Instrument Notes

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INDEX
1. Instrumentation…
2. Instrument abbreviations…
3. Instrument symbols…
4. Safety…
5. Multimeter…
6. Relay & contactor….
7. Two wire & four wire transmitter system…
8. Temperature measurement…
9. Pressure measurement…
10. Level measurement…
11. Flow measurement…
12. I to P converter…
13. Control valve…
14. Loop diagram, safety barrier and loop checking…
15. HART communicator…
16. Vibrating monitoring system…
17. Cable gland, Cable lug, Cable tray and Tube…
18. Interview questions for process control instruments…
CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

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INSTRUMENTATION
What is instrument?
 Measurement
 Controlling
 Monitoring
 Display
Instrument is a device which is use for measurement, controlling, monitoring and display of process variables.
OR
Instrument is used for measurement and controlling of process variable.
What is instrumentation?
Instrumentation is a branch of an engineering which deals with measurement, controlling, monitoring and
display of process variable.
Crude oil

Process

Heat

Petrol Diesel Naphtha Kerosene Gasoline
What are the process variable?

 Temperature
 Pressure
 Level
 Flow
INSTRUMENT TECHNICIAN

  
Project works Shut down works Maintenance works
Construction works, to build new plant (Running plan repair & maintenance)
 
Instrument installation  Trouble shutting
Calibration (problem solve; break down)
Loop checking
Function test CM – Corrective maintenance
Cable Glanding PM – Preventing maintenance
Cable pooling / dressing
Cable tray work, Tubing work

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INSTRUMENTS ABBREVIATIONS
 ISA : Instrument Society of Automation
 DCS : Distributed control System
 PLC : Programmable Logic Controller
 SCADA : Supervisory Control and Data Acquisition System
 HMI : Human Machine Interface
 HART : Highway Addressable Remote Transducer
 LRV : Lower Range Value
 URV : Upper Range Value
 FF : Foundation Field bus
 PROFIBUS : Process Field bus
I/P : I to P converter
 ILD : Instrument Loop Diagram
 P & ID : Piping & Instrument Diagram
 IP : Ingress Protection
 ESD : Emergency Shut Down
 PPE : Personal Protective Equipment
 EX : Explosion Proof
 IS : Intrinsically Safe
 NO : Normally Open
 NC : Normally Close
 TT : Temperature Transmitter
 PT : Pressure Transmitter
 LT : Level Transmitter
 FT : Flow Transmitter
 DPT : Differential Pressure Transmitter
 TI : Temperature Indicator
 PI : Pressure Indicator
 LI : Level Indicator
 FI : Flow Indicator
 TIC : Temperature Indicating Controller
 PIC : Pressure Indicating Controller
 LIC : Level Indicating Controller
 TB : Terminal Block
 FIC : Flow Indicating Controller
 TCV (TV) : Temperature control Valve
 PCV (PV) : Pressure Control Valve
 LCV (LV) : Level Control Valve
 FCV (FV) : Flow control Valve
 TE : Temperature Element
 RTD : Resistance Temperature Detector
 T/C : Thermocouple
 TW : Thermo well
 C/V : Control Valve
 CV : Coefficient Value
 AS : Air Supply
 AFR : Air Filter Regulator

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 FC : Fail To Close
 FO : Fail to Open
 SOV : Solenoid Valve
 SDV : Shut Down Valve
 MOV : Motor Operated Valve
 PSV : Pressure Safety Valve
 TSO : Tight Shut Off
 LSC : Limit Switch Close
 LSO : Limit Switch Open
 PSI : Pound Per Square Inch
 MMWC : Millimeter Water Column
 PV : Process Value
 SP : Set Point
 PTW : Permit to Work
 PID : Proportional + Integral + Derivative
 FBM : Field bus Module
 PG : Pressure Gauge
 TG : Temperature Gauge
 JB : Junction Box
 TB : Terminal Block
 ZB : Zone Barrier
I/O : Input output
I/P : Input
O/P : Output
 AI : Analog Input
 AO : Analog Output
 DI : Digital Input
 DO : Digital Output
 TAH : Temperature Alarm High
 TAL : Temperature Alarm Low
 TAHH : Temperature Alarm High High
 TALL : Temperature Alarm Low Low
 PAH : Pressure Alarm High
 PAL : Pressure Alarm Low
 PAHH : Pressure Alarm High High
 PALL : Pressure Alarm Low Low
 LAH : Level Alarm High
 LAL : Level Alarm Low
 LAHH : Level Alarm High High
 LALL : Level Alarm Low Low
 FAL : Flow Alarm Low
 FAH : Flow Alarm High
 FALL : Flow Alarm Low Low
 FAHH : Flow Alarm High High
P/P : Pneumatic Positioner
E/P : Electro Pneumatic Positioner

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INSTRUMENTS SYMBOLS
: Transmitter (PT, TT, FT, LT, DPT)
: Indicator
I/P : I to P Converter
T/I : Temperature Indicator (LI, FI, PI)
TIC : Temperature Indicating Controller (PIC, LIC, FIC)
PS : Pressure Switch (TS, FS, LS)
: RTD – (Resistance Temperature Detector)
: Thermo Couple
: Orifice Plate
: Earthing (Shielding)
: DCS Supply Voltage
: Venturi tube
: Pump
: Reducer
I : Interlock

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: PLC (Programmable logic controller)
: DCS (Distributed control system)
: NO Push button (Normally Open)
: NC Push button (Normally Close)
: Horn
: Control Valve
P/P
: Control valve with pneumatic positioner
E/P
: Control valve with electro pneumatic positioner
S
: Solenoid valve 2 way
S
: Solenoid valve 3 way
: Ball valve
: Butterfly valve
M
: Motor operated valve

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: Air to open valve
: Air to close valve
: Electrical signal (ILD)
: Pipeline signal (P & ID)
: Air line or pneumatic signal
: Electrical signal continuous
: Internal data link
: Capillary line
: Hydraulic line
: Resister
: Capacitor
: Diode
: Coil
: AC signal
: DC signal
: Open tank
: Close tank
: Pipeline

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SAFETY
What is PPE? What are the PPE?

PPE: Personal Protective Equipment
 Safety Helmet
 Safety Shoes
 Safety Goggles
 Ear Plug
 Nose Mask
 Hand Gloves
 Coverall
What are the types of work permit?

1. Hot Work Permit
2. Cold Work Permit
3. Confined Space Entry Permit / Enclosed Space Permit
HOT WORK
The work which creates spark, heat, smoke and flame that work is called hot work.
E.g. welding, Cutting, Grinding, Drilling
COLD WORK
The work which does not creates smoke, heat and flame but there is possibility to create spark that work
called cold work.
E.g. Instrument Installation, Field Calibration, Loop Checking, Trouble shooting, Function Test
CONFINED SPACE
The space which having only one entry but there no exits that space is called confined space.
E.g. Tank or vessel, pipeline (inside), distillation column, well or sump, excavation (>1.2 meter)
What is hazardous area?

Hazardous area is an atmosphere that consists of explosive gas, vapor, mists and dust.
Hazardous area means it’s a danger area, oil and gas area is called hazardous area where an explosive gas is
mixed with air and atmosphere.
What is zone?
Zones are used to define the hazardous material or explosive gas presents in atmosphere.
What are the types of zone?

There are three types of zone
 Zone 0 - Most dangerous area
 Zone 1
 Zone 2

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Zone 0
Area in which an explosive gas is presents continuously
OR
Presents of an explosive gas in atmosphere above 1000 hrs in a year.
Zone 1
Area in which an explosive gas presents for short time.
OR
Presents of an explosive gas in atmosphere from 10 to 1000 hrs in a year.
Zone 2
Area in which an explosive gas presents for very short time.
OR
Presents of an explosive gas in atmosphere less than 10 hrs in a year.
MULTIMETER
What is multimeter?
Multimeter is a device which is used to measure Voltage (AC / DC), Current (AC / DC), resistance, milli
ampere, milli volts and Cable Continuity.
Company : Fluke, USA

Rishabh
Motwani
UNITS OF MEASUREMENT
Measurement Units Symbol

Voltage Volt V
Current Ampere A,I
Resistance Ohm Ω
Power Watt W
Frequency Hertz Hz
Capacitance Farad F
Ω
mV Diode
V mA
A
V A mA com. VΩ MA (micro ampere)
OFF Red Red Black Red

Fix

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RED PROBE
BLACK PROBE
AC VOLTAGE DC VOLTAGE
E N + L = 230V AC
E + L = 230V AC
N + E = 0V
N P
How to measure voltage and current?
P A
Current
230V V voltage M motor
 Voltage always measured in parallel.

 Current always measured in series.
RELAY
COIL
+ -
C C = Common
Open 0Ω NO = Normally Open
(OL) NC = Normally Close
NO NC
What is relay?
Relay is used to change over contact from NO to NC and NC to NO.
Relay is used to operate low ampere device that is bulb, alarm, contactor and solenoid v/v.
Generally 24V DC Relay is used.
How to check of Relay, Contactor and SOV?

