.

 What are the used of HART communicator ?

 1. To change the Range of transmitter.
2. To change the Unit of transmitter.
3. For Calibration.
4. For Loop Checking.
5. To change Transmitter Output from linear to square root and square root to linear.
6. For Zero Trim (adjust).
7. To change Sensor Type from RTD to T/C and T/C to RTD.
8. Can check mA output and Process Value of transmitter.
9. Can check Configuration of transmitter.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0015 HART communicator

 How to connect HART communicator with transmitter while using for LAB and FIELD ?


---: HOW TO ONLINE AT LAB :---

 How to SWITCH OFF HART ?



Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0015 HART communicator

 How to do LOOP CHECKING using HART 375 & 475 ?



Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0015 HART communicator

 How to change UNIT of transmitter with HART 375 & 475 ?



Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0015 HART communicator

 How to change RANGE of transmitter with HART 375 & 475 ?



Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0015 HART communicator

 How to do ZERO TRIM of transmitter with HART 375 & 475 ?



Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0015 HART communicator

 How to change TRANSMITTER OUTPUT from LINEAR TO SQURE ROOT and SQURE ROOT TO
LINEAR with HART 375 & 475 ?


Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0015 HART communicator

 How to change SENSOR TYPE from RTD to T/C and T/C to RTD with HART 375 & 475 ?


Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

---: INTERVIEW QUESTION FOR PROCESS CONTROL INSTRUMENTS :---

 What is Instrument ?
 Instrument is a device which is used for measurement, monitoring, controlling & display of process variables.

 What is Instrumentation ?
 Instrumentation is a branch of engineering which deals with Measurement, Monitoring, Controlling &
Display of process variables.

 What are the Process Variable ?

 Temperature.
 Pressure.
 Level.
 Flow.

 What are the Defination of Temperature ?

 It is to be measure hotness and coldness of process medium.

 What are the Defination of Pressure?

 Force acting per unit area.

 What are the Defination of Level ?

 Difference between two heights of liquid in tank or vessel.

 What are the Defination of Flow ?

 Quantity of gas or liquid moving through pipeline with in standard time is in minutes or hour.

 What are the Units of Temperature ?

0
 Degree Celsius ( C )
0
 Degree Fahrenheit ( f )
0
 Degree Kelvin ( K )
0
 Degree Rankin ( R )

 What are the Units of Pressure ?

2
 Units of high Pressure :- kg/cm
Bar
PSI (pounds per square inch)
 Units of low Pressure :- pascal ( KPA = killo pascal )
mm h2o
mm Hg
Inch h2o
Inch Hg

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What are the Units of Level ?

 percentage (0 to 100%)
 Meter
 Feet
 Inch
 Cm

 What are the Units of Flow ?

 Units of liquid Flow :- Litre per minute (LPM).
Litre per hour (LPH).
Gallons per minute (GPM).
Gallons per hour (GPH).
Barrel per day (BPD). (1 Barrel === 158.98 Liter)
3
 Units of GAS and AIR Flow :- m min (meter cube per minute).
3
M hour (meter cube per hour).
CFM (cubic feet per minute).
CFH (cubic feet per hour).
 Units of steam Flow :- Kg/min.
Kg/hour.

 What are the Types of Permit ?

 Cold work permit.
 Hot work permit.
 Confined space permit.

 What are the Cold Work Permit ?

 The work which does not creates smoke, heat and flame but there is possibility of creating spark that work
is called cold work..
 EXAMPLE OF COLD WORK :- instrument instrallation.
field calibration.
loop cheking.
function test.
Trouble shooting (fault finding).

 What are the Hot Work Permit ?

 The work which creates smoke,heat,spark and flame that work is called hot work..
 EXAMPLE OF HOT WORK :- welding.
cutting .
drilling.
grinding.

 What are the Types of Fire Extinguishers ?

 Water.
 Powder.
 Foam.
 Carbon dioxide.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What is Zone And There Types ?

