1 Types of process variables Pressure, temperature, level, flow, pH, density, humidity, conductivity, etc.

2 Types of Level measuring Differential pressure, displacer, Air bubbles, Capacitance, Float, level gauge, Radar, Radiation,
instrument Ultrasonic, Vibrating switches, Resistance tape, laser,,
3 Types of Flow measuring Coriolis mass flowmeter, magnetic flowmeter, vortex flowmeter, restriction type flowmeter, positive
instrument displacement flowmeter (oval gear, turbine flowmeter, variable area flowmeter, ultrasonic flowmeter,
pitot tube, thermal.
4 How do you conduct zeroing of The flowmeter sensor must be full of process fluid and the flow of fluid through the sensor must be
coriolis mass flowmeter stopped before zeroing the flowmeter.
5 What is the purpose of valve It is use to cause accurate positioning of the control valve as dictated by instrument pressure signal
positioner from an automatic controller. It is not to get faster stroking.To improve speed of opening/closing of the
valve VOLUME BOASTER is required
6 Types of process control mode On-off, proportional control, proportional + integral, proportional plus integral plus derivative, two
position control
7 What is the difference between Feedback control loop – the actual product was measured, compared with reference point and
feeback, feedforward, and Open corrective action was taken.
control loops. Feedforward control loop – the measurement was taken in the process feedstream, and a predicted
amount of correction was made.
Open Control loop – no actual process measurement is made in process feedstream, and a predicted
amount of correction is made.
8 Reason for using Cascade control It is use to transfer the disturbance out of the control loop that recovers slowly into another loop that
recovers quickly. It reduces the effects of load changes near their source & improves control by
reducing the effect of time lag.(P-F, T-P, L-F, T-F)
9 In PID control mode what is the 1) Integral control or reset control is tuned to eliminate offset caused by proportional control. It act to
purpose adding integral & restore control point to original set point.
derivative control 2) Derivative or rate control is tuned to reduce or eliminate overshoot (excursions above the set
point). It is use to reduce the delay of correction and stabilize the process more quickly.
10 What is fail safe action A characteristic of a particular type of actuator, which upon loss of power supply, will cause the valve
plug, ball, or disc to fully close, fully open or remain in fixed position to make the process safe and
non-hazardous.
11 Hazardous areas Area in w/c explosive atmosphere of dangerous quantity can occur as a result of local & operational
conditions.
12 Intrinsically safe The entire circuitry and sensor combination is incapable of igniting a specified atmosphere even under
specified circuit condition.
13 Intrinsic safety Type of protection in which the energy in the electrical circuitry is limited so that no sparks can cause
an ignition of an explosive atmosphere, not even in fault It is a system concept involving safe and
hazardous area equipment usually communicating through a separate IS interface (safety barrier).
14 Intrinsically safe equipment Equipment and wiring that under normal or abnormal conditions, are incapable of releasing
sufficient electrical or thermal energy to cause ignition of a specified hazardous atmosphere mixture
in its most easily ignitable concentration.
15 Intrinsically safe circuit A circuit in which any spark or thermal effect, produced either normally or in specified fault
conditions, is incapable under specified test conditions of causing ignition of a mixture of flammable
or combustible material in air in the mixture most easily ignited concentration.
16 Intrinsically safe apparatus Energy strong apparatus employed in hazardous area must be designed to prevent the energy escaping
and be certified as intrinsically safe for installation in the relevant zone, gas group a gas ignition
temperature. It must be used within the ambient limit for which it is designed and certified.
17 Intrinsic safety (EEx ia) Explosion protection capable of remaining safe with two countable faults applied. A protection
designed to be safe even with any two component fault occurring simultaneously. The only form of
protection permitted in zone 0.
18 Intrinsic safety (EEx ib) A protection designed to be safe with only a single component fault occurring. Explosion protection
capable of remaining safe with one countable fault applied.
19 Increase safety (EEx e) Type of protection that prevents an intolerable rise in temperature and the generation of sparks. This
equipment is constructed with circuitry of such low power level that any spark, arc or thermal effect
produced under normal or fault conditions is incapable of causing ignition of gas/air mixture.
Increase safety enclosure is usually made of aluminum alloy, metal or special molded fiberglass
polyester. Electrical materials such as junction boxes, lighting fittings, measuring instruments,
transformer, panel boards conforms to “e” technology, providing there is absolutely no risk of
producing electrical arcs, sparks or excessive temp. in normal operation.
20 Zone 0 Explosive gas/air mixture is constantly present or is present for long periods (typically more than 1000
hrs/year.
