Basic instrumentation engineering interview questions

What are the process Variable?

 Flow 
 Pressure 
 Temperature 
 Level 
 Quality i. e. % O2, CO2, pH etc.

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

Flow: Defined as volume per unit of time at specified temperature and pressure. Conditions are
generally measured by positive-displacement or rate meters.

Units : kg / hr , litter / min, gallon / min , m3 / hr , Nm3 / hr. ( gases )

Pressure : Force acting per unit Area. P = F/A Units : bar , Pascal , kg / cm2 , lb / in2.

** Level:** Different between two heights. Units : Meters, mm, cm, percentage.

Temperature: It is the degree of hotness or coldness of a body. Units : Degree Centigrade, Degree
Fahrenheit, Degree Kelvin, Degree Rankine.

Quality: It deals with analysis.( pH, % CO2, % 02, Conductivity, Viscosity ).

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

Air to close:

1. Reflux lines.
2. Cooling water lines.
3. Safety Relief services.

Air to open:

1. Feed lines.
2. Steam Service

What is Furnace Draft control?

Balanced draft boiler are generally used negative pressure of the furnace. When both the forced draft
and the induced draft are used together, at some point in the system the pressure will be the same as
that of the atmosphere.
Therefore, the oven pressure must be negative to avoid hot gas leaks. However, the excessive vacuum in
the furnace produces heat losses through air infiltration. The most desirable condition is that the one
you have is a very slight negative pressure (approximately 0.1 "H20) from the top of the oven.

What is feedback control? What is feed forward control?

Feedback control

Feed back  control involves the detection of the controlled variable and counteracting of charges its it’s
value relative to set point, by adjustment of a manipulated variable. This mode of control necessities
that the disturbance variable must affect the controlled variable itself before correction can take place.

Feedforward control:

Feedforward  control system is a system in which corrective action is based on measurement of

disturbances inputs into the process. This mode of control responds to a disturbance such that is
instantly compensates for that error which the disturbance would have otherwise caused in the
controlled variable letter in time.

What are Intrinsically safe systems?

Intrinsic safety 1 is a technique for designing electrical equipment for safe use in locations made
hazardous by the presence of flammable gas or vapours in air.

The Intrinsically safe circuit is one in which any spark or thermal effect produce either normally or under
specified fault conditions is incapable of causing ignition of a specified gas or vapour in air mixture at the
most easily ignited concentration.

An operator tells you that flow indication is more? How would you start checking?
 First flushing the transmitter. Flush both the impulse lines. Adjust the zero by equalizing if
necessary. If still, the indication is more then.
 Check L.P. side for the choke. If that is clean then.
 Check the leaks on L.P. side. If not.
 Calibrate the transmitter

Close one of the valve either H.P. or L.P. opens the equalizing valve. The O/P should read zero

How will you calibrate a level troll in the field?

1. First close both the primary isolation valves and drain the liquid inside the chamber.
2. Adjust the zero to get 0% output.
3. Connect a transparent PVC tube to the drain point as shown in hook up.
4. Fill it to the center of the top flange.
5. Adjust the specific gravity or span adjustment ( Electronic Level ).
6. Fill it up to 50 %, check linearity.
How will you check zero of a level D.P. transmitter while is line?

1. Close both the isolation valves.

2. Open the vent valve on L.P. leg and H.P. leg drain.
3. Check and adjust zero if necessary.

[color=#ff0000][size=5] Why is a converter used in a temp. recorder?

The converter is designed to convert D. C. input voltage into an A. C. input voltage proportional in
amplitude to the input.

Why are Thermowells used?

In many applications, it is not desirable or practical to expose a temperature sensor directly to a process
material. Therefore, the wells are used to protect against corrosion, erosion, abrasion and high pressure
processes. A thermowell is also useful to protect a sensor from physical damage during handling and
normal operation.

What is reset-wind up?

When a reset action is applied to the controllers where the measurement is far from the set point for
long periods, the rest can bring the output to its maximum, which results in the break ending. When the
process starts again, the output will not leave its maximum until the measurement crosses the point,
which will cause large overshoots. This problem can be avoided by including an anti-reset winding circuit
that eliminates the problem of output saturation.