 Zone are used to define the pressence of explosive gas in atmosphere.
 THERE ARE THREE TYPES OF ZONE
ZONE 0 :- an explosive gas mixed with air in atmosphere is continuosly presents ..
ZONE 1 :- an explosive gas mixed with air in atmosphere in normal condition..
ZONE 2 :- an explosive gas mixed with air in atmosphere for short time.

 What is Multimeter ?
 Multimeter is a device which is used to measure voltage(AC&DC), current(AC&DC),resistance
milli ampere(mA), milli volt (mV), and cable continuity…

 How to measure Voltage and Current ?

 Voltage is always measured in parallel, and Current is always measured in series.

 What will be the result resistance in parallel and series ?

 In parallel ------> resistance will be decrease.
 In series ------> resistance will be increase.

 What is Relay ?
 Relay is an electromechnical device.which is used to change over contacts from normally open(NO) to
normally close(NC) and normally close (NC) to normally open (NO)..

 How to check Coil of Relay, Contactor and Sov ?

 Keep multimeter in resistance (Ω) mode.
If coil is ok ===== 150 Ω to 2000Ω
If coil is not ok ===== open (0L) & short (0Ω)..

 Why 4 to 20 mA DC signal is used for signal transmitssion?

 Voltage will drop for long distance so that voltage signal will not used.
 Using 0 to 20 mA DC signal we can not differentiel that actual process value is zero or there is open circuit .
 Liner graph we can get (4, 8, 12, 16 and 20)..
 4 mA is called “live zero” ..

 What is Transmitter?
 Transmitter is a device which is used to measure process variables that is temperature, pressure, level and
flow..

 How to connected Indicator, DCS, PLC and controller ?

 always connected in series.

 What is a Input and Output of transmitter ?

 Transmitter Supply Voltage = 24 V DC (world wide)
 Transmitter Output = 4 to 20 mA DC (world wide)

0 0 0 0
 What are the formula Conversion from C to f and f to C ?

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What Are The Temp. Sensing Elements ?

 RTD & thermocouple..

 What is mean by PT 100 ?

 When temprature is 0 degree celsius, resistance is 100 ohms (Ω).

 What are the RTD Sensing Elements ?

 Resistance Bulb.

 What is Output of RTD ?

 Resistance in ohms(Ω).

 What is the Principle of RTD ?

 Changes in resistance.

 What is the Difference in between Two Wire and Three Wire RTD ?
 Two Wire RTD is used for short distance, and Three Wire RTD is used for short distance.

 What is the Used of Four Wire RTD ?

 Four Wire RTD is used for Very Long Distance.

 What will be the resistance at 100 degree celsius ?

 138.51 ohms(Ω).

 What is calibration ?
 “Compairing measuring instrument with standard instrument for its best accuracy.” OR
 “calibration means the instrument under test is being compared with more accurate(standard) instrument
which includes adjustment of instrument to show correct reading.”

 Which calibrator/source are used for calibration of temperature transmitter ?

 Resistance source. ( USE RTD) and mV source (USE THERMOCOUPLE)..

 For which purpose thermocouple are used ?

 Measure high Temperature.

 What is the output of Thermocouple ?

 millivolts (mV)

 What is the principle of thermocouple ?

 Seebeck effect

 What is the Seebeck effect ?

 When heat is applied to hot junction, millivolt is genetated at cold junction.

 What are the Sensing Element of Thermocouple ?

 Two different metal.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 Which type of thermocouple is mostly used in industries ?

 K Type Thermocouple.

 What are the type of thermocouple ?

 E type T/C, J type T/C, K type T/C , R type T/C, S type T/C, T type T/C.

 What is the range,material of metal and colour code of K type thermocouple ?

0 0
 RANGE = -180 C TO 1260 C
 METAL = Chromel Alumel
(+) (-)
 COLOUR = Yellow Red

 What is the specialty of thermocouple lead wire ?

 Lead wire should be of the same material as the thermocouple metal material.

 How to check TT (Thermocouple Input) without connecting thermocouple or millivolt source ?

 Connect short link at thermocouple input terminal (+) and (-) of TT.TT should show room temp. if TT shows
room temp. then TT is ok..

 What is Skin Thermocouple ?

