Control Valve

OBJECTIVE QUESTIONS

1. The gain of a PID controller is "1", Then proportional band is (B)

(a) 0%
(b) 100%
(c) 50%
(d) 1%
2. What is the unit of CV in control valves (D)
(a) Liters / Minute
(b) M3 / Hour
(c) Gallons / Hour
(d) None of the above
3. What is Beta Ratio on orifice flow calculation (A)
(a) Orifice dia / Pipe ID
(b) Pipe ID / Pipe OD
(c) Orifice dia / Pipe Od
(d) Orifice dia / 2
4. The drawback in Proportional only controller is (B)
(a) Dead band
(b) Offset
(c) Oscillatory response
(d) All of the above
5. The flow and the Differential Pressure across an Orifice Plate are (B)
(a) Inversely Proportional
(b) Directly Proportional
(c) Not related with each other
(d) Insufficient data
6. In a Reverse Action Controller, the controller output increases when process value is -------
--- set point (B)
(a) More than
(b) Less than
(c) Equal to
(d) None of the above
7. Zener Barrier is used for (A)
(a) To make the instruments intrinsically safe
(b) To make the instruments explosion proof
(c) To save energy
(d)
(e) To make the instrument respond fast
(f) Why are bleed valves used in gas turbines?
 A) Bleed Valves are provided to avoid surge in the air compressor during start-
up

1. When the pressurizing valve will open? Explain the logic.

2. What are the kind the control valves installed in GCs.
3. Name the parts of control valves?
4. Define proportional, integral, & derivative actions?

5. What is ratio control?

A) Ratio Control maintains the magnitude of a controlled variable at a fixed ratio to

another variable.

Transmitter
OBJECTIVE QUESTIONS

8. The two metal alloy elements in "K" type thermocouple is (B)

(a) Copper- Constantan

(b) Chromel - Alumel

(c) Platinum - Rhodium

(d) Chromel - Constantan

9. The resistance of PT-100 RTD is (C)

(a) 100 ohms at ambient temp.
(b) 0 ohms at 100 c
(c) 100 ohms at 0 c
(d) None of the above
10. The square root output of a flow transmitter when the input is 25% of the calibrated
range is (D)
(a) 5%
(b) 25%
(c) 62.5%
 (d) 50%
11. If Pressure Transmitter is calibrated in the range 0-60 kg/cm2, what is the output (in terms
of 4-20 mA) when the input is 22.5 kg/cm2 (A)
(a) 10 mA
(b) 12 mA
(c) 8 mA
(d) 16 mA
12. The type of Thermocouple for "Iron-Constantan" element is (D)
(a) T Type
(b) K Type
(c) R Type
(d) J Type
13. The output of a Turbine flow meter is in (B)
(a) Milliamperes
(b) Pulses
(c) Ohms
(d) Millivolts
1) The resistance of PT -100 RTD is (C)

a) 100 Ohms at ambient temp

b) 0 Ohms at 100 deg c.
c) 100 Ohms at 0 deg c.
d) none of the above.
2) How do you zero check a flow transmitter?

A) a) Open equalizing valve

b) Close impulse line valves

c) Open drain valves
3) Give the most commonly used engineering units for the following?

a) Very low Pressure (Inches of H2O)

b) Flow of Oil (BPD or Barrels per day) and (GPM or Gallons per Minute)

c) Temperature (Deg. C, Deg. F)

e ) Density (kg/cu.m and gm/c.c)

4) Name two methods detecting ignition?

A) U. V. Detector
Flame Rod
Thermocouple

5) What is the procedure of installing Bentley Nevada vibration probes?

A) a) Check linearity of probe using TK -3

b) Confirm length of the extension cable

c) Clean probe mounting area
d) Install vibration probe and adjust gap voltage accordingly
e) Tighten all connections
f) Check & note gap voltage

1 Describe briefly the calibration procedure of K type temperature indicator using

a milli volt source?