Where is a quadrant orifice used ?

If the fluid is viscous and the operating Reynolds number is low quadrant orifice is preferred.

Why are two plugs provided on a D.P transmitter?

1.The top plug is a vent plug for venting the air entrapped inside the cell.

2.The bottom plug is a drain plug for draining the liquid accumulated inside the cell.

Control valve interview questions and answer

What is a Control valve?

A control value is the final control element, which directly changes the valve of the manipulated variable
by changing the flow rate of the control agent.

A control valve consists of an operator and a valve body. The operator provides the power to vary the
position of the valve plug inside the body. The plug is connected to the operator by a rod, which slides
through a packing box. The air signal from the controller is applied to the diaphragm.

What are the different types of control valves ?

The commonly used control valves can be divided as follows.

1. Depending on Action.

2. Depending on the Body.

1. Depending on action:

Depending on action there are two types of control valves,

1. Air to close,
2. Air to open.

2. Depending on body:

1. Globe valves 12 single or double seated.

2. Angle valves.

3. Butterfly valves. 7

4. Three-way valves 4.
What is the use of single seated valve?

The single seat valve is used in smaller sizes and in larger sized valves, where absolute closure is
required. The use of a single seat valve is limited by the pressure drop across the valve in the closed or
nearly closed position.

What is the use of double seated valve?

In double-seat valves, the forces up and down in the plug due to the reduction in fluid pressure are
almost equal. It is generally used in larger valves and high pressure systems. The required actuator
forces are less, that is, a small-sized actuator.

What is Cv of a control valve ?

Cv is the capacity of a valve and is defined as :

"No of gallons per minute of water which passes through a fully open valve at a pressure drop of 1 psi.
CV = q ( ▲P / G )

Where: Cv = Valve co-efficient

q = Volumetric flow rate ( gallons minute )
▲P = Pressure drop across the valve in psi.
G = Specific gravity of flowing fluid.

How to define seat leakage class for control valves?

A control valve’s ability to shut off has to do with many factors. Seat material, actuator thrust, pressure
drop, and the type plug (balanced or unbalanced) can all play a part in how well a particular control
valve shuts off. Seat Leakage Classifications.

There are actually six different seat leakage classifications as defined by IEC 60534-4 3 std or ANSI/FCI
70.2. They commonly range from CLASS IV to CLASS Vl CLASS IV is also known as metal to metal.

What is the difference between flashing and cavitation?

Cavitation 2 is a condition that occurs in the liquid flow where the internal pressure of the liquid, at
some point, falls below the vapour pressure and vapour bubbles formation takes place. After this point,
the pressure rises above the vapour pressure again and during this pressure recover stage (recall also
the concept of FL) the bubbles collapse, and cavitation takes place.

Flashing 2 is a condition that occurs with the liquid flow where the pressure falls below the vapour
pressure (same as cavitation) and remains below it. There are then two phases flowing (i.e. liquid and
vapour) downstream and no collapsing of bubbles takes place.
How will you work on a control valve while it is line ?

While the control valve is in line or in service, it has to be bypassed and secondly the line to be
depressurized and drained.

When can a bypass be not used on a positioner ?

A by pass on a positioner cannot be used when :

1. Split Range operation.

2. Reverse Acting Positioner.

3. Valve bench set not standard.

What is the use of three-way valves?

Three-way control valves are only used on special systems, where a dividing or mixture of flows
according to a controlled ratio is required.

Why the orifices of Pressure Safety Valves indicated by manufacturers are with non-API dimensions,
even though designation is as per API?

The API 520 recommends making a preliminary dimensioning of the safety valves with the proposed
flow coefficients 0.975 for gas/steam, 0.65 for liquids and the effective orifice areas written in API 526 (D
to T). Then, the API uses effective discharge coefficients and effective areas. In the end, this standardizes
flow capacity and allows engineers to select valve sizes in the initial stages.

What valves are stop valves?

Stop valves are used to shut off or, in some cases, partially shut off the flow of fluid.