Keep multi meter in resistance (Ω) mode. It will show ok or not ok.
Ok = 100 Ω to 2000 Ω
Not ok = Open (OL, M Ω)
= Short (0 Ω)
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 Simple circuit diagram using relay and bulb:-
N P 24V DC
230V
AC + -
C Relay
NO NC
P
Bulb (230V AC)
N
CONTACTOR (K)
24V DC
OR K
230V AC
What is contactor?
Contactor is used to change over the contact from NO to NC and NC to NO.
Contactor is used to operate high ampere device that is motor, heater.
Generally 24V DC and 230V AC contactor is used.
N P 24 DC
230V + - Relay
AC C
NO NC
3ø phase
A1/P
K
230V
AC
A1/N
M Motor

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TRANSMITTER
What is transmitter?
Transmitter is a device which is used for measurement of process variable those are temperature, pressure,
level and flow.
Manufacture Company
Name Of Company Country Color of Instrument

Rosemount USA Blue
Emerson USA Blue
Endress + Houser ( E + H ) USA Blue + White
Honeywell USA
Foxboro USA Grey
Yokogava Japan Dark green
Siemens Germany Green
Krohne Germany Dark blue
ABB Switzerland White
TWO WIRE TRANSMITTER SYSTEM
Transmitter supply voltage = 24V DC

Transmitter Output = 4.00mA to 20.00mA DC
TWO WIRE TRANSMITTER DIAGRAM
24v
DC Transmitter
Supply
M/M
4.00mA to 20.00mA DC

Process Variable
 Generally all Transmitter works on two wire transmitter system.

 Transmitter supply voltage is 24V DC which is applied to transmitter in parallel.
 Transmitter output is 4.00mA to 20.00mA DC that is current output.
 We know that current is always measured in series so here (-) to (-) line (in diagram) is standard
series line so using multi meter in series we can measure output 4.00mA to 20.00mA DC.
 From this 4.00mA to 20.00mA DC signal we can get process variable those are temperature,
pressure, level and flow.
24v
DC Transmitter 24VDC Transmitter
Supply Supply
DCS DCS
Two wire transmitter diagram Note: Indicator, DCS, PLC and controller are always connected in series.

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Why 4.00mA to 20.00mA DC signal use for signal transmission?
Tx
+ 4.00mA 4.00mA +
DCS 0o/open
- 0mA -
Cable cable break (open)
0mA to 20.00mA DC
Tx
+ 0mA 0mA +
DCS 0o/ 0o C
- 0mA -
Cable cable break (open)
 Voltage will drop for long distance so that voltage signal will not used.
 Current will not drop for long distance so that 4.00mA to 20.00mA signal is used.
 Using 0mA to 20.00mA signal we cannot differentiate that actual process value is zero (0) or there
will be open circuit (cable break).
 Linear part can be check that is 4.00mA, 8.00mA, 12.00mA, 16.00mA, 20.00mA.
 4.00mA is called live zero.
FOUR WIRE TRANSMITTER
Tx. Supply terminal

Supply 24V DC +/P
OR -/N Output terminal

230V AC Output DCS
24V DC
Supply
(SMPS) Terminal Block
Jumper
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
DCS
TT TIC
DCS
Loop 1 PL LIC
DCS
Loop 3
PT PI PIC
Loop 2

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TEMPERATURE MEASUREMENT
What is temperature?
Temperature is the degree of hotness and coldness of a body.
It is to be measure hotness and coldness of process medium.
UNITS:
 Degree Celsius ( oC )
 Degree Fahrenheit ( oF )
 Kelvin ( K )
 Degree Ranking ( oR )
Conversion from oC to oF and o

F to oC
Formula: o
C = oF – 32 1
1.8
 o
C x 1.8 = oF - 32
 (oC x 1.8) + 32 = oF
o
F = (oC x 1.8) + 32 2
Example = 1 Example = 2 Example = 3 Example = 4
1000 F = ? oC 1500 C = ? oF 50oC = F? -40oC = F?
C = oF – 32
o 0
F = (oC x 1.8) + 32 0
F = (oC x 1.8) + 32 0
F = (oC x 1.8) + 32
1.8
= ( 150 x 1.8 ) + 32 = (50 x 1.8) + 32 = (-40 x 1.8) + 32
100 – 32
1.8 = 270 + 32 = 90 + 32 = -72 + 32
68 = 3020 F = 122oF = -40oF

1.8
= 37.77 0C

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What are the temperature sensing elements (TE)?

RTD, Thermocouple
TTx DCS
RTD or T/C
TIC
RTD
RTD = Resistance Temperature Detector
 RTD is a temperature sensing element.

 RTD is used to measure low temperature.
 Range of RTD is -1000C to 3000C.
 Output of RTD is resistance of source in ohms (Ώ).
 RTD works on the principle of “change in resistance”.
 When temperature changes resistance also change.
 When temperature increase resistance also increase.
TEMPERATURE (Celsius)oC PT 100 RESISTANCE (ohms) Ω

0 100.00
30 111.86
50 119.46
100 138.51
150 157.33
200 175.86
300 212.05
What is PT 100?
Terminal
PT 100
Head
SS Tube
Platinum 100 Ώ Resistance Bulb
When temperature is O 0C, Resistance is 100 Ω…. RTD

0
O C 100 Ω

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What is PT 100 formula to find out resistance?
1st Formula
RT = Ro * (1 + αT)
Where,
RT = Resistance of temperature to be measure.
Ro = Resistance at 0o C = 100 Ω
α (alpha) = temperature coefficient = 0.00385
T = temperature to be measure.
Example: 1. Example: 2.
30 oC ?Ω 100 oC ?Ω
RT = Ro * ( 1 + αT ) RT = Ro * ( 1 + αT )
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. Example: 4.
200 oC ?Ω 300 oC ?Ω
RT = Ro * ( 1 + αT ) RT = Ro * ( 1 + αT )
R200 = 100 * (1 + (0.00385*200)) R300 = 100 * (1+ (0.00385*300))
= 100 * (1 + 0.77) = 100* (1 + 1.155)
= 100 * 1.77 = 100 * 2.155
= 177 Ω = 215.5 Ω
2nd Formula
RT = R0 * ( 1 + AT + BT2) Where, A = 3.9083*10-3
B = -5.775*10-7
300 oC ?Ω
RT = R0 * ( 1 + AT + BT2)
R300 = 100 * { 1 + (3.9083*10 -3*300)+(-5.775*10-7*3002)}
= 100 * ( 1 + 1.17249) + (-0.051975)
= 100 * 2.12
= 212.05 Ω
What are the types of RTD?
There three type of RTD

 Two wire RTD PT 100
 Three wire RTD PT 200
 Four wire RTD PT 1000
Cu 2000
Ni 120

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TWO WIRE “RTD”
RTD RTD Tx
100 Ω 100 Ω
1main 2com.
Cable
111Ω 0o C Short distance
Depends on room temp.
 Two wire RTD is used for short distance.

 Not accurate for long distance.
 Can be use up to 100 meters.
THREE WIRE “RTD”
RTD
RTD Tx
1main com.2 3com 100 Ω 100 Ω
111 Ω 0Ω
cable
111 Ω 0C o
Long distance
Depends on room temp.
 Three wire RTD is used for long distance.

 Accurate for long distance.
 Can be used up to 500 meters.
Note : 3rd wire is used to cancel the resistance of cable (lead wire). OR Used to compensate
the resistance.
FOUR WIRE “RTD”

RTD
Main com.
1 2 3 4
 It is used for very long distance.
 Can be use up to 1000 meters. (1 Km)
SIMPLEX DUPLEX
3 Wire RTD 3 Wire RTD
M M
C C C

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CALIBRATION
What is calibration?
It is to be compare measuring instrument with the 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”.
Measuring Compare Standard

Instrument Instrument
 
Instrument to be source / calibrator
Calibrate / test ** Fluke – US
** Druck – Germany,
** Bemax – UK
TEMPERATURE TRANSMITTER
 Temperature transmitter is used to measure process temperature of tank, pipeline and machine.
 Output of temperature transmitter is 4.00mA to 20.00mA DC.
 Two temperature sensor that is RTD and thermocouple connected to temperature transmitter (But
one at a time only).
CALIBRATION: 1
Company : Rosemount
Model No.: 244 1 2 3 + -
Range: 0 to 200oC main common 24V DC
Supply
Output: 4.00mA to 20mA DC
Supply voltage: 24V DC
Input PT100 (RTD)
Calibration Table:
Standard Instrument
mA Output Range in C o
Resistance in Ω
(Z) 4.00 0o 100.00 Resistance source
8.00 50o 119.46 OR
(L) 12.00 100o 138.51 Resistance Calibrator
16.00 150o 157.33 OR
(S) 20.00 200o 175.86
Resistance Simulator
Calibration Circuit Diagram
24V DC Tx
Supply
m/m +
Resistance Source

Page 19 of 137
Resistance Source Box
9 9 9 9 9 9 9 9 C
100K 10K 1K 100 10 1 0.1 0.01 M
175.86 Ω
1 7 5 8 6 175.86Ω 1 2 3 Sensor
Terminal
1 0 0 0 0 100.00Ω TTx.
1 1 9 4 1 119.41Ω
SUPPLY
0 0 0 1 3 5 5 1 135.51Ω
1 3 5 5 1 135.51Ω 24V DC Supply TERMINAL
0 8 0 3 1 080.31Ω
MM
Resistance Simulator
600o 400o
o
800
200o
0oC 100o
10o 80o
20o 40o
M C
Sensor terminal
1 2 3
TTx.
Supply + Supply terminal

24V DC -
- +
M

Page 20 of 137
How to calibrate temperature transmitter?
 Connect 24V DC supply to transmitter.