 Skin thermocouple are those which are directly connected to the process without any thermowell. It is used
for measuring the skin temperature of heater,furnace and boiler.

 What will be the millivolt at 100 degree celsius for K type thermocouple ?
 4.069 mV (according to chart).

 How to calibrate RTD, Thermocouple and Temp. Switch ?

 RTD, Thermocouple and Temp. switch is calibrated by using Temperature Bath..(Sand bath or Oil bath)

 What are the Sensing element of Temp.switch ?

 Bellows.

 What is the used of Temp. switch ?

 Temp.switch is used for Heater control,alarm purpose and tripping circuits.

 What is Thermowell ?
 Thermowell is used to protect temp. sensor against damage,corrosion and high pressure process.

 What are the Pressure sensing elements ?

 BOURDON TUBE :- (Pressure Gauge)
 ‘C ’ type Bourdon Tube..
 Helical
 Spiral
 BELLOWS :- (Pressure switch)
 DIAPHRAGM :- (Pressure Transmitter , DPT)

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What is the Principle of Pressure sensing elements ?

 Shape change Principle.

 What are the Range of C type Bourdon Tube ?

 Range = 0 To 1,00,000 PSI

 What are the three instrumens to Measure Pressure ?

 Pressure transmitter.
 Pressure gauge.
 Manometer.

 What is Absolute Pressure ?

 It is pessure presents in the atmosphere.

 What is Gauge Pressure ?

 Gauge Pressure = Atmospheric Pressure + System Pressure.

 What are the Parts of Pressure Gauge ?

 ‘C ’ type Bourdon Tube. Connecting link .
Hair spring. Zero & Span Adjustment.
Pointer. Scale.
Gear Sector & Pinion Arrangement.

 What is the Principle of Pressure Gauge ?

 Hook’s law states that “ measuring pressure in elastic medium”.

 What are the Material used of Bourdon Tube ?

 Stainless steel. (for High pressure measurement).
 Copper. (for Low pressure measurement).

 What is Compound Gauge ?

 Compound Gauge is used to measure both gauge pressure and vacuum pressure.

 What is Vacuum Pressure ?

 Any pressure below atmospheric is called vacuum pressure it is called negative pressure.

 What is Maximum Vacuum ?

 -760 mm Hg

 What is Dead weight tester ?

 Dead weight tester is used for pressure gauge calibration.

 What is the Principle of Dead Weight Tester?

 Dead weight tester is works on the principle of Pascal Law .

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What is states Pascal Law ?

 Pascal Law States that “ pressure applied on the liquid will be remains same in all direction “.

 What is Pressure Switch ?

 Pressure switch is a device which is used to change over contacts from NO to NC and NC to NO. when
pressure reaches to set point.
There are two setting for Pressure switch.
1. Cut in = Set
2. Cut out = Reset

 What is the used of Pressure, level and flow Switch ?

 Pump Protection, Alarm And Tripping Purpose.

 What is Pressure Transmitter ?

 Pressure transmitter is used to measure process pressure with output 4 To 20 mA.

 Which calibrator/source are used for PT, PS & PG Calibration ?

 Pressure source

 What are the pressure source/calibrator is used ?

 There are two types of Pressure Source Pneumatic (Air) and Hydraulic (Oil).

 What are the material of diaphragm and flange in pressure transmitter ?

 SS 316 L

 What are the types of instruments used for level measurement ?

 Leveltrol OR Displacer type level transmitter
 DPT type level transmitter OR Hydrostatic Head type level transmitter
 Radar type level transmitter OR Non contact type level transmitter

 What are two type of level switch ?

 Float Type Level Switch.
 Vibrating Fork Type Level Switch.

 What are the Sensing element of Float Type Level Switch ?

 Float

 What is leveltrol ?
 Leveltrol is the one of the most common instrument used for measuring level in tank.

 What are the Sensing element of Leveltrol ?

 Displacer

 What is the Principle of leveltrol ?

 Leveltrol works on the Weightloss principle of “ Archimedes Low”.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What is states Archimedes Low ?

 When body is immersed in the liquid, the weight of the body will be get loss.