Stop valves are controlled by the movement of the valve stem.

Stop valves can be divided into four general categories: globe, gate, butterfly, and ball valves.

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

The link serves as the feedback to the value. The movement of the ant valve is detected by this link.
Sometimes, due to pressure changes in the line in H.P. the position of the valve can be changed, the link,
in turn, detects this change and the positioner will produce an output that will operate the valve to the
original position.
 How will you change the action of a control valve?

1. If the control valve is without bottom cap. The actual needs to be changed.

2. If bottom cap is provided.

 Disconnect the stem from the actuator stem.

 Separate the body from the bonnet.

 Remove the bottom cap and the plug from body.

 Detach the plug from the stem by removing the pin.

 Fix the stem at the other end of the plug and fix the pin back.

 Turn the body upside down. Connect it to the bonnet after inserting the plug and stem.

 Connect back the stem to the actuator stem.

 Fix back the bottom cap.

 Calibrate the valve.

When can a bypass be not used on a positioner?

A by pass on a positioner cannot be used when :

1. Split Range operation.

2. Reverse Acting Positioner.

3. Valve bench set not standard

What are the types of Control Systems?

What are the types of Control Systems?

A control system can be functioned electrically, mechanically, pressure by fluid (gas or liquid), or it can
be combination of these ways. Control systems are used to arrange and manage components in a way
that the required condition or output is obtained. A control system is a system, which controls other
systems

There are two types of control systems depending upon the configuration of systems:

Open loop control systems

Open loop control system are systems with no feedback which means those systems in which the output
has no effect on the control action.

An open-loop control system takes input under the consideration and doesn’t react on the feedback to
obtain the output. This is why it is also called a non-feedback control system.

• Input: the excitation applied to the system from an external sources to attain an output is called input
signal.

• Control system: It is an arrangement or a combination of various physical components also called the
sub systems connected in such a manner so as to attain an output.

• Control action: it is quantity that is responsible for activating the system

• Output: the actual system attain from the system is called output signal.

Practical Examples of Open Loop Control System

Electric Hand Drier - Hot air (output) comes out as long as you keep your hand under the machine,
irrespective of how much your hand is dried.

Automatic Washing Machine - This machine runs according to the pre-set time irrespective of washing is
completed or not.

Bread Toaster - This machine runs as per adjusted time irrespective of toasting is completed or not.

Automatic Tea/Coffee Maker - These machines also function for pre adjusted time only.
Timer Based Clothes Drier - This machine dries wet clothes for pre-adjusted time, it does not matter how
much the clothes are dried.

Light Switch - Lamps glow whenever light switch is on irrespective of light is required or not.

Volume on Stereo System - Volume is adjusted manually irrespective of output volume level.

Closed loop control systems

A closed loop system is also referred as a feedback control system. A system in which the control action
is dependent on the output is called a closed loop system. In closed loop system the output is constantly
monitored and adjusted to the required value by the system.

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The output signal is fed back and compared with the reference input. Depending upon the difference
between the output signal and reference input, corrective actions are taken by the controller to adjust
the output. For example air conditioning unit.

Practical Examples of Closed Loop Control System

Automatic Electric Iron - Heating elements are controlled by output temperature of the iron.

Servo Voltage Stabilizer - Voltage controller operates depending upon output voltage of the system.

Water Level Controller - Input water is controlled by water level of the reservoir.
Missile Launched and Auto Tracked by Radar - The direction of missile is controlled by comparing the
target and position of the missile.

An Air Conditioner - An air conditioner functions depending upon the temperature of the room.

Cooling System in Car - It operates depending upon the temperature which it controls.

Why are control valves sometimes very noisy?

Control valves regulate flow by increasing or decreasing the fluid pressure drop across an element.
These pressure drop adjustments are usually accompanied by noise generation.

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The potential of vibration and noise exist whenever there is a disturbance in the flow such as a change in
piping configuration causes turbulence in the system. When the flow is disturbed it generates an
acoustic pressure fluctuation.