A) I) Note milli volts for ambient temp. from the table - X mV.

ii) Note milli volts for Zero - A mV and span - B mV.

iii) Apply (A-X) mV from the source and adjust zero.
iv) Apply (B-X) mV from the source and adjust span.
v) Repeat III & IV till no adjustment is required.
vi) Check meter for 25%, 50% and 75%.

2 What are most commonly used tap locations in orifice plate and why and for
what application bleed hole is provided?

A) Flange Taps, Pipe Taps

3 What are the various protection systems in a Gas Turbine?

A) a) Over Temperature

b) Over Speed
c) Under Speed
d) Surge
e) Vibration
 f) Diff – EGT (Exhaust Gas Temperature)
g) Lube Oil Temp. & Pr.
h) Fire and Gas
i) Low Fuel Gas

4 What is the principle of proximity type vibration probes?

A) Proximity probe works on the principle of Eddy current losses in the proximity of
conducting Material.

5 Name three types of pressure measuring elements?

A) Bourdon tube, Diaphragm & Bellows

6 What is surge in a compressor?

A) Momentary reversal of flow is called surge in a compressor.

The two metal alloy elements in "K" type thermocouple is (B)

a) Copper - Constantan

b) Chromel - Alumel

c) Platinum - Rohmium

d) Chromel - Constantan

The type of T/C for "Iron - Constantan" element is (D)

a) "T" Type
b) "K" Type
c) "R" Type
d) "J" Type
 Q. 4 What are commonly used unit of pressure? (C)

a) Meter
b) Feet.
c) PSI
d) Pound

What is the difference between "Absolute and Gauge pressure"? (A)

a) Absolute pressure > Gauge pressure

b) Gauge pressure > Absolute pressure + 14.667

c) Absolute pressure = Gauge pressure + 14.667

d) Gauge pressure = Absolute pressure + 14.667

Q.8 What are 5 commonly used units of flow rate measurement?

A) 1) M3 /Hrs.

2) GPM
3) BBL/DAY
4) SCFD
5) Litters per minute

Q. 9 How do you identify upstream side of an orifice plate from outside?

A) Marking on orifice tab is always on the up stream side.

 GIVE THE FLOW DIRECTION FOR THE GIVEN ORIFICE PLATE

Q.10 Give three most commonly used methods for level measurements?

A) 1) Manometer

2) Level transmitter with a sealed diaphragm sensing the head.

3) Displace type transmitters.

4) Differential pressure transmitter

5) Capacitive probes.

6. What is the difference between seismic probe and proximity probe?

7. Calibration procedure of flow transmitter, pressure transmitter and temperature
transmitter.
8. Write the specification of DP Transmitter?
9. How the tapping point is taken for flow transmitter for Gases, Liquids?
10. Write the kinds of thermocouples and its range? Also what type of thermocouples are
used in KOC areas?
11. What are the minimum tools required for instrument technician?
12. What is the type of instrument used to measure level in tank and separator? What is the
difference?

13. Explain each working functions.

14. A pressure Transmitter is calibrated for 600-psig range. We want change its range to 150
psig how can this be done and what are instruments required for calibration?

15. What is orifice Plate? Make a drawing of orifice palate? Where are orifice plates
installed in our plants?

16. What is the difference between reciprocating compressor and centrifugal compressor?
17. Explain the logic and protection devices used in Ruston Turbine?
18. Name the instruments installed in pump area and explain the logic?
19. What is UV / IR detector? What is Gas Detectors? Explain.
20. Explain the process of CRU by diagram.
21. When pump trips why CRU also trips after sometime? Explain the reason.
1. Which thermocouple is best suited for a range of 0-1200-deg C.

A) K-type (Chromel allumel)

2. Name some of the commonly used pressure measuring devices in process industry
B) Bourdon tube, Diaphragm, capsule, bellows

3. Draw a simple automatic control loop.

4. If the flow transmitter o/p is 6 psi what is the actual flow in %.

A) 50%

5. Describe briefly the calibration procedure of an inter-face Level Transmitter?

 A) On an interface level there are two liquids of different Densities.