 What is Displacer ?
 Displacer is a cylindrical shape pipe sealed and filled in side with sand or some weight the purpose of this is to
convert change in level to primary motion.

 What is the minimum Height of Displacer ?

 minimum height of Displacer 14”

 What is the limitation of leveltrol ?

 Limitation of leveltrol is that it can measure level up to 72” only.

 What will happen, if Displacer Has Fallen Down, while in live ?

 Output will be maximum (20.00mA)

 What will happen, if Displacer Has Hole In It, while in live ?

 Output will be minimum (4.00mA)

 What are the Specific Gravity of Water, Oil, petrol, Sea water and Glycol ?
 Water = 1.0
 Oil = 0.84
 Petrol = 0.73722
 Sea water = 1.023
 Glycol = 0.94

 What is interface level ?

 When tank is filled with two different specific gravities of liquid than that level is called interface level..

 What is DPT ?
 DPT is used to measure Differential Pressure.

 What is the Principle of DPT type level transmitter ?

 Pressure produced by the height of liquid which is to be measure in terms of level.

 How to install DPT in open tank with using 3 way manifold ?



Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What is Zero Suppression ?

 Compensation of an unwanted pressure at HIGH SIDE of level transmitter. OR
To cancle the unwanted pressure at HIGH SIDE of level transmitter.

 What is Zero elevation ?

 Compensation of an unwanted pressure at LOW SIDE of level transmitter”. OR
To cancle the unwanted pressure at LOW SIDE of level transmitter”.
THERE ARE TWO TYPES OF LEG :-
1. WET LEG
2. DRY LEG

 Which liquid is mostly used as a seal liquid ?

 Glycol. (SG = 0.94)

 What is the use of seal liquid ?

 Protect the Diaphragm of DPT type LT.

 What is the Principle of Radar type level transmitter ?

 Time of flight system. or FMCW = frequency modulated continous wave.
which measures distance from top of the tank to the surface of process liquid.

 What are the sensing element of Radar type level transmitter ?

 Micro wave.

 What are the types of Radar type level transmitter ?

 Wave strick type.
 Horn or cone type.
 Guided wave type.

 What are the types of instruments used for flow measurement ?

 DPT type flow transmitter (air or gas flow)
 Electromagnetic flow transmitter (water flow)
 Mass flow transmitter (oil flow)
 Vortex flow transmitter
 Turbine flow transmitter
 Ultrasonic flow transmitter
 Rotameter or variable area flowmeter

 What are the sensing element of DPT type flow transmitter ?

 Orifice plate.

 What is the Principle of DPT type flow transmitter ?

 Bournoli ’s theoram

 What is states Bournoli ’s theorem ?

 When there is restriction (flow sensor) in pipeline flow produces Differential Pressure across the restriction.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 How to measure flow ?

 Flow is always measured in square root (√).

 What Difference has to be Change while using DPT for level and flow ?
 While using for level DPT should be in linear mode.
 While using for flow DPT should be in squre root mode.
 Linear and squre root is to be change by using HART communicator.

 What are the flow sensing elements ?

 Orifice plate
 Venturi tybe
 Pitot tube
 Flow nozzle
 Annubar

 What is orifice plate ?

 Orifice plate is used to produce differential pressure (DP) in the pipeline.

 What are the types of orifice plate ?

 Concentric orifice plate.
 Ecentric orifice plate.
 Segmental orifice plate.
 Quadrant edge orifice plate.
 Integral orifice plate.

 What are the used of concentric orifice plate ?

 This orifice plate has hole in centre so that it is called concentric orifice plate.
1. Ideal Liquid Flow
2. Gas Or Air Flow
3. Dry Steam Flow

 What are the used of Ecentric orifice plate ?

 This Orifice Plate Has Hole In Ecentric So That It Is Called Ecentric Orifice Plate.
1. Liquid Containing Solids 2. Oil Containing Water
3. Wet Steam 4. Viscous Liquid
5. Slurry Liquid

 What are the used of Segmental orifice plate ?

