Instrument Technician Trade Test

1)

Convert the following measurement :

A) 40 Psi to inches water gauge
B) 25 PSI to BAR

Psi to inches water gauge:

1 Psi = 27.68 inches water gauge
40 psi = 40 x 27.68 = 1107.0 inches water gauge
b) Psi to bar
1 psi = 0.069 bar
25 psi = 1.725 bar
2)Name 3 instruments that can be used to measure pressure?
Instruments used to measure pressure :
a) Pressure gauges
b) Manometer
c) Vaccum gauges
d) Barometer
3) What is a Dead Weight Tester used for?
Dead Weight tester:
A dead weight tester apparatus uses known traceable weights to apply pressure to a fluid for
checking the accuracy of readings from a pressure gauge. A dead weight tester (DWT) is a
calibration standard method that uses a piston cylinder on which a load is placed to make an
equilibrium with an applied pressure underneath the piston.
Typically deadweight testers are used in calibration laboratories to calibrate pressure transfer
standards like electronic pressure measuring devices.
4) Calculate the head pressure of liquid in a vessel, 25 inches in diameter, and 60 inches high.
The specific gravity of liquid is 0.6?
P=rho*g*h
where
p is the pressure due to the difference in water heights in Pa (or N/m^2)

rho is the density of the water, about 1000 kg/m^3

g is gravitational field strength, 9.81 N/kg
h is the head in m

5)What is the difference between gauge pressure and absolute pressure?

Gauge pressure and absolute pressure:
Absolute pressure is zero-referenced against a perfect vacuum, so it is equal to gauge pressure
plus atmospheric pressure.
Gauge pressure is zero-referenced against ambient air pressure, so it is equal to absolute
pressure minus atmospheric pressure. Negative signs are usually omitted.
PA = PG + P atm
PG = PA -P atm
6)What is the difference between a level-trol and level switch?
The leveltrol is used for measuring level of liquids in a closed vessel. : It works on a Archimedes
principle the loss in weight of a body immersed in a liquid is equal to amount of liquid
displaced by the body. Level low to high can be monitored.
Level Switch : On off switch for level.
7)Explain Fail Safe feature in temp. measurement?
A fail-safe or fail-secure device is one that, in the event of failure, responds in a way that will
cause no harm, or at least a minimum of harm, to other devices or danger to personnel.
8)Convert the following temperature :
a) 120 degree Centigrade to Fahrenheit
b) 50 degree Fahrenheit to Centigrade
Degree Celsius to Fahrenheit:
C x 9/5 + 32 = F
Degree Fahrenheit to Centigrade
(F - 32) x 5/9 = C
a) 120 x9/5 + 32 = 248 F
b) (50-32) x 5/9 = 10 C
9)Briefly explain the steps that you would take to caliberate a D.P flow Tx. Consider that the
flow transmitter output is connected to a trip circuit?

10)Why are valve positioner used?

The valve positioner is used for following reasons:
o
o
o
o
o
o
o

Quick Action control valve.

Valve hysteresis.
Valves used on viscous liquids.
Split range.
Line pressure changes on valve.
Valve bench set not standard.
Reversing valve operation.

11)Calculate the output in mA of Electronics D.P Tx. When applied a D.P of 125 inches of
water gauge, knowing that the range is 0 to 300 inches of WG?

12) Calculate the following?

a) Voltage : When I=30mA & R =20 Ohm
b) Current : When V=20 V & R = 10 Ohm
c) Resistance : When V= 10 volt & I = 15 mA
V = IR
a) V = 30 x 10-3x20 = 0.6 Volts
b) I = 20/10 = 2 A
c) R = 10/(15x 10-3) = 666.7 Ohm
13)Briefly explain cascade control ? You may draw it to illustrate if you wish.
Cascade Control :
In single-loop control, the controllers set point is set by an operator, and its output drives a
final control element.
In a cascade control arrangement, there are two (or more) controllers of which one controllers
output drives the set point of another controller. For example: a level controller driving the set
point of a flow controller to keep the level at its set point. The flow controller, in turn, drives a
control valve to match the flow with the set point the level controller is requesting.