Adjust zero level with the chamber filled with lighter liquid

PL note zero level = H*D H = ht of the displacer

D = sq.gr of the lighter liquid

Adjust span with the chamber filled with heavier liquid

6. Draw a block diagram of a Gas Turbine?

7. What is the difference b/w centrifugal and reciprocating compressor?

9) A) In a reciprocating compressor, a quantity of gas is drawn into a cylinder and

compressed by positive displacement where the mechanical energy is converted to
pressure energy.

In a centrifugal compressor compression is achieveded by applying inertial forces to

the Gas velocity energy is then converted to pressure Energy by decelerating the gas
through the diffuser
8. What is LEL with reference to Gas detection?

A) LEL stands for lower explosive limit

PLC
OBJECTIVE QUESTIONS

14. In Honeywell TDC - 3000 DCS, the controller should be put in ----------mode while
configuration a data point. (B)
(a) Auto mode
(b) Manual mode
(c) Cascade mode
(d) Auto -cascade mode
15. The output of a two input AND gate when both of the inputs are 1 is (B)
(a) 0
(b) 1
(c) 10
(d) None of the above
9. What are the advantages of PLC over conventional relay logic?

A) PLC is a) Compact

b) Easy to change the logic

c) Quick action (Fast scan rate)
d) No moving parts
e) Minimum failure
e) Can be interfaced with DCS and other control devices

f) Can perform complex functions

10. Draw the Architectural diagram of a DCS

6) What are the advantages of PLC over conventional relay logic?

A) a) Compact
b) reliable
c) performs complex functions
d) Logic can be changed easily
e) Can force the out put

7) The O/P impedance of an ideal op-amp is (B)

a) infinity b) zero c) unity

d )1000Ohms

7 Draw a simple block diagram of PLC?

8 What is the difference between EPROM and EEPROM which is better suited for
re-programming?
A) EPROM -Erasable Programmable Read Only Memory

EEPROM -Electrically Erasable Programmable Read Only Memory

Q.1 Zener Barrier is used for (A)

 a) To make the instrument intrinsically safe.
b) To make the instrument explosion Prof.
c) To save energy.
d) To make the instrument respond fast.

Q.7 The output of a two input AND gate when both of the inputs are 1 is: (B)

a) 0
b) 1
c) 10
d) None of the above.

22. What are the instruments connected to separators?

23. What are the continuos controls in CRU area?
24. Explain the plant shutdown logic with diagram.
25. Explain the controls in fuel gas system and HP system with controls.
26. Draw the logic and protection devices in CRU area.
27. Explain the Rosemount DCS system with diagram?
28. What is barrier? Where is it installed in our plants? What are classification of Zones in
our plants?
29. What is PLC Explain its working?
Q. 5 In Honeywell TDC - 3000 DCS, the controller should be put in ----------- Mode while
configuration of data point. (B)

a) Auto mode
b) Manual mode
c) Cascade mode
d) Auto - Cascade mode

DCS
OBJECTIVE QUESTIONS

8) Name the essential parts of a typical DCS system?

 A) a) I/O Modules

b) Signal Processor
c) History Module
d) Application Module
e) Work station (Including, Pheri-Pherals)
f) Removable media drives
g) Power Supply

9 When the operator puts a controller in automatic mode he has direct control
over (A)
a) Set point b) Process variable c) Output

1. Explain the Foxboro DCS with drawing explaining the basic components.
2. Name the DCS components of Foxboro I/A.
3. Explain the process of Desalter unit?
4. Explain heater logic with protection devices.
5. Explain the MMMS system followed in the KOC system? How the instruments are classified?
6. What is a loop diagram?
7. What is meant by Cause and Effect Diagram?

Q.11 Identify the symbols given below.

 NPN Transistor PNP Transistor Diode Zenor Diode SCR

+V

A A Volt
Y A Y Y
B
Vin
B

-V

-
Nand Gate Not Gate Exclusive OR Gate Op. Amp.
V

Lamp
C
Q This question itself is wrong
B
R1

+
S1

1 + -

+ - 2
 a) With switch SI connected to battery No.1 what is the status of the lamp ON or
OFF---------------why?
b) If the switch is operated to connect the battery No.2 what will be the status of
the lamp?
ON or OFF ------------why?