 Connect multimeter in series with supply.
 Connect resistance source at sensor terminal in temperature transmitter.
 Apply resistance from resistance source and check Zero, Span and Linearity according to range.
 Now apply resistance according to range (LRV).
 Check Zero (4.00mA). If it is disturb than adjust it using Zero pot or Push button or HART.
 Now apply resistance according to range (URV).
 Check Span (20.00mA). If it disturb than adjust it using Span pot or Push button or HART.
 Check Linearity (12.00mA) by applying 50% input temperature.
 If Zero, Span, Linearity is ok than calibration is ok.
CALIBRATION: 2
Company: Rosemount HART Smart

Model Number: 3144
Range Limit: -200 to 850oC
Output: 4.00mA to 20.00mA DC.
Supply Voltage: 12 to 42.4V DC (24V DC)
Input type: PT 100 type (RTD)
PT 100, α = 0.00385, 3 wire
Note: In this transmitter we can change range and unit by using HART communicator. Actual range
limit for this temperature transmitter is -200 to 850oC. So we can change any range in between
-200 to 850oC.
Field Terminal
1
2 Sensor Terminal
(RTD and TC)
24V DC 3
Test Point
4
5
1 2 1 2 1 2
3 3 3
4 4 4
5 5 5
TWO WIRE RTD TRHEE WIRE RTD FOUR WIRE RTD

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Calibration Range: 0oC to 300oC

 
LRV URV
 
4.00mA 20.00mA
Calibration Table:
mA Output Range in oC Resistance in Ω

(Z) 4.00 0o 100.00
8.00 75o 128.99 Resistance Source
(L) 12.00 150o 157.33
16.00 225o 185.01
(S) 20.00 300o 210.05
Calibration Diagram:
TTx
1 2 3
Resistance source (Ω)
24V DC
supply
HART
mA (output)
CALIBRATION: 3

Model number: 644
Range Limit: -200oC to 850oC
Output: 4.00mA to 20.00mA
Supply Voltage: 12 to 42.4V DC (24V DC)
Input Type: PT 100 (RTD)
PT 100, α = 0.00385, 3 Wire
1 2 3 4 Sensor Terminal
o
C/mA M C C X
Display of
“BED SENSOR FAIL” Transmitter + -

Page 22 of 137
Thermocouple
2 wire
4 wire
3 wire
Calibration Range: -50oC to 150oC

 
LRV URV
 
4.00mA 12.00mA
Formula:--- Division: URV - LRV

4
Calibration Table:
mA Output Range in oC Resistance in Ω

(Z) 4.00 -50o 80.31
8.00 0o 100.00 Resistance Source
(L) 12.00 50o 119.46
16.00 100o 138.51
(S) 20.00 150o 157.33
What are the instruments used for temperature transmitter (RTD) calibration?
 Resistance Source
 Multi meter
 HART Communicator
 24V DC Supply
 Necessary tools
THERMOCOUPLE (T/C)
 T/C is a temperature sensing element.

 T/C is used to measure High temperature.
 Output of T/C is millivolt (mV)
 T/C works on the principle of “Seeback Effect”.
 T/C was first introduced in the year of 1821 by German scientist called T.J.Seeback.
What is “Seeback Effect”?

When heat applied at hot junction, millivolt generated at cold junction.

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Temperature Terminal
mV + -
+ - Cold Junction
(Reference Junction) T/C
Metal A Metal B SS Tube

(+) (-)
Hot Junction
What are the types of T/C?

 E Type T/C
 J Type T/C
 K Type T/C
 R Type T/C
 S Type T/C
 T type T/C
Which type of T/C is mostly used in industry?

“K” type Thermocouple.
What is the range, metal and color code of “K” type T/C?
Range: -180oC to 1260oC
Metal: Chromel Alumel
(+) (-)
Color: Yellow Red
TYPES OF T/C, METAL, COLOR AND RANGE
TYPES POSITIVE METAL NAGATIVE METAL RANGE

E CHROMEL CONSTANTAN -1800C to 8700C
( PURPLE ) ( RED )
J IRON CONSTANTAN -1800C to 7600C
( WHITE ) ( RED )
** K CHROMEL ALUMEL -1800C to 12600C
( YELLOW ) ( RED )
R PLATUNUM WITH 13% RHODIUM PLATINUM 00C to 15930C
( BLACK ) ( RED )
S PLATUNUM WITH 10% RHODIUM PLATINUM 00C to 15380C
( BLACK ) ( RED )
T COPPER CONSTANTAN -1800C to 3500C
( BLUE ) ( RED )

Page 24 of 137
What are the difference between RTD and T/C?
RTD THERMOCOUPLE
RTD is used to measured low temperature T/C is use to measured high temperature
Output of RTD is Resistance in ohms (Ω) Output of T/C is Millivolt ( mV)
Principle of RTD is Change in Resistance Principle of T/C is Seeback Effect
RTD sense temperature by resistance Bulb T/C sense temperature by two different metal
RTD having terminal of main and common T/C having terminal of (+) and (-)
Any cable can be use for signal transmission Special purpose cable is used for signal transmission
(Between T/C and TTx)
OR
Same metal of T/C, cable is used, if “K” type T/C use
than “K” type cable is used.
Calibration of temperature transmitter (T/C Input)
When calibrating temperature transmitter, millivolt is to applied from millivolt source according to range and
chart value. But here chart value given at cold junction 00C, but our cold junction is at room temperature. So
here room temperature millivolt is to be minus from chart millivolt then actual millivolt to be apply from mV
source to temperature transmitter.
Sensor Terminals
+ -
Millivolt Source
+ -
For Example:
Room Temp. = 300C

300C = 1.203 mV
Formula:
Actual mV = Chart mV – Room temp mV.
For 1000C = 4.096 mV – 1.203 mV For 5000C = 20.644 mV – 1.203 mV

= 2.893 mV = 19.441 mV

= 6.935 mV = 40.073 mV

= 11.006 mV = 47.635 mV

Page 25 of 137
CALIBRATION: 1

Model Number: 3144
Range Limit: -1800C to 13720C
Output: 4.00mA to 20.00mA
Supply Voltage: 12V to 42.4V DC (24V DC)
Input “K” type T/C.
Field Terminal 1
2
+
24V DC
Supply 3
-
Test Point
4
5
Calibration Range: 00C to 12000C

 
LRV URV
 
4.00mA 12.00mA
Calibration Table:
mA Output Range in oC mV at 30 oC
(Z) 4.00 0o -1.203
8.00 300o 11.006 Millivolt Source
(L) 12.00 600o 23.702
16.00 900o 36.123
(S) 20.00 1200o 47.635
0 mV Room Temp. ( 30 oC)
CALIBRATION DIAGRAM
TTx
Millivolts
24V DC Source
supply
HART
mA (output)

Page 26 of 137
How to get room temperature in temperature transmitter?
Sensor Terminal
+ -
mV
Short Link
Connect Short Link at (+) and (-) Sensor, Terminal TTx shows room temperature.
If T/C is on the table, room temperature is 70 oC. Than what will be the millivolt output of
thermocouple?
Actual mV = Chart mV – Room temp. mV

= 2.851mV – 2.851mV
= 0 mV
** Hot junction temperature = Cold junction temperature = 0 mV
If T/C is in the tank. Tank temperature is 1500C. Room temperature is 370C than what will be the mV
output of T/C?
Actual mV = Chart mV - Room temp

= 6.138 mV - 1.489 mV
= 4.649 mV
If T/C is in the tank. Output T/C is 5.98 mV. Room temp is 330C. Then what will be the temperature of
tank?
Actual mV = Chart mV - room Temp mV

Chart mV = Actual mV + Room Temp mV
= 5.98 mV + 1.326 mV
= 7.306 mV
Tank Temp. = 1790C
How to calibrate temp Transmitter (T/C input)?
 Connect 24v DC supply to transmitter.

 Connect multimeter to transmitter in series with supply.
 Connect millivolt source at sensor terminal in temp Transmitter.
 Apply millivolt from millivolt source and check zero, span and linearity according to range.
 Now apply millivolt according to range.(LRV)
 Check zero (4.00mA), if it is disturb than adjust in using zero POT or push button or HART.
 Now apply millivolt according to range (URV)
 Check Span (20.00mA).if it is disturb than adjust using POT or push button or HART.
 Check linearity (12.00mA) by applying 50% input millivolt.
 Now zero, span, linearity ok than calibration is ok.

Page 27 of 137
What are the instruments used for temp transmitter (T/C) calibration?
1. Millivolt source
2. Multimeter
3. 24V DC supply.(optional  Depend on field OR lab)
4. HART communicator.
5. Necessary Tools/Tool kit.
THERMOWELL
What is Thermo well?
Thermo well is used for protect temperature sensor (RTD, T/C) from high pressure process and corrosion.
1000C
RTD or T/C
To Tx
Thermo well
Tank
Silicon oil
TEMPERATURE SWITCH (TS)
Company: Danfoss
1/C 4/NO
Temperature
C Switch
2/NC
0 Ω C = Common
NO = Normally Open
Contact
NO NC Open (OL) NC = Normally Close
Bellows
USE (Applications):
 Temperature switch is used to change over contact from NO to NC and NC to NO when
temperature reaches to set point.
 Generally mercury type or Gas filled type switch is used.
 If set temperature is 700C on temperature switch will operates and change its contact from NC to
NO and NO to NC.
 Temperature switch is used for Alarm purpose and Heater control.

Page 28 of 137
3
C NO NC
2
How to calibrate RTD, T/C, Temp. Switch and Temp. Gauge?
Temperature bath is used to calibrate RTD, T/C, Temperature Switch and Temperature Gauge.
TEMPERATURE BATH
Multimeter
(Ω, mV, Contact)
Temp.controller
Set: 100
Read:100 Insert RTD, T/C, TS, TG
Heater & Fan system
 Switch ON temperature bath.

 Keep temperature sensor (RTD, T/C) in temperature bath.
 Connect multimeter at sensor terminal.
 Set temperature on temperature bath.
 Wait till temperature get stable according to set temperature.
 Now check resistance, millivolts and contact change in multimeter according to set temperature.
 For RTD: If set temperature is 1000C then check resistance is 138.51Ω in multi meter.
 For T/C: If set temperature is 1000C then check millivolts in multimeter (chart mV – room temp,
mV).
 For Temperature Switch: If set temperature is 700C. When Temperature reaches to 700C then
check its contact from NO to NC and NC to NO.
 For Temperature Gauge: Check deflection of pointer on scale as per Set Temp. Then increase
temp. and check for other value.