21 Zone 1 Explosive gas/air mixture is likely to occur under normal operating conditions (typically between 10 to
1000 hrs/year). Intermittent hazard.
22 Zone 2 Explosive gas/air mixture is unlikely to occur in normal operation but if it occurs, will be short
duration (typically less than 10 hours/year. Hazard under abnormal conditions (between 0.1 to 10
hr./year).
23 If the signal from field device Adjust the PV Filter (Filter parameter TF by calling-up the analog input point. The values of 0 to 60
exhibit some form of noise (jitter). minutes can be entered. Care must be used when adjusting this Filter. Too much filter dampens actual
What action you will do to process changes.
eliminate signal noise.
24 What is the purpose of red tag Red tag is a safety feature to prevent controller outputs from being changed when the valve or other
feature in DCS final control element is out of service. To turn on the red tag the point must be in Manual & External
mode switching (ESWENBST), if present must be disabled.
25 In case of I/O bad (for PV), Forced to manual with alarm
what action the controller
should be configured
26 What are the standard 1 – CPU controllers
redundancy in DCS 2 – Power supply
3 – Data highway
27 Methods of Protection. a) Energy Limitation (EEx ia/EEx ib)
b)Containment of Explosion (EEx d)
c) Exclusion of Explosive atmosphere: (Pressurization-EExp, Encapsulation -(EExm), Oil Immersion -
(EEx o), Sand Filling – EEx q)
d)Specialized Electromechanical Design: Increase Safety-EExe, Special protection –Exs.
28 Simple Apparatus Apparatus that can be installed freely in IS circuit. No further certification is required. Power rating
should be: <1.2V, <0.1A, <25mW, <20uJ. The ability of the hot surface to cause ignition depends on
their size. Simple apparatus with 20 sq.mm to 10 sq.mm area is classified T4 when the matched output
power of the interface device does not exceed:
1.3W into 40 deg.C ambient.
1.2W into 60 deg.C ambient
1.0W into 80 deg.C ambient
29 Non-incendive circuit A circuit in which any arc or thermal effect produced in normal operating conditions of the equipment
is not capable under prescribe conditions, of igniting the specified flammable gas, vapor in air mixture,
combustible dusts, or ignitable fibers or flyings.
30 Live Zero The live zero is commonly used for reference because of the following reasons:
1) Instruments can be checked and calibrated more accurately when a signal below the zero reference
can be read on test equipment.
2) The dynamic response of a decreasing signal is improved with live zero. Pneumatic transmitters
decrease system pressure by exhausting air to the atmosphere. With a live zero, substantial differential
pressure is available to produce exhaust flow, even at minimum output.
31 Probe tip correct gapping Proximity probe should be gapped at, or close to, the center of the transducer system’s linear range.
Correct gapping of displacement transducer is mandatory in cases where most of the transducer’s
linear range is required for a particular measurement/application. Correct gapping and documentation
of gap voltage is also very important when measuring radial vibration. In axial position applications,
incorrect gapping reduces the transducer system’s linear range.
32 Axial Position monitoring The objective of axial position monitoring is not to save the machine bearing from wear, but to save the
objective machine from a severe axial rub and potential destruction.
33 We have a closed loop control Tune process controller to match the gain & time functions of proportional, PI, and PID controllers to
system w/c is cycling. We those of the process and other loop components (such as process, transmitters, valves, etc.)
should…
34 Cv or Kv may be define as The volume of water in gallons that will pass through the wide open valve in 1 minute with pressure
drop of 1 lb/sq. inch. Across the valve at 60 deg. F temperature.
35 Basic function of the spring in Oppose diaphragm so as to position valve according to signal pressure.
a control valve
36 If proportional plus reset Create stability problem
control is good, the addition of
derivative may…
37 The advantage of adding The ability to react more quickly to measurement change.
derivative to a controller is for:
38 A double seated valve is used: To minimize line pressure action on the plug. This design can often be useful on high pressure drop
applications where dynamic forces on conventional single ported valve plug would necessitate use of a
very large actuator.
39 If a control valve permits only Single seat.
minimum leakage when it is
closed, the choice would be
single seat or double seat
40 Mass flow measurement for Coriolis flowmeter
high flow rate
41 Mass flow measurement for low Thermal mass flow meter.
flow rate.
42 Diaphragm Flexible pressure responsive element which transmit force to the diaphragm plate & actuator.
43 PV tracking The purpose of having a controller perform PV tracking is to provide bumpless mode transfer when a
controller goes from the manual mode to any automated control mode.
44 Initialization It is used in cascade loop situation to provide “bumpless” mode transfer at any time the operator takes
the secondary controller out of Cascade mode and later returns it to Cascade mode.