Q. What is the output logic?

0 OUT PUT? Zero

0
 OUTPUT ?

Q.11 What is "Off Delay" and "On Delay" timer? Draw them symbolically.

Q.12 Define following terms used in digital system?

CPU:-------------- HiwaY:----------------

ALU:-------------- DCS:--------------------

EPROM:------------ SCADA:----------------

RAM:---------------- PLC:---------------------

FLOPPY DISK:---- HARD DISK:--------

 MODEM:--------------

Q.13 Convert the following quantities:

Quantity Convert to

1200 mm H2O ------------------- psig

180 0 F ------------------- 0C

75 M -------------------- Feet

Q.14 What safety devices used in instrument air compressor?

Q.15 Write the truth table of "AND" gate.

Q,16 What are standard signals used for electronic and pneumatic transmitters?

a) Electronic -----------------------------------

b) Pneumatic ------------------------------------
Q.17 Give most commonly used Engineering units for the following in imperial system

Temperature ---------------- Density ------------------------

Gas Flow ------------------- Pressure -----------------------

Oil Flow --------------------- Vibration -----------------------

Tank Level ------------------

Q.18 What is meant by "Fail Close" and "Fail Open" in control valves?

What is importance?

Q.19 What is "Configuration" in a distributed control system?

Q. 20 Write 3 important sensors of temperature measurement?

Q. What is voltage logic levels of TTL and Ohms Ics Draw a TTLAND gate.

A. TTL operates normally at 12 V DC and 0V ohms ICS operate on 5v DC and 0V.

Ye

A
 B

Q. Draw half wave. Full wave and bridge rectifier. How a bridge rectifier is more efficient
than full wave rectifier.

-
 Full Wave

Half Wave

A. Bridge rectifier is more efficient than ordinary

Bridgefull wave rectifier because it requires
small transformer due to full use of its secondary.
Q. Draw a failsafe relay diagram with reset push button to give a contact for shutdown if
either pressure rises above 100psi or temp. goes below 50c.
Reset ps

R1
TS PS

R1

150'c 100 Psi

Q. What is Off delay and On delay timer. Draw them symbolically.
A. OFF DELAY - The timer relay whose contact change after the set delay after it is de-
energized. The contact however change immediately. It is energized again..
B. ON DELAY - The timer relay whose contact change after the set delay after it is
energized. The contact however immediately it de-energizes.

ON DELAY OFF DELAY

TDR
TDR
TR TR

Q. briefly explain the relay logic given below

A. At 50 psi (R) pressure timer operates if timer remain operated for set time and it
Rx is closed, the relay "R" energized. Relay "R" contact 1 energizes SOV and relay
"R" contact 2 gives lamp indication.

Rx
R
T1
 Sov
R1

R2

Q. Draw a typical motor start/stop push button with "AUTO" contract from inst. Interlocks.
Lamp

START STOP

R1
M

psi

R1

Q Draw a flow control loop showing flow of signals in DCS.

HTD
 DATA

DCS
H-WAY

O/P

ISB SLOT
A/D  CPU
CARD

I/P ISB
IS

s
 Fy

Q. What will be the reading on an uncompensated mV temp. indicator in two cases

shown below.