Page 29 of 137
What will be the mA output of temperature transmitter when temperature of tank is 125 0C?
Range = 00C to 3000C Process Value = 1250C URV = 3000C
mA =
= (0.4166 X 16) + 4
= 6.66 + 4
= 10.66mA
Pipeline temperature = 650C
PV = 650C Range = 00C to 1000C
mA =
= (0.65 X 16) + 4
= 10.4 + 4
= 14.4mA

Page 30 of 137
PRESSURE MEASUREMENT
What is pressure?
Force acting per unit area.
Pressure = Force / Area = P = F/A
UNITS:
 kg / cm2
Use for
High pressure
 Bar
 psi (Pound Per Square Inch)
 Pascal (kpa = kilo Pascal)
 mmH2O (MMWC = millimeter water column)
Use for  mmHg
Low Pressure
 InH2O
 InHg
PRESSURE CONVERSION:
 1 Kg / cm2 = 14.223 psi

 1 Bar = 14.504 psi
 1 kg / cm2 = 0.98 Bar
 1 Bar = 1.0197 kg/cm2
 1 Bar = 100000 pascal (100 kpa)
 1 kg / cm2 = 1000 mmH2O
 1 kg / cm2 = 735.5 mmHg
 1 Bar = 750 mmHg
Convert Following
1. 55 psi = ? Bar 2. 3.5 kg/cm2 = ? psi
14.504 psi 1 Bar 1 kg/cm2 14.223 psi

55 psi ? Bar 3.5 kg/cm2 ? psi
= 55 / 14.504 = 14.223 * 3.5
= 3.792 Bar = 49.780 psi
= 3.8 Bar = 49.8 psi
3. 500 psi = ? kg / cm2 4. 10 kg / cm2 = ? Bar
14.223 psi 1kg / cm2 1 kg / cm2 0.98 Bar

500 psi ? kg / cm2 10 kg / cm2 ? Bar
= 500 / 14.223 = 10 * 0.98
= 35.15 kg / cm2 = 9.8 Bar

Page 31 of 137
PRESSURE CONVERSION
TO/FROM PSI kpa InH2O mmH2O InHg mmHg BAR mBAR kg/cm2 gm/cm2 atm Mpa
PSI 1 6.8948 27.73 704.332 2.036 51.715 0.0689 68.9476 0.0703 70.307 0.06805 0.0069
kpa 0.145 1 4.0218 102.155 0.2953 7.5006 0.01 10 0.0102 10.197 0.01 0.001
In/H2O 0.0361 0.2486 1 25.4 0.0734 1.865 0.0025 2.4864 0.0025 2.5355 0.0025 0.00025
mmH2O 0.0014 0.0098 0.0394 1 25.4 0.0734 0.0001 0.0979 0.00001 0.0998 0.0001 0.00001
InHg 0.0412 3.3864 13.6195 345.936 1 25.4 0.0339 33.8639 0.0345 24.532 0.034 0.003
mmHg 0.0193 0.1333 0.5362 13.6125 0.0394 1 0.0013 1.3332 0.0014 1.3595 0.0013 0.0001
BAR 14.504 100 401.86 10197.2 29.53 750.06 1 1000 1.0197 1019.72 0.99 0.1
mBar 0.0145 0.1 0.4022 10.2155 0.0295 0.7501 0.001 1 0.001 1.0197 0.00099 0.0001
2 14.223 98.067 394.09 10000 28.959 735.559 0.9807 980.665 1 1000 0.968 0.1
Kg/cm
2
gm/ cm 0.0142 0.0981 0.3944 10.018 0.029 0.7356 0.001 0.9807 0.001 1
What are the pressure sensing elements?
There are three types’ of pressure sensing elements:
1. Bourdon Tube
 C type bourdon tube
 Helical
 Spiral
2. Bellows
3. Diaphragm
Above all pressure sensing elements works on “Shape Change” principle.
“C” TYPE BOURDON TUBE
Range: 0 to 100000 psi (7030.86 kg/cm2)
Movement (Shape Change)
Close End
(Tip)
Pressure
 Bourdon tube material

o Copper
o SS (Stainless Steel)
o Bronze

Page 32 of 137
BELLOWS
Close End
Seamless Tube

Pressure
Range : 0 to 800 psi -----55.16 Bar
DIAPHRAGM
 Diaphragm is used to low pressure measurement.

 Diaphragm is very sensitive to small change in pressure.
 Diaphragm is used in pressure transmitter and differential pressure transmitter.
Diaphragm
PRESSURE GAUGE
Company:Wika
Ashcroft
Baumer
Altop
 Pressure gauge is used to measure process pressure of tank, pipeline, machine.

 Pressure gauge works on the principle of “Hook’s Law”.
 Hook’s Low state that “Measuring pressure in elastic medium”.
Scale
Close End
Pointer
Zero Adjustment
Hair Spring Connecting Link
Span Adjustment
Gear sector
and Pinion arrangement
Pressure

Page 33 of 137
What are the parts of Pressure Gauge?
1. “C” type bourdon tube

2. Scale
3. Pointer
4. Hair spring
5. Connecting link
6. Zero adjustment
7. Span adjustment
8. Gear sector and pinion arrangement
Why Oil filled gauge is used?
Oil filled gauge is used where there is vibration present in tank or pipeline or machine.
Silicon oil or Glycerin
Oil filled Gauge
What is siphon?
 Siphon is used to protect pressure measuring instrument from sudden change in pressure.
 Siphon is also use to protect pressure measuring instrument from high temperature process medium
that is steam and hot water.
 Then siphon is first installed it should be filled with suitable separating liquid.
Pressure
Gauge
Siphon
I/L O/L
What is compound gauge?
Compound gauge is used to measure both positive pressure and negative pressure. (Gauge Pressure and
vacuum pressure).
What is gauge pressure?
Gauge pressure = Atmospheric pressure + System pressure.
What is vacuum pressure?
Any pressure below atmospheric pressure is called Vacuum pressure. It is also called as negative pressure.

Page 34 of 137
What is maximum vacuum?
-760 mmHg.
What is atmospheric pressure?
It is pressure presents in atmosphere.

Atmospheric pressure = 14.7 psi.
PRESSURE GAUGE CALIBRATION

 Dead weight tester and oil comparator is used to calibrate pressure gauge.
 Dead weight tester and oil comparator is works on the principal of “Pascal Law”.
 Pascal Law states that “when pressure applied on the liquid, it will be remaining same in all
direction.
OIL COMPAIRATOR
Digital Gauge to be calibrate OR Test

Standard
Gauge Oil tank
Isolation v/v.
OIL
Pressure source
Hand wheel
DEAD WEIGHT TESTER

Gauge to be calibrate OR Test
Standard
Weight Oil tank
Isolation v/v.
Floating piston OIL
Pressure source
Company: Burdon berg (UK)
Hand wheel
 Dead weight tester is used to calibrate pressure measuring instrument that is pressure gauge,
pressure switch pressure transmitter.
 Dead weight tester works on the principal of “PASCAL LAW”.
 There are three component of DWT that is oil, piston, cylinder and weight.
 When calibrating pressure gauge with DWT accurate weight loaded on piston which rises freely
with in its range.
 DWT uses standard weight to apply known pressure to instrument.

Page 35 of 137
How to calibrate pressure gauge on “Dead Weight Tester”?
 Connect pressure gauge at test part of DWT as per diagram.

 First check the test gauge reading is zero, if not then correct the zero.
 Place the accurate weight on piston according to maximum range of pressure gauge.
 Now rotate the hand wheel clock wise which increase pressure at both side that is at gauge and
weight.
 When weight start to lift the gauge pressure show be same as the pressure indicated by weight.
 Reduce weight from piston that is half of the range and heck weight lift according to pressure.
 Again check zero of pressure gauge.
 If above all pressure points are ok then we can say that pressure gauge calibration is ok….
PRESSURE SWITCH (PS)
Company: Danfoss
: Indfoss
: Swifter
4 / NO
C Pressure switch 1/C
2 / NO
NO NC C = Common
Bellows NO = Normally Open
NC = Normally close contact
What is pressure switch?
Pressure switch is used to change over contact from NO to NC and NC to NO when pressure reaches to the
set points.
There are two settings of pressure switch.

 Cut in = set ( 4.00kg/cm2 = 60 psi )
 Cut out = reset ( 3.00kg/cm2 = 40 psi ) For example only
KNOB (CUT IN SETTING)
BAR SPRING
4
MICRO SWITCH
3
SCALE C NO NC
2
0
MULTIMITER
DIFFRENTIAL
(CUT OUT SETTING)
DIAPHRAGM
PRESSURE

Page 36 of 137
Calibration of pressure switch
Example: 1
Set = 4.00kg/cm2 knob
Reset = 3.00kg/cm2 X
Diff. = 1.00kg/cm2 Differential Setting
         
1 2 3 4 5 6 7 8 9 10 Approx Settings
         
0kg 0.5kg 1kg 1.2kg
How to calibrate pressure Switch?
Pressure switch
C
NO Digital standard gauge
NC
Pressure source
Multimeter
Procedure:
 Connect pressure switch and standard gauge at pressure source.
 Connect multimeter to pressure switch contact (C – NO).
 Set cut in (set) and cut out (reset) setting.
 Now apply pressure and check contact change from NO to NC and NC to NO according to
pressure setting.
 If not then adjust it.
What are the instruments used for pressure switch calibration?