 This Orifice Plate Has Hole In From Of Segmental Of Circule So That It Is Called Segmental Orifice Plate.
1. Liquid Containing Solids 2. Oil Containing Water
3. Wet Steam 4. Viscous Liquid
5. Slurry Liquid 6. Colloidal Liquid

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 Why quadrant edge orifice plate is used ?

 Quadrant edge orifice plate is used for viscous flow measurement.

 Why integral orifice plate is used ?

 Integral orifice plate is used for low flow measurement.

 How to Identify High Side of an orifice plate ?

 Marking of INLET on the tab is High side of an orifice plate.

 Why Orifice Tab is Provided ?

 Indication of orifice plate in pipeline.
 Marking of inlet (high side) of orifice plate in tab.
 Tag number marked on it.
 Orifice hole diameter marked on it.
 Material used for orifice plate marked on it.

 How to do tubing or piping of impulse line for DPT for liquid line, air or gas line and steam line ?
 For Liquid line DPT is mounted below the orifice plate.
 For Air or Gas line DPT is mounted above the orifice plate.
 For Steam line DPT is mounted below the orifice plate with condensate pot.

 If running plant suddently flow is showing More, Less or Fluctuating than how how will you start chcking ?
 First drain or Flush the DPT.
 Check Choking if there then flush both impulse line .
 Check Leackage at both impulse line.
 Check Zero of DPT,if disturbed then adjust it.
 Check 24 V DC Supply Voltage it shouldnot drop to minimum supply voltage of transmitter.
 Check Calibration of DPT.

 How to check Zero of DPT ?

 Close isolation valve of manifold either high side or low side then open equilisation valve DPT output will be
zero (4.00ma). OR
 Close isolation valve of manifold and open both drain pot output of DPT will be zero(4.00ma).

 What is impulse line ?

 It is tube which is connected between the transmitter and tapping point for process variable input.

 What are the Tappings used for Orifice Plate ?

 Flange tapping.
 Corner tapping.
 Radius tapping.
 Vena contracta tapping.
 Pipe tapping.

 What is corner tapping ?

 This is used on line size less then 2 inches. they are directly located at the force of the orifice plate.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What is Flange tapping ?

 Flange tapping is used on line size 2 inches or larger.they are locked in the orifice flange 1” from upstream
and 1” from downstream from face of the orifice plate.

 What is the transmitter (DPT) output in square root ?

 square root output = 4.00, 12.00, 15.31, 17.85 and 20.00..

 What are the sensing elements of Ultrasonic flow meter ?

 Micro wave.

 What is the Principle of Ultrasonic flow meter ?

 Change In Frequency Of Sound Wave. OR Shift In Frequency Of Sound Wave.

 What are the sensing elements of Magnetic Flowmeter ?

 Magnetic coil with electrode.

 What is the Principle of Magnetic Flowmeter ?

 Faraday’s law of electromagnetic induction

 What is states Faraday’s law ?

 Whenever conductor moves in electromagnetic field voltage is generated in conductor.

 What are the sensing elements of Mass Flowmeter ?

 Oscillating tube.

 What is the Principle of Mass Flowmeter ?

 Corioli’s Effect

 What is states Corioli’s Effect ?

 When there is no flow through oscillating tube it does not twist but when there is flow through oscillating
tube, the tube will twist.”

 What are the sensing elements of Vortex Flowmeter ?

 Bluff body/ Shredder bar.

 What is the Principle of Vortex Flowmeter ?

 Karman Vortex Street..

 Which type flow switch is mostly used in Plants ?

 Paddle type flow switch..

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What are the I/P ,O/P and Air Supply for i to p converter ?
 I/P = 4 To 20 mA DC ( That is comes for the DCS).
2
 O/P = 3 To 15 PSI (0.2 TO 1 kg/cm ).
2
 AIR SUPPLY = 20 PSI (1.4 kg/cm ).

 Which is a master signal for Control Valve ?

 Output 3 TO 15 PSI That is comes for the I to P converter.

 Which calibrator/source is used of calibration I to P converter ?

 mA Source..

 What is control valve ?

 Control valve is final control element. which is used to regulate(control) material flow in the process..

 What are the types of control valve Depending on Body ?