BATH -100 0 C

mV

- 10 0 C

FREEZER
DPDT SWITCH

Bath Temp reading -(100-25 =75* C

Freezer reading - (-10-25) = 35*C Ambient Temp. 25*C

Ans; A dP transmitter is to be calibrated for Crude (Density=0.85) tank level measurement as

shown below;(Pneu-3 to 15 psi and electronics-4 to 20mA)

2.50c _

Crude

50' h _

output

DP

Q. Describe briefly how a displacer type level transmitter works

Filter

Volts
 Air
Supply

RLY

Out pout

Q. Draw a simple sketch to show mounting of a dP cell for the following:

Ans. Gas flow measurement

DP

Cell

output
 Gas Flow

Crude Flow Measurement:

Crude

DP

Cell

output
Q Draw a simple dP cell installed for measurement. Name the parts and write steps
to perform on line zero check.

a) Open equalizer valve.

b) Isolate downstream and upstream isolation valve.
c) Opoen both drain valve.
d) Check zero and adjust if necessary.
e) Close drain valves.
f) Open upstream valve and check if any shift on zero.
g) Open downstream valve.
h) Close equalizing valve.

Orifice Plate

DP

Cell
 out

-put

Q. Three orifice are shown below. Write down the typical application for each of them .
Ans. A) Liquid flow (eccentric) B) Gas flow (concentric) C) Slurry (segmental)
Q. Draw a simple sketch of a pneumatic relay and explain.
Ans. When a back pressure from flapper nozzle changes pressure on the diaphragm, the
control ball attached to it changes it's positions whether more or less air supply to pass through
it thereby changing the output.

Filter Diaphragm

Nozzle

output

Q. Draw a 'AND' gate and a 'OR' gate for two inputs using pneumatic relays.
Ans. A) AND gate B) OR gate
A

Y A

C
C A C A C A

B B B B

Note:-

A) No pressure on diaphragm A to C
B) Pressure on diaphragm B to C
C) Y=A*B
Q. Explain 3 most commonly used valve plugs with characteristic curves.
Ans.

100% 100% Flow 100% Flow

0% 0% 0%

open open open

A) Linear B) Equal or Quadratic C) Quick opening

Or Parabolic

Q. Draw a simple flow control loop with square root extractor and a recorder to control
crude flow.
 P/P 3-15 psi

FCV

FR

A/S

Dp cell FC I/P

xmitter
 4-20 mA

A-20MA

Q. What is a cascade control? Why is cascading of controllers required in a certain

applications?
Ans. A) A cascade control is a control involving two or more controllers connected in such a
way that the output of one controller called the master of primary controller goes as a remote
set point to the other controllers called the slave or secondary controller.

B) A cascade control is used when the process control requirements for the master or primary
controlled process variable dictates a high degree of accuracy for the slave or secondary
controlled process variable.

TT
T/C

P/C

4 -20 m

A/s

I/P
P.T.
3 - 15 Psi
Q. Draw a flow control loop showing flow of signals in DCS.

I
I

Fev

4-20mA

PIV

Other PIVS or Com.

P Process

Interface

_ Unit

__
4-20 mA

Data

Hiway
O.P.

Stations

Traffic

Committee

Operator

Station
A) ADP tranmitter is to be calibrated for Crude (Density 0.85 ) Tank level measurement as
shown below-

2.5" wc
Vapour Pressure

50'

CRUDE Output
DP

Cell

Drain
B) Describe briefly how a displacer type level transmitter works.

A.S.

Relay
Q) Draw simple sketch to show mounting of a DP cell for
I) Gas measurement II) Crude Flow measurement.

DP

Cell

GAS DP

Cell

CRUDE
Q) Draw a simple DP cell installed for flow measurement name the parts and write steps to
perform on line zero check.

Secondary isolation Equalizer

DP

Cell

Drain Valve

Primary Isolation

Drain

Up stream

Process line Orifice

Q) What is a CASCADE Control, why is casecading of controllers required in certain
applications.

M.V.1 Master Slave

MVL
Controller Controller

R/2
O/P Remo--- selection

Set Point

Lower set point

Q) Draw a bridge circuit using resistance thermometer for measurement indication?

RTA

Q) Draw simple sketch to show mounting of a DP Cell and Orifice for Gas measurement.

DP

Cell
 GAS

Q) Draw a relay circuit with manual reset push button to give indication whenever either
temperature goes high or pressure goes low?

MASTER

Shave

S.P. M.V. S.P. M.V.

To actuator

O/P
P&ID
OBJECTIVE QUESTIONS