 Multimeter
 Standard source (oil comparator)
 Digital standard gauge
 Pressure switch to calibrate
 Necessary tools
USE (Application):
Alarm (for indication)

(1) Pump Protection
Bulb (for indication)
P/S
Outlet
Inlet PUMP

Page 37 of 137
(2)
Start/stop
Air
Suction
Air Compressor
Machine
PS Set = 8 bar for example
Reset = 4 bar
Receiver
Tank
To Field
 Pressure switch is used to protect the pump, when there is no flow pump will stop automatically.
 Pressure switch is also used for alarm purpose.
 Pressure switch is used for tripping (interlock) for emergency stop.
DCS/PLC
24V DC Supply
C
Relay
Coil
By pass timer
230V C NO NC (20 sec.setting)
AC
RYB
NO NC
A1
230V AC K
C Pressure switch
A2 NO
NC
I/L Motor O/L

Page 38 of 137
PRESSURE TRANSMITTER (PT)
 Pressure transmitter is used to measure process pressure of tank, pipeline, and machine.
 Output of pressure transmitter is 4.00mA to 20.00mA DC.
 Sensor of pressure transmitter is “Diaphragm”.
Company: Rosemount Model Number: 3051 / 3051S

Honeywell Model Number: ST 3000
Endress + Houser Model: Delta bar 75
Yokogava Model: EJA 530A
CALIBRATION: 1

Model: 3051
Range limit: -1 to 55.2 bar (800 psi max)
Output: 4.00mA to 20.00mA DC
Supply voltage: 10.5V to 55V DC (24V DC)
IP = 66 (Ingress Protection)
6 = protection against entry of dust.
6 = protection against high pressure water jet from all direction.
7 = protection against partially immersed in water.
8 = protection against completely immersed in water.
Diaphragm material = SS 316L.
FIELD TERMINAL
MODEL: 3051 MODEL: 3051 S

+ - + + - -
S T T
S = supply (24V DC), T = Test Point
Tx
24V DC Supply
+ -
Multimeter

Page 39 of 137
ZERO AND SPAN ADJUSTMENT
PUSH BUTTON
ZERO SPAN
 
ZERO DISTURB SPAN DISTURB
 
ZERO ADJUST SPAN ADJUST
 
PUSH 2 SECONDS PUSH 2 SECONDS
 
Msg. “ZERO PASS” Msg. “SPAN PASS”
 
4.00mA 20.00mA
Calibration Range: 0 to 10 Bar

 
LRV URV
 
4.00mA 20.00mA
Calibration Table:
mA Output Range in Bar

(Z) 4.00 0.0
8.00 2.5 Pressure
(L) 12.00 5.0 Source
16.00 7.5
(S) 20.00 10.0
PRESSURE SOURCE

 
PNEUMATIC PRESSURE SOURCE HYDRAULIC PRESSURE SOURCE
 
LOW PRESSURE HIGH PRESSURE
 
AIR OIL
PT 3051
+ + - +
24V Digital standard
DC - Gauge
Relief Valve
Tube
Pneumatic hand pump

HART
(Pressure Source)
mA(output)
CALIBRATION DIAGRAM

Page 40 of 137
PT 3051
+
24V
DC - Digital standard gauge
supply
Pneumatic Pressure source

(Druke DPI 610)
HART
mA (output)
“Note: In interview draw this diagram only”
How to calibrate pressure transmitter in field?
DP
C O
Isolation valve Drain valve
2 way Manifold
(vent)
Primary Drain Point

Isolation valve O
Digital Standard Gauge
Pneumatic Pressure Source
Inlet Outlet
Pipeline
PROCEDURE:
 Take work permit.

 Take loop in manual from DCS.
 Isolate pressure transmitter form process pressure gauge 2 way manifold. Close isolation valve and
open drain valve of manifold.
 Connect HART at supply OR connect multi meter at test point.
 Check Zero (4.00mA). If it is disturb then adjust it using zero push button OR HART.
 Connect pressure source and standard gauge at drain point of manifold.
 Apply pressure according to range (URV).
 Check Span (20.00mA). If it is disturb then adjust it using push button OR HART.
 Check Linearity (12.00mA) by applying 50% input pressure.
 Reduce pressure to zero. Remove pressure source, close drain valve and open isolation valve of
manifold.
 Take loop in auto from DCS.

Page 41 of 137
What are the instruments require for pressure transmitter calibration?

 Pressure source
 Digital standard gauge.
 HART communicator
 Multi meter
 Necessary tools
 24V DC Supply
CALIBRATION: 2
Company: Honeywell, USA

Model Number: ST 3000 HART SMART
Range = -14psi to 500psi (35kg/cm2)
Output: 4.00mA to 20.00mA DC
Supply voltage: 11V to 42.4V DC (24V DC)
IP = 66/67
7 = protection against partially immersed in water.
Sensor: Diaphragm – Material SS 316L.
FIELD TERMINAL:
+ Signal Signal: Supply voltage (24V DC)

- Test: Output 4.00mA to 20.00mA DC
+ Test
PT ST 3000
Calibration Range: 0 to 5.00 kg/cm2

 
LRV URV
 
4.00mA 20.00mA
Calibration Table:
mA Output Range in kg/cm2

(Z) 4.00 0.0
8.00 1.25 Pressure
(L) 12.00 2.5 Source
16.00 3.75
(S) 20.00 5
PT ST 3000
+
24V
DC Digital Standard Gauge
Pneumatic Pressure Source

HART (Druke DPI 610)
mA (output)
Page 42 of 137
Calibration of Pressure transmitter using HART 375 and HART 475
DEVICE SETUP

DIGNOSTIC / SERVICE

CALIBRATION

SENSOR TRIM (Adjust)

 
LOWER SENSOR TRIM (Zero) UPPER SENSOR TRIM (Span)
 
APPLY LOW PRESSURE APPLY HIGH PRESSURE
 
PRESS OK WHEN PRESSURE IS STABLE PRESS OK WHEN PRESSURE STABLE
 
OK OK
 
ENTER APPLIED PRESSURE VALUE ENTER APPLIED PRESSURE VALUE
 
ENTER ENTER
 
4.00mA 20.00mA
What will be the mA output of pressure transmitter when pressure of pipeline is 6.65 Bar?
Range: 0 to 10 Bar
mA Output =
=
= (0.665 * 16) + 4
= 10.64 + 4
= 14.64mA

Page 43 of 137
LEVEL MEASUREMENT
What is level?
Difference between two heights of liquid in tank or vessel.
UNIT:-
 Percentage (0% to 100 %)
 Meter
 Feet
 Inch
What are the types of instrument used for level measurement?

1. DPT type level transmitter OR Hydrostatic head type level transmitter
2. Radar type level transmitter OR Non contact type level transmitter
3. Leveltrol OR Displacer type level transmitter
SIGHT GLASS
Isolation v/v
O 100 %
Process Scale
Liquid
Glass Tube
Liquid Level
Tank
Isolation v/v
O
0%
C Drain v/v
DPT TYPE LEVEL TRANSMITTER

OR
HYDROSTATIC HEAD TYPE LEVEL TRANSMITTER
Tank
Open DPT Output
4.00mA to 20.00mA DC % Level
DPT type LT works on the principle of “pressure produce by the height of liquid which is to be measure
in terms of level”.

Page 44 of 137
Water Water Water Water
P1 = P2 = P3 = P4 = Same Pressure
Pressure depends on height and liquid SG (specific Gravity), not diameter of tank or vessel.
What is DPT?
DPT is used to measure differential pressure (DP).
DPT
High H L Low
Side Side
 
P1 P2
DP = H - L
How to install DPT in open tank using 3 way manifold?
Process Isolation v/v Diaphragm

Liquid DPT Isolation v/v
Open O O
Tank H L
C
O
Open to
Equalize v/v Atmosphere
Primary
Isolation v/v
SPECIFIC GRAVITY (SG) OF LIQUID

 Water = 1.0
 Oil = 0.84
 Kerosene = 0.82
 Petrol = 0.737
 Sea water = 1.026
 Silicon = 0.94
 Mercury = 13.570

Page 45 of 137
DPT Range Calculation:-

Example: 1
100% process
liquid
2000mm
water LT
SG = 1.0
H L
0% Open to atmosphere
Process liquid = water

SG of water = 1.0
Tank height = 2000mm = 78.74 inch
Range in mmH2O
Range = Height * SG
= 2000mm * 1.0
= 2000mmH2O
Calibration Range: 0 to 2000mmH2O

 
LRV URV
 
4.00mA 20.00mA
 
0% 100%
Range in InH2O
Range = Height * SG
= 78.74inch * 1.0
= 78.74 InH2O
Calibration Range: 0 to 78.74 InH2O

 
LRV URV
 
4.00mA 20.00mA
 
0% 100%

Page 46 of 137
Example: 2
100% process
liquid
2000mm
Oil LT
SG = 0.84
H L
0% open to atmosphere
Process Liquid = Oil

SG of Oil = 0.84
Tank Height = 2000 mm (78.74 inch)
Range in mmH2O Range in InH2O
Range = Height * SG Range = Height * SG

= 2000mm * 0.84 = 78.74inch * 0.84
= 1680mmH2O = 66.14 InH2O
Example: 3
Sketch a simple DPT to measure level in tank and find out calibration range in mmH 2O and InH2O.
100% process
liquid
2540mm
water LT
SG = 1.0 H L
0% Open to atmosphere
Tank height = 2540mm (100inch)

Process liquid = water
Range in mmH2O Range in InH2O
Range = Height * SG Range = Height * SG

= 2540mm * 1.0 = 100inch * 1.0
= 2540 mmH2O = 100 InH2O
Example: 4
Calculate head pressure of level, 25 inch in diameter and 60 inch height. The SG of liquid is 0.6
Tank height = 60inch, SG of liquid = 0.6

Range = Height * SG
= 60inch * 0.6
= 36 InH2O

Page 47 of 137
Example: 5
Practical with open tank using water

Tank height = 600mm
Process liquid = water, SG = 1.0
100% process
liquid
600mm
water LT
SG = 1.0
H L
Range = Height * SG
= 600mm * 1.0
= 600 mmH2O
Calibration range = 0mmH2O to 600mmH2O
Calibration Table:
mA Output Range in mmH2O Level in %

(Z) 4.00 0 0
8.00 150 25
(L) 12.00 300 50
16.00 450 75
(S) 20.00 600 100
Example: 6
100% process
liquid
600mm
petrol LT
SG = 0.737
H L
Tank height = 600mm

Process liquid petrol, SG = 0.737
Range = Height * SG
= 600mm * 0.737
= 442.2 mmH2O
Calibration range: 0mmH2O to 442.2mmH2O

Page 48 of 137
What is zero suppression?
Compensation for an unwanted pressure at high side of level transmitter.