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The acoustic field generated by the turbulent pipe flow persists and creates externally radiated noise.
This fluctuating internal wall pressure excites the vibration in the pipe wall depending upon the pipe
diameter, material, pipe wall fitness. Some noise frequency will radiate through the pipe wall and create
sound waves that people can hear.

The mechanical noise produced by the control valves is the result of random pressure fluctuations
within the valve body and/or the impact of fluid from the internal parts of the valve that come into
mechanical contact with the fluid flow. The sound produced by this type of vibration is normally found in
the frequency range of 1,500 Hz.

Noise can be generated in three basic ways: by the mechanical vibration of the valve components, by
the turbulent gas flow (aerodynamic noise), or by cavitation of the liquid flow (hydrodynamic noise). For
more details please go through

 https://automationforum.in/t/what-are-the-different-problems-in-control-valve/2948 31

If the control valve noise is not addressed, it may introduce process control problems, present safety
hazards to workers or require costly repairs to valves, pipes, other instruments, and surrounding
equipment.

The two basic approaches to controlling the noise of the valve are the treatment of the source and the
path. The source treatment avoids the excessive noise that would otherwise be generated within the
control valve, while the path treatment reduces the noise after it has been generated.
What are Flanges?

A flange is an external or internal rib used for connecting pipes, valves and other equipment to frame a
piping system. A flange is to strength or attachment to another object, as the flange on the end of a
pipe.

Flanges are used, when the joint needs dismantling. Flange joints are mainly used at the pipe, valves and
equipment joints where frequent maintenance is needed.

In connection with pipe connections, the flange is a type of coupling, which is used to join two lines,
using bolts and a joint between them. Therefore, it is clear that it is not the bridle alone, which makes
the joint. It is the set of flanges, joints and bolts, which forms the flanged connection.

Special controls are required in the selection and application of all these elements to attain a joint,
which has acceptable leak tightness.

Types of Flanges:

Flanges can be classified according to several criteria, such as pipe fixing, pressure-temperature
classification, coating, face finish, construction material and standards followed.

1. Welding Neck Flanges:

They are the most commonly used flanges type, high strength. These have a distinctive long conical cone
(for greater strength and reinforcement to the flange) and a smooth transition from the local thickness
to the preparation of the weld end (important when the operating conditions impose repeated bends
and variable forces on the joint).

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They are suitable class 1 pipework and other conditions where 100% radiography is necessary. They are
costlier, but welding cost for the flange is less.

2. Slip-on Flanges:

The sliding flange has the same size as the outer side of the pipe. These are joined by welding inside and
outside. Normally, these flanges are forged construction and are provided with a hub. Sometimes, these
flanges are made from plates and are not provided with the hub. The plate used (when fabricated from
plates) may distort during welding, which insists machining to recover flatness.

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These flanges are used predominantly when the initial cost is low; the tube does not need to be cut to
precise lengths; the ease of alignment is considered.

3. Socket Welded Flanges:

Just like slip-on flange but welded on one side and are not recommended for severe services. Fillet
welding is done from outside on the pipe. These are used for small-bore lines only. The thickness of the
connecting pipe should be specified for this type of flanges to ensure proper bore dimension.
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These flanges are guaranteed containment for radioactive, toxic and flammable fluids. These flanges are
costlier than slip-on flanges of same static strength, the fatigue properties of these flanges are greater.

4. Lap Joint Flanges:

Lap joint flange consists of two components, a stub end, and a loose backing flange. This stub ends will
be butt-welded to the piping and the flanges are kept loose over the same. The inside radius of these
flanges is chamfered to clear the stub end radius.
Unlike other flanges, the bolt holes can be aligned to any desired position after fixing the pipe, a useful
consideration in pipe work that requires frequent dismantling for inspection and cleaning.

Control valve interview questions and answers part2

1. What are functions of valves 30?

Isolation, regulation, non-return and special purposes

2. What are the steps in selection of valve?

What to handle, liquid, gas or powder, fluid nature, function, construction material, disc type, stem type,
how to operate, bonnet type, the body ends, delivery time, cost, warranty.

3. What are special valves?

Multi-port, flush bottom, float, foot, pressure relief, a breather.