14)Why are seal pots used on flow installations?

Seal Pots
It is a section of pipe which is installed either horizontal or vertical lines between the flow
meter and the pressure transmitter. Seal pots provide external liquid seal between an
instrument and flowing gases such as steam. It functions as barrier to the fluid line permitting
direct sensation of the flow conditions

15)What is meant by Zero Suppression?

Zero suppression:
Zero suppression is a condition of which zero value of the measured variable is less than the
lower range value. Zero suppression occurs in level measurement using DP transmitter installed
below the lower process taps.
Zero supression is to decrease the reading of Tx to zero when it is showing a higher reading
than normal. This is result of accumulation of process fluid in High pressure leg of tx.
16)What is the main difference in orifice flange tapping for flow transmitters in

a) Gas Service
b) Liquid Service?
Liquids lines: On liquids line the transmitter is mounted below the orifice plate because liquids
have a property of self draining.

Gas Service: On gas service the transmitter is mounted above the orifice plate because gases
have a property of self venting and secondly condensate formation.

17) Name 3 types of instrument related protections against explosions in Hazardous area?
There are three basic methods of protectionexplosion containment, segregation and
prevention.
Explosion containment: The only method that allows the explosion to occur but confines it to a
well-defined area, thus avoiding the propagation to the surrounding atmosphere. Explosionproof enclosures are based on this method.
Segregation: A method that attempts to physically separate or isolate the electrical parts or hot
surfaces from the explosive mixture. This method includes various techniques, such as
pressurization, encapsulation, etc.

Prevention: A method that limits the energy, both electrical and thermal, to safe levels under
both normal operation and fault conditions. Intrinsic safety is the most representative
technique of this method.
18)Why are compensating leads used with thermocouples?
19)Explain how differential pressure measurement can be used to measure the level of liquid
in a open tank. Give a sketch.
The bottom connection of the vessel is connected to high pressure side of the transmitter.

Different Pressure = H*D

This difference pressure is applied to H.P. side of the transmitted and calibrated.
On an open tank level measurement the L.P. side is vented to atmosphere. Whatever pressure
acts is on the H.P. side which is a measure of level.
SPAN=(X)(SP.GRAVITY)
ZERO SUPPRESSION=(Y) (SP.GRAVITY)

20)What is meant by Intrinsic Safety (I.S)

Intrinsic safety (IS) is a protection technique for safe operation of electrical equipment in
hazardous areas by limiting the energy available for ignition. In signal and control circuits that
can operate with low currents and voltages, the intrinsic safety approach simplifies circuits and
reduces installation cost over other protection methods. Areas with dangerous concentrations
of flammable gases or dust are found in applications such as petrochemical refineries and
mines. As a discipline, it is an application of inherent safety in instrumentation. High-power
circuits such as electric motors or lighting cannot use intrinsic safety methods for protection
21)Do you connect the instrument cable Earth wire to both side?
NO
22)Write the full form of the below symbols for the instruments?
PG : Pressure Gauge
PT : Pressure Transmitter
LS : Level Switch
LT : Level Transmitter
23)What is the difference between IS and NIS cable and mention the color of IS cable.
IS Cable: Intrinsicaly Safe (Circuits) Cable
Outer sheath is Blue. They are normally used for Analog Signals i.e. Signal Cables. It will have
individual for each pair as well as over all cable shields.
Non IS Cable: Non Intrinsically Safe (Circuits) Cable.
Outer sheath is black.
They are normally used as Control as well as Signal cables. It may have only an over all cable
sheath or individual pair + over all shield according to Client's specification requirements.
24) What is clean earth and mention the minimum acceptable valve.
The electrical clean earth refers to the earth which is kept separate and linked only at one point
to prevent noise from causing interference in sensitive electronics connected to the clean
earth. This depends on local regulations and standards, as a general rule of thumb only.
The earthing of these electronic equipment are connected to a different earthing system which
consists of a flat plate with insulators. From here the earthing goes direct to a separate
earthing pit and hence the other end of the earthing pit may then be connected to the ground
bus. Never are any electronic earth connected to the electrical earth or these electronic
sensitive equipment will get damaged.