OR
To cancel an unwanted pressure at high side of level transmitter.
Process
liquid
Filling v/v
Seal liquid (Silicon)

LT
Impulse line H L
Open to atmosphere
What is the use of Seal liquid?

Seal liquid is used to protect the diaphragm.
Which liquid is used as a seal liquid?

Silicon or Glycol.
Example: 7 with suppression
100 %
Process
5000mm liquid
SG = 0.8
0%
Seal liquid SG = 0.9
1500mm LT
H L
Open to atmosphere
SG of process liquid = 0.8
SG of seal liquid = 0.9
LRV (0%) = Height * SG URV (100%) = (Height * SG) + (Height * SG)

= 1500mm * 0.9 = (1500mm * 0.9) + (5000mm * 0.8)
= 1350mmH2O = 1350mmH2O + 4000mmH2O
= 5350mmH2O
Calibration Range: 1350mmH2O to 5350mmH2O

Page 49 of 137
Calibration Table:

(Z) 4.00 1350 0
8.00 2350 25
(L) 12.00 3350 50
16.00 4350 75
(S) 20.00 5000 100
Example: 8 with suppression practical
100 % Suppression Open tank

Close tank
Process Elevation Close tank
460mm liquid
SG = 1.0
0%
541mm
LT
H L
SG of process liquid = 1.0 open to atmosphere
SG of Seal liquid = 1.0

= 541mm * 1.0 = (541mm * 1.0) + (460mm * 1.0)
= 541mmH2O = 541mmH2O + 460mmH2O
= 1001mmH2O
Calibration Range = 541mmH2O to 1001mmH2O
What is zero Elevation? (Only in close tank)

Compensation of an unwanted pressure at low side of level transmitter.
OR
To cancel an unwanted pressure at low side of level transmitter.
Filling v/v
Vapor
Impulse line
Seal liquid
Close
Tank Wet leg
LT
H L

Page 50 of 137
(1) H  P  mA  % level
(2) L  P  mA  % level (3) H = L = 4.00mA (zero)
There are two types of leg.
1. Wet leg.
2. Dry leg.
Wet leg:
 When process liquid vapor is condensable (Liquid Vapor  Liquid) then wet leg is used.
 Wet leg can be filled with seal liquid OR process liquid.
 When using wet leg the liquid in the leg must remains same at constant level.
Dry leg:
 When process liquid vapor is not condensable then dry leg is used.
Example: 9 with elevation using dry leg.
100 %
Process Dry leg

6000mm liquid
SG = 0.8
0%
2000mm LT
H L


= 2000mm * 0.9 = (2000mm * 0.9) + (6000mm * 0.8)
= 1800mmH2O = 1800mmH2O + 4800mmH2O
= 6600mmH2O
Example: 10 with Elevation using wet leg.
100 %
Process Wet leg

6000mm liquid
8000mm
SG = 0.8
0%
2000mm LT
H L
Page 51 of 137

LRV (0%) = (Height * SG) – (Height * SG)

= (2000mm * 0.9) – (8000mm * 0.9)
=1800mmH2O – 7200mH2O
= - 5400mmH2O
URV (100%) = (Height * SG) + (Height * SG) – (Height * SG)
= (6000mm * 0.8) + (2000 * 0.9) – (8000mm * 0.9)
= 4800mm + 20 + 1800mmH2O – 7200mmH2O
= - 600mmH2O
Calibration Range: = - 5400mmH2O to - 600mmH2 O
Calibration Table:

(Z) 4.00 -5400 0
8.00 -4200 25
(L) 12.00 -3000 50
16.00 -1800 75
(S) 20.00 -600 100
Example: 11 with elevation using wet leg practical.
100 %
Process Wet leg

460mm liquid
1005mm
SG = 1.0
0%
541mm LT
H L

SG of seal liquid = 1.0

= (541mm * 1.0) – (1005mm * 1.0)
= 541mmH2O – 1005mmH2O
= - 464mmH2O
= (460mm * 1.0) + (541mm * 1.0) – (1005mm * 1.0)
= 1001mmH2O – 1005mmH2O
= - 4mmH2O
Calibration Range: - 464mmH2O to – 4mmH2O

Page 52 of 137
Calibration Table :

(Z) 4.00 -464 0
8.00 -349 25
(L) 12.00 -234 50
16.00 -119 75
(S) 20.00 -4 100
How to calibrate DPT (Level Transmitter) in field?
Digital standard gauge

Isolation v/v SG (low pressure)
Pressure source
(Pneumatic)
Process LT 24V DC
Liquid O supply
Tank O Drain pot
H L Isolation v/v
C C C
O HART
mA
Primary Iso. v/v Equalize v/v

Open to atmosphere
Or Leg side
PROCEDURE
 Take loop in manual from DCS
 Isolate DPT from process liquid using 3 way manifold close both isolation valve and open both
drain pot.
 Connect HART at supply OR connect Multimeter at test point.
 Check Zero (4.00mA). If it is disturb then adjust it using zero push button or HART.
 Connect pneumatic pressure source at high side and low side open to atmosphere.
 Apply pressure at high side according to URV.
 Check Span (20.00mA). If it is disturbed than adjust it using span push button OR HART.
 Check linearity (12.00mA) by applying 50% input pressure.
 Reduce pressure to zero. Remove pressure source. Close both drain pot and open both isolation
valves.
 Take loop in auto from DCS
Calibration Range = 0 mmH2O to 2000mmH2O

 
LRV URV
 
4.00mA 20.00mA

Page 53 of 137
Calibration Table:

(Z) 4.00 0 0
8.00 500 25
(L) 12.00 1000 50
16.00 1500 75
(S) 20.00 2000 100
CALIBRATION DIAGRAM
DPT
+ + - +
24V s t
DC -
supply
H L
Digital standard gauge

SG
Open to atmosphere
HART pneumatic
mA (output) Pressure source
REMOTE SEAL TYPE DPT
Tank flange
DPT Flange
L
Capillary tube
Diaphragm Silicon Oil

SG =0.94
Tank
H
DPT
Capillary tube H L

Page 54 of 137
Example:-12
Remote seal type DPT
L
SG = 0.8
4000mm Diaphragm
5000mm
H SG= 0.934
DPT
1000mm
H L
LRV (0%) = (Height * SG) - (Height * SG)

= (1000mm * 0.934) - (5000mm * 0.934)
= 934mmH2O – 4670mmH2O
= -3736mmH2O  -147.086 InH2O

= (1000mm * 0.934) + (4000mm * 0.8) – (5000mm * 0.934)
= (934mmH2O + 3200mmH2O – 4670mmH2O
= 4134mmH2O – 4670mmH2O
= -536mmH2O  -21.102 InH2O
Calibration Range: - 3736mmH2O to -536mmH2 O

 
LRV URV
 
4.00mA 20.00mA
 
0% 100%
Calibration: 2
Company: Rosemount HART smart

Model number = 3051
Range limit = - 25400mmH2O to 25400mmH2O
Output = 4.00mA to 20.00mA DC
Supply voltage = 10.5V to 55V DC
IP 66
Diaphragm material = SS 316L
Page 55 of 137
Example: 13 (Home Work)
100 %
SG = 0.94
4000mm SG = 0.8 4000mm
LT
0% H L

Height = 4000mm
Wet leg height = 4000mm

= (0mm * 0.8) – (4000mm * 0.94)
= 0mmH2O – 3760mmH2O
= -3760mmH2O
URV (100%) = (Height *SG) – (Height * SG)

= (4000mm * 0.8) – (4000mm * 0.94)
= 3200mmH2O – 3760mmH2O
= -560mmH2O
RADAR TYPE LEVEL TRANSMITTER

OR
NON CONTACT TYPE RADAR TRANSMITTER
Company: Rosemount  Model Number: 5301 GWR

Endress + Houser  Model Number: FMR 532
Vega / Vegaplus – 63
 Radar type LT works on the principle of “FMCW”- Frequency Modulated Continuous Waves
OR “Time of Flight System” OR TDR – “Time Domain Reflectromery”.
 Radar type LT is also called “Non contact type LT” because there is no contact between LT &
process liquid.
 Radar type LT measures distance from top of the tank to the surface of process liquid.
 Radar type LT transmits high frequency electromagnetic waves to the surface of process liquid
which is receive by same antenna.
 Radar type LT always mounted on top of the tank.