 1. Single seated valve.
2. Double seated valve.
3. Angle valve.
4. Three way valve.
5. Butter fly valve.
6. Needle valve.
7. Ball valve.
8. Globle valve.
9. Pinch valve.

 What are the types of control valve Depending on Action ?

 1. Air to open. (fail to close = FC)
2. air to close. (fail to open = FO)

 What are the Parts of control valve ?

 1. Positioner 2. Actuator
3. Spring 4. Diaphragm (Material is RUBBER )
5. Yoke 6. Stem
7. scale (0 to 100%) 8. Indicating edge
9. Feedback link 10. Valve body
11. Plug 12. Plug seat
13. Bonnet 14. Gland packings ( Material is TEFLON)
15. Gland pusher 16. Gland nut
17. Three Gaugs

 What is CV of control valve ?

 CV = coefficient value.
“ Numbers of us gallons per minute (GPM) of water which passes through fully (100%) open control valve
is pressure drop of 1 PSI ”.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What are the air supply of control valve ?

 Not fixed
 Depends on spring design.
 It is printed on name plate.

 What is the use of valve positioner ?

 Zero and span can be adjust using valve positioner.
 Quick action of control valve (opening and closing of control valve will be fast).
 Valve Hysteresis (error) will be zero.
 Valve can be used for viscous liquid.
 If line pressure change suddenly then also there will be no effect on control valve.
 Reversing valve action from FO to FC and FC to FO.

 What are the different types of valve characteristics ?

 Linear
 Quick opening
 Equal percentage

 Where is an air to close and air to open valve is used ?

 Air to close = Flair Line ( Access gas line)
Cooling water line
 Air to open = Steam line
Feed line

 What is loop ?
 The loop which having transmitter, DCS and control valve for measurement and controlling of process
variables.

 What is open loop ?

 The loop which having only indication of process variables that loop is called open loop.
 Open loop which having transmitter and DCS for indication of process variables.

 What is close loop ?

 The loop which having both indication and controlling of process variables that loop is called close loop.
 Close loop which having transmitter, DCS and control valve.

 What is safety Barrier ?

 Safety barrier is used to protect instrument in hazardous area.
 Safety barrier is works as a fuse in loop.

 What is loop checking ?

 Loop checking is a process to check signal continuity from transmitter to DCS and DCS to control valve.

 What are the two types of loop checking ?

 Cold loop checking.
 Hot loop checking.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428

 0016 interview questions for process control instruments

 What are the instruments required for loop checking ?

 1. Multimeter.
2. Source / calibrator.
3. HART communicator.
4. Communication device (walkie - talkie).
5. Instrument data sheet.
6. Instrument loop diagram (ILD).
7. Piping & instrument diagram (P&ID).
8. Necessary tools.

 What is HART communicator ?

 HART communicator is a device which is used to communicate with SMART instruments that is transmitter
and positioner.

 Where to connect HART communicator ?

 HART communicator is connected at (+) and (-) terminal of 24V DC supply of transmitter.

 What are the used of HART communicator ?

 1. To change the Range of transmitter.
2. To change the Unit of transmitter.
3. For Calibration.
4. For Loop Checking.
5. To change Transmitter Output from linear to square root and square root to linear.
6. For Zero Trim (adjust).
7. To change Sensor Type from RTD to T/C and T/C to RTD.
8. Can check mA output and Process Value of transmitter.
9. Can check Configuration of transmitter.

 What is sov and where it used ?

 Solenoid valve is an electrically operated valve.
 Solenoid valve is used to control liquid and gas flow.
 Solenoid valve is controlled by electrical voltage which is applied to coil.
 When voltage is applied to coil magnetic field will generates. So that plunger inside the coil will moveup and
down.
 Depending on design of value plunger will open and close the valve.
 Generally 24 V DC Solenoid valve is used.
--- There are two types of valve ---
1. Normally open.
2. Normally close.

---: APPLICATION :--- (USE)

 To operate the ON-OFF control valve.

 For emergency shutdown (ESD) system.

Created By : Vimlesh P. Patel – Surat,Gujarat = +91 9714251428