4. What materials are used for the construction of valves?

Cast iron, bronze, gun metal, carbon steel, stainless steel, alloy carbon steel, polypropylene and other
plastics, special alloys.

5. What is trim?

Trim is composed of stem, seat surfaces, back seat bushing and other small internal parts that normally
contact the surface fluid.

6. What is wire drawing?

This term is used to indicate the premature erosion of the valve seat caused by excessive velocity
between seat and seat disc when the valve is not closed tightly.

7. What are pressure tests carried out on valves?

Shell-hydrostatic, seat-hydrostatic, seat-pneumatic

8. What are available valve operators?

Handlever, handwheel, chain operator, gear operator, powered operator likes electric motor, solenoid,
pneumatic and hydraulic operators, Quick acting operators for non-rotary valves (handle lift).

9. What are ball valve 22 body types?

Single piece, double piece, three pieces, the short pattern, long pattern, sandwich and flush bottom
design.
10. What are types of check valve?

Lift check valves and swing check valves 31.

11. What are non-slam check valves?

Swing check valve, conventional check valve, wafer check valve, tilting disc check valve, piston check
valve, stop check valve, ball check valve.

12. What are the types of bonnets?

Bolted bonnet, bellow sealed bonnet, screwed on the bonnet, union bonnets, A U-bolt and clamp type
bonnet, breechlock bonnet, pressure seal bonnet.

13. Where is WYE body globe valve 9 used?

In line ports with stem emerging at 45 degree, for erosive fluids due to smoother flow pattern.

14. How to install a globe valve?

Full port: More than 85% of bore size,

Reducer port: One size less than the connected pipe

15. What is metal seated lubricated plug valve?

A plug valve with no plastic material, where grease is applied to contacting surfaces for easy operation.

16. What is Teflon sleeved plug valve?

PTFE sleeve between plug and body of the valve, low turning effort, minimum friction, temperature
limitation, anti-static design possible.

17. What are uses of four-way valve 5?

Reversal of pump suction and delivery, By pass of strainer or meter, reversal of flow through filter, heat
exchanger or dryer.

18. What are the types of bonnets?

Bolted bonnet, bellow sealed bonnet, screwed on a bonnet, union bonnets, A U-bolt and clamp type
bonnet, breechlock bonnet, pressure seal bonnet.
19. What is lantern ring?

It’s a collection point to drain off any hazardous seepages or as a point where lubricant can be injected,
it is in the middle of packing rings.

20. What is dimensional standard for plug valve?

API 599.

Basic instrumentation Interview questions?

Interview Q & A

instrumentation

Jan 2018

1/1

Jan 2018

Jan 2018

areejsidhik

2 

Jan '18

1.What is instrumentation ?

Instrumentation is a study of instruments used for indicating ,measuring,recording ,controlling the

process variable is called instrumentation .The process variables commonly used in industries
are Temperature 28, Humidity, Flow, Level, Pressure 29,pH,density etc

2.Define range?

Distance between zero and span is called range.

3.Define zero?

Minimum value of range is zero.

4.Define span?
Maximum value of range is called span

5.What is absolute pressure?

It is the total pressure in the system

absolute pressure =Gauge pressure + atm pressure.

6.What are the types of pressure measuring methods in electronics transmitter?

Resistance type,capacitance type,inductance type

7. An electronic pressure transmitter range 0-60psi .what will be the output at 24 psi?

10.4ma

step: (24/60)*16+4=10.4ma

8.What are the commonly used manometer liquids ?

Alcohol,mercury,water.

9.Explain calibration procedure of DP transmitter?

a) Adjust zero of the transmitter

b) Static pressure test:give equal pressure on both side of the transmitter .
zero should not shift .if it is shifting carry out static alignment.
c) vacuum test :apply equal vacuum on both side the zero should not shift.
d)Calibration procedure:give 20psi air supply to the transmitter ,vent LP side to atmosphere.
e) apply required pressure to HP side of the transmitter an adjust span
f) adjust zero again if necessary.

10.Generally for a temprature control _________action will be suitable.

Derivative action