Page 56 of 137
LT
Flange
Wave stick
100mm
100% (20.00mA)
Tank Measuring
Height Height
Process Liquid
0% (4.00mA)
PG
M LT
Flow Wave stick
O
Ladder Chamber
Isolation v/v
Agitator
C
Drain v/v

Page 57 of 137
RADAR TYPE LEVEL TRANSMITTER
LT LT LT
SS Rod
230
WAVE STICK TYPE RADAR HORN TYPE OR GWR

Cone Type Radar (Guided Waves Radar)
Data (parameters) to be enter in HART
 Tank Height = 1260mm * Measurement Mode = Liquid, Solid, Interface

 LRV (0 %) = 0 mm * Mounting = Chamber OR Direct
 URV (100 %) = 600 mm * Length Unit = mm, cm, inch, feet, meter
E+H Model 245
E = Empty distance (Tank Height)

F = Full distance (Measuring Height)
D = Distance
L = Level

Page 58 of 137
VEGA / VEGAPULS – 63
Range in meter and feet only
Vessel height = 0.62 mts.
LT Max. Adjust = 0.18 mts.
Min. Adjust = 0.62 mts.
Max. Adjustment
100%
Min. Vessel 180

Adj. Height
X
0%
LEVELTROL OR DISPLACER TYPE LEVEL TRANSMITTER
Company: Fisher Model No. DLC 3010

Masoneilan
Mobery
 Leveltrol works on the “weight loss” principle of “Archimedes Law”.

 Archimedes law state that “When body is immersed in the liquid the weight of body will be get
loss”.
 Displacer type LT detects liquid level by measuring weight of displacer immersed in process
liquid.
 Displacer is cylindrical shape pipe scaled and filled inside with sand or some weight.
 The change of process liquid level, changes net weight of displacer increasing and decreasing the
load on torque tube. The change in directly proportional to the change in level and specific gravity
of liquid.
 Using level troll maximum measurement can be done up to 72” (inch).
 Minimum displacer height is 14 inch. & maximum displacer height is 72 inch.
 Other displacer height is 32”, 48” and 60”.
What is limitation of leveltrol?

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

Page 59 of 137
What will happen if displacer has fallen down, while in live?

Maximum Output 20.00mA DC (approximate)
What will happen if displacer has a hole in it, while in live?

Minimum Output 4.00mA DC (approximate)
Tank Isolation v/v Hang Torque tube
O LT
Process liquid 100% (20.00mA)
Center point (50%)
Displacer chamber
Displacer
O 0% (4.00mA)
Isolation v/v C Drain v/v
LEVELTROL RANGE CALCULATION
Example: 1 LT
355.6mm
Process liquid = Water Process (100%)
SG of water = 1.0 Liquid
Height of displacer = 14” = 355.6mm
177.8mm
Range: = Height * SG (50%)
= 355.6 * 1.0 WATER
= 355.6mm
Calibration Range: 0mm to 355.6mm 0mm

  (0%)
LRV URV
 
4.00mA 20.00mm
 
0% 100 %

Page 60 of 137
Example: 2
Process liquid = Oil

SG of oil = 0.84
Height of displacer = 14” = 355.6mm
Range = Height * SG
= 355.6 * 0.84
= 298.704mm
Calibration range: 0mm to 298.704mm
How to calibrate leveltrol in field?
Filling v/v
C LT
100%
Process
Liquid Isolation v/v Transparent pvc tube
Tank
50%
C
0%
O Drain v/v
PROCEDURE:
 Isolate tank from displacer chamber, close both isolation valve and open drain valve.
 Wait till liquid drain from displacer chamber.
 Check Zero (4.00mA), if it is disturb then adjust it using zero pot or push button or HART.
 Connect transparent PVC tube at drain valve and make marking on the tube for 0 %, 50% and
100% according to height of displacer and center point.
 Now fill liquid up to 100% (top of the displacer).
 Check Span (20.00mA), if it is disturb then adjust it using span pot or push button or HART.
 Drain liquid up to 50% and check linearity (12.00mA)
 Drain liquid from displacer chamber, remove PVC tube, close drain valve and open both isolation
valve.

Page 61 of 137
What is Interface level?
When tank filled with two different specific gravity of liquid then that level is called Interface level.
Tank 100%
Lighter liquid
Interface level
0%
Heavier liquid

Page 62 of 137
How to calibrate Interface leveltrol?
Displacer height = 1000mm

Low SG = 0.84
High SG = 1.0
LRV (0 %) = Height * SG URV (100 %) = Height * SG

= 1000mm * 0.84 = 1000mm * 1.0
= 840mm = 1000mm
Calibration range = 840mm to 1000mm
LEVEL SWITCH
Company: Wega
Endress + Houser
Mobery
 Level switch is used to control liquid level of tank.

 Level switch havening two contacts NO – NC and common.
 Level switch is directly mounted in tank at which point level is to be control.
 When level touches to switch, switch will operates and change its contact from NO to NC and NC
to NO.
 For industrial application “Float type level switch” is used.
 Level switch is used to prevent overfilling of tank and alarm purpose.
There are two types of level switch
 Float type level switch.

 Vibrating fork type level switch.
FLOAT TYPE FORK TYPE
Flange Magnet Flange
C Float 24V + C
NO DC NO vibrating fork
NC - NC
Field Terminal Cable Entry
Float type level switch Vibrating fork type level switch

Page 63 of 137
DCS/PLC
24V DC Supply
Coil
Relay Float switch
230V C
AC
Open tank
RYB
NO NC
A1
Pipe line
230V AC
K
A2
I/L Motor
What will be the mA Output of level transmitter when level of tank is 48%?
mA Output =
= 11.68mA

Page 64 of 137
FLOW MEASUREMENT
What is flow?
Quantity of gas or liquid moving through pipeline within a standard time is in minutes or hours.
UNITS
 Liter per minute (LPM)
 Liter per hour (LPH)
 Gallon per minute (GPM)
 Gallon per hour (GPH)
 Barrel per minute (BPM)
 Barrel per hour (BPH)
 M3 / min (meter cubic per minute)
 M3 / hour (meter cubic per hour)
 CFM (cubic feet per minute)
 CFH (cubic feet per hour)
 Kg / min
 Kg / hour Steam flow
What are the type of instrument (FT) used for flow measurement?
 DPT type flow meter
 Mass flow meter
 Magnetic flow meter
 Vertex flow meter
 Ultrasonic flow meter
 Turbine flow meter
 Rota meter (variable area flow meter)
DPT type flow meter (FT)

Restriction (Flow sensor)
Orifice plate
I/L O/L
H L
DP

DPT

Output
4.00mA to 20.00mA(√ )

Flow

Page 65 of 137
 DPT type flow meter works on the “Bournolli’s” principle.

 When there is restriction (flow sensor) in pipeline, flow produces differential pressure (DP) across
the restriction.
 Flow is not a linear.
 Flow is always measured in “square root (√)”.
 Flow is directly proportional to the square root of differential pressure (DP).
Flow α √differential pressure

Flow α √H-L
What is to be change in DPT, when using for level and flow?
Level Linear
DPT HART
Flow Square root
 When using for level, DPT, should be in linear mode.

 When using for Flow, DPT should be in square root mode.
 Linear and square root is to be change by using HART communicator.
What are the flow sensing elements (FE)?

 Orifice plate
 Venturi tube
 Pitot tube
 Anubar
 Flow nozzle
What is Orifice plate?
Orifice plate is a flow sensing elements which is used to create differential pressure (DP).
What are the types of Orifice plate?

 Concentric orifice plate
 Eccentric orifice plate
 Segmental orifice plate
 Quadrant edge orifice plate
 Integral orifice plate
Concentric Orifice plate
This orifice plate has a hole in center, so that it is called concentric orifice plate.
Tab Use (Application)

Bawel at 450 Ideal liquid flow
Air and Gas flow
Vent hole 450 Dry steam flow
Flow
Hole in H L
Center
Drain hole
Front view Side view

Page 66 of 137
Eccentric orifice plate

This orifice plate has an eccentric hole, so that it is called eccentric orifice plate.
Tab Use (Application)

Oil containing water
Liquid containing solids
Wet steam flow
Eccentric hole Viscous liquid
Slurry liquid
Segmental orifice plate

This orifice plate has a hole in from of segment of circle, so that it is called segmental orifice plate.
Use (Application)
Oil containing water
Tab Liquid containing solid
Wet steam flow
Viscous liquid
Segmental hole Slurry liquid
How to identify high side of an orifice plate?

Marking of inlet on the tab is high side of an orifice plate.
I Upstream
N
L
E
T
Tab
How to install orifice plate in pipeline?
Orifice plate
Flange Gasket (packing)
Inlet Upstream H L Downstream Outlet
Pipeline
HP LP
DP

DPT

Page 67 of 137
Why there is small hole sometimes above and below of an orifice plate?
Vent hole Weep hole

or
Breath hole
Drain hole
 Small hole above and below of an orifice hole is called weep hole or breath hole.
 Liquid flow: Weep hole will be at top of the orifice hole to pass out any air or gas or vapor
particles presents in liquid.
 Air / Gas flow: Weep hole will be at bottom of the orifice hole to pass only any liquid particles
presents in air or Gas.
What are the tapping used for an orifice plate?
1. Flange tapping
2. Radius tapping
3. Corner tapping
4. Vena contract tapping
5. Pipe tapping
Flange tapping
Flange tapping is used for line size 2 inches or larger. They are located in the orifice flange 1 inch upstream
and 1 inch downstream from face of the orifice plate.
I/L O/L
Upstream H L Downstream
Tapping 1”1”
H L

Page 68 of 137
How to install DPT in pipeline using 5 way manifold?
Orifice plate
I/L O/L
H L
Pipeline O O Primary Iso.v/v
Impulse line (SS tube ½ inch)
Isolation v/v
5 ways Manifold
O O
Equalize v/v
C C C
Drain v/v Drain v/v
Drain pot H (DP) L Drain pot

C C
DPT
Condition:-
 H = L = 0 (zero) flow (4.00mA)
 H ≠ L = Flow
In running plant, suddenly flow is showing less, more or fluctuating then how will you start checking?
1. First drain or flush the DPT.
2. Check choking in impulse line, if there is choke impulse line.
3. Check any leakage in impulse line.
4. Check Zero (4.00mA) of DPT, if it is disturb then adjust it.
5. Check 24V DC supply, it should not drop to minimum supply voltage which is specified in
transmitter.
6. Check calibration of transmitter.