25)How will you commission the DP transmitter?

Commission D.P. transmitter in field in pressurized vessel. :

Close both the isolation valves, Vent the H.P. side.

Fill it with the sealing liquid.
Open the L.P. side vent valve.
Adjust zero with suppression spring.
Close the L.P. side vent valve.
Open both the isolation valves.

26)How will you check the DP transmitter?

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 drain.
3. Check and adjust zero if necessary.
27)Draw the PT calibration connection Diagram?
Pressure instrument calibration is the process of adjusting the instrument out put signal to
match a known range of pressure. Basic calibration procedure includes zero, span, and linearity
adjustments. Proper calibration provides the desired beginning and ending pressure, and
produces and output signal that is proportional to the process pressure.

TEST EQUIPMENTS REQUIRED

1. 24VDC Power supply.

2. Multimeter.
3. AFR.

4. STD PG.

RANGE = 0-1000 MMWC

I/P MMWC

O/P MA

0.00

4.00

25

250.00

8.00

50

500.00

12.00

75

750.00

16.00

100

1000.00

20.00

Calibration
Step 1: turn on the transmitter and allow the internal components to each normal operating
temperature.

Step 2: connect AFR with STD PG in HP side (low side open to atmosphere) for giving input
pressure to the instrument

Step 3: apply 0 mmwc to the instrument and check whether the out put is 4 mA. If there is any
variation, adjust the zero and set it to 4 mA.

Step 3: apply 1000 mmwc to the instrument and check whether the out put is 20 mA. If there is
any variation, adjust the zero and set it to 20 mA.

Step 4: apply 25%, 50%, 75% input to the instrument and check whether the output obtained
according to the input.
28)What is hot loop check and cold loop check?

Cold Loop checking: Checking of wires continuity of respective field instrument-Junction boxDCS/PLC -marshalling panel terminal.
Hot loop checking: Once you powerup your field instrument through DCS/PLC system, by
stimulating process input from respective field instrument and cross check its response at
DCS/PLC system
29)What is the maximum operating temperature?
The Maximum Operating Temperature is the maximum body temperature at which the
thermistor is designed to operate for extended periods of time with acceptable stability of its
electrical characteristics.
30)What is the potential free contact?
Potential free contacts (also called "dry contacts") are simply contacts which are physically
operated with the main device, but not electrically connected to it.
31)What is the voltage range used for caliberation?
0-24 V, 9(4-20 mA
32)What happen if transmitter wire gets shorted?
The Tx will show error.
33)What are analog input/output & Digital input/output?
Digital signals are either ON (binary 1) or OFF (binary 0). Digital input signals are used to
represent items that only have two (2) states, such as... ON or OFF states ALARM or NORMAL
conditions Similarily, Digital output signals are used to control items that again only have two
states, such as.. START or STOP a device turn an indicator ON or OFF.
Analog signals are variable, they have multiple states. Analog input signals can represent such
items as temperature or level or rate of flow. Analog output signals are also variable and can be
used for such things as opening a valve to a desired position. So, use digitals for 2 state devices
and analogs for multiple state devices
34)What is open loop & close loop?

OPEN LOOP SYSTEM: An Open loop System is also known as the control system without
feedback . These systems do not have any any portion of output feedback to the input for
comparison and measurement. The components of these system are: input, processing system
and output.

CLOSED LOOP SYSTEM:

These system are also known as the system with feedback.In this system a portion of output is
feedback to the input side which is compared with the reference element and thus the error
occurred at that time is filtered out and output is desire output.
35)What are temperature elements?
Temperature sensors are devices used to measure the temperature of a medium. There are 2
kinds on temperature sensors: 1) contact sensors and 2) noncontact sensors. However, the 3
main types are thermometers, resistance temperature detectors, and thermocouples. All three
of these sensors measure a physical property (i.e. volume of a liquid, current through a wire),
which changes as a function of temperature. In addition to the 3 main types of temperature
sensors, there are numerous other temperature sensors available for use.
36) What is the use for cable entry in control room?(sleeves & MCT)