Page 69 of 137
How to check Zero of DPT?

1. Close isolation valve of manifold either high side or low side then open equalize valve. DPT output
will be Zero (4.00mA).
H L
O C
O
C C
H L
2. Close both isolation valve and open both drain valve of manifold output will be zero (4.00mA).
H L
C C
C
O O
H L
Where to install DPT for liquid line, Gas or air line and steam line?
 Liquid line:-
For liquid line DPT is installed below the orifice plate.
I/L H L O/L
DPT
H L
 Gas line:-
For Air/Gas line DPT id installed above the orifice plate.
I/L H L O/L
DPT
H L

Page 70 of 137
 Steam line:-
For steam line DPT is installed below the orifice plate with condensate pot.
Orifice plate
I/L H L O/L
Condensate pot Condensate pot
DPT
How to Calibrate DPT (Flow meter) in field?
+ 24V DC +
DPT - Supply -
Drain pot O O
Drain pot
H L
C C
Digital std gauge
Isolation v/v C Isolation v/v
SG
Equalize v/v
Low pressure gauge
HART
mA
Pneumatic
Pressure source primary iso.v/v
O O
I/L O/L
H L

Page 71 of 137
PROCEDURE
 Isolate DPT from process medium using 5 way manifold close both isolation valve and open both
drain valve (POT) of manifold.
 Connect HART at supply OR connect multimeter at test point.
 Check zero (4.00mA), if it is disturbed than adjust it using zero push button or HART.
 Connect pneumatic pressure source at high side and low side open to atmosphere.
 Apply pressure at high side according to upper range valve (URV).
 Check span (20.00mA), if it is disturbed than adjust it using span push button OR HART.
 Check linearity by applying 50% input pressure.
 Reduce pressure to zero remove pressure source close both drain valve and open both isolation
valve.
Calibration Range = 0mmH2O to 2000 mmH2O

 
LRV URV
Calibration Table:
mA Output Range in mmH2O

(Z) 4.00 0
12.00 500
(L) 15.31 1000
17.86 1500
(S) 20.00 2000
Formula for square Root output: (FOR FLOW)
mA output= * 16) + 4
DP=1000 mmH2O DP=1500 mmH2O
mA output= * 16) + 4 mA output= * 16) + 4
= * 16) + 4 =( * 16) + 4
=( * 16) + 4 =( *16) + 4
= (0.7071 * 16) + 4 = (0.8660 * 16) + 4
= 15.3136 = 17.856
= 15.31mA = 17.86mA

Page 72 of 137
DP = 0mmH2O DP = 500mmH2O DP = 2000mmH2O
mA output= * 16) + 4 mA output= * 16) + 4 mA output= * 16) + 4
= * 16) + 4 =( * 16) + 4 = * 16) + 4
= (0 * 16) + 4 =( *16) + 4 = ( * 16) + 4

=0+4 = (0.5 * 16) + 4 = 16 + 4
= 4.00mA = 12mA = 20.00mA
Calibration Diagram:-
DPT
24V DC+ + - +
Supply S T
-
H L
Open to atmosphere
SG Digital standard gauge

HART
Pressure source
mA output (Pneumatic)
How to convert linear to square root output?
Formula:-mA output= * 16) + 4

L=4.00, 8.00, 12.00, 16.00, 20.00
L=8.00mA L=12.00mA L=16.00mA
mA output= * 16) + 4 mA output= * 16) + 4 mA output= * 16) + 4
= * 16) + 4 = * 16) + 4 = * 16) + 4
= * 16) + 4 = * 16) + 4 = * 16) + 4
= * 16) + 4 = * 16) + 4 = * 16) + 4

= (0.25 * 16) + 4 = * 16) + 4 = (0.8660 * 16) + 4
= = 11.31+ 4 =
= = =

Page 73 of 137
PITOT TUBE
H
DPDPT
L
I/L O/L
VENTURI TUBE
H
L
I/L O/L
FLOW NOZZLE
H L
I/L O/L
Nozzle
ROTAMETER (Variable Area Flow meter)
Flange
2000 LPH
Scale Indicating Edge

Float
Glass Tube
0 LPH
Flange
Inlet

Page 74 of 137
ULTARASONIC FLOWMETER
Ultrasonic Flow meter works on the basic principle of “Shift in frequency of sound wave”.
OR “Change in frequency of sound wave”.
Flow meter
Flow/ LPH
Transmitter Receiver
I/L O/L
Change in Frequency
Flow
MASS FLOWMETER
Company:- Emerson Model – Micro motion 1700

Endress + Hauser model promass 80
√ Liquid (oil)
√ Air
√ Gas
√ Steam
 Mass flow meter works on the principle of “Coriolli’s effects”.

 Mass flow meter is also known as coriolli’s flow meter”.
 Mass flow meter is used to measure the flow of liquid, air, Gas and steam.
 Generally Mass flow meter is used to measure the flow of oil and related applications.
Vibrate
Flow in (twist) Flow out
Inlet
Sensor Outlet Sensor
Middle
Sensor Oscillating tube
 Mass flow meter having oscillating tube to sense the flow.

 Coriolli’s effect state that -
When there is no flow through oscillating tube the tube does not vibrate (twist) but when
there is flow through oscillating tube will vibrate (twist).
 There are two sensor located inside the flow meter that is inlet sensor and outlet sensor.
 These two sensors generator phase shift.
 Phase shift is directly proportional to flow rate.
Phase shift α Flow

Page 75 of 137
FTx. Supply terminal

+/P
24V DC or 230V AC output terminal
-/N DCS
4.00mA to 20mA DC
I/P O/L
HART
Flange
Oscillating tube
NOTE:- In 4 wire transmitter system HART is connect at output terminals.
MAGNETIC FLOWMETER
Company: Rosemount model 8700

Undress + Hauser model promo 50
√ Liquid (Conductive water liquid)

 Air
 Gas
 Steam
 Magnetic flow meter is used only for conductive liquid.
 Generally magnetic flow meter is used to measure the flow of water and related applications.
 Magnetic flow meter works on the principle of “Faraday’s law” of electromagnetic induction.
V
coil Magnetic field
I/L O/L
D
Coil Electrode
V voltage
Faraday’s law state that when conductor moves in the electromagnetic field, voltage is generated in
conductor.
 Generally voltage is depends on density of magnetic field (B), velocity of liquid (V) and diameter
of pipeline (D).
E =K * B * V * D
Where,
E=Generated voltage.
K=Instrument constant. EαV
B=Flux density E=V
V=velocity of liquid
D=Diameter of pipeline

Page 76 of 137
FTx.
+/P Supply
24V DC or 230V AC Output
-/N output
I/L O/L
HART
VORTEX FLOWMETER
Company: Rosemount model 8800

Endress + Houser Model prowirl 72
Yokogava model DYF 025
√ Liquid
√ Air
√ Gas
√ Steam mostly use for
 Vortex flow meter works on the principle of “Von Karman effect”.

 Vortex flow meter can measure the flow of liquid, air, gas and steam.
 Generally vortex flow meter is used to measure the flow of steam.
 Vortex flow meter has a sensor called “Bluff Body” or “Shedder Bar” which is placed vertically
in flow meter. Bluff body
I/L O/L
Vertices
 When flow passes through Bluff body flow produces series of vertices.
 Vertices are directly proportional to the flow.
Vertices α Flow
+ -
FTx
24V DC Supply
I/L O/L
HART
Flange Bluff body Vertices

Page 77 of 137
What is two wires Transmitter system?

In two wires transmitter system supply and output in same cable.
What is four wires Transmitter system?

In four wire Transmitter system supply and output both in different cable.
FLOW SWITCH
Company: Honeywell
Sika (Standard Company - Germany)
 Flow switch is used to change over the contacts from NO to NC and NC to NO in response to the
flow of process liquid.
 Flow switch is directly mounted in pipeline according to direction (Arrow) and online setting
 Generally in industries “Paddle type flow switch” in use.
 Flow switch is operates through the use of paddle which gets displaced due to the force of process
liquid moving through pipeline.
 There is no calibration of flow switch.
Online setting
Terminal C NO NC
Cable entry Fitting
Paddle
FS
I/L O/L
Paddle
When flow is ON
Alarm (for indication)

Pump protection Bulb (for indicator)
FS
O/L
I/L Pump
 Flow switch is use for pump protection when there is no flow or low flow pump stop automatic.
 Flow switch is also used for alarm purpose.
 Flow switch is used for tripping (Interlock) (for Emergency stop).

Page 78 of 137
I to P CONVERTER
Current to Pressure Converter.

Company: Fisher
ABB
Control Air
from DCS
Input + I
4.00mA to 20.00mA Output
- P = 3 to 15psi C/V.
AFR
Air supply
AS=20 psi = 1.4 kg/cm2
I to P converter is used to convert input 4.00mA to 20.00mA to output 3 to 15 psi.
How to calibrate I to P converter?
+ G
Milliampere Source I Test Gauge
4.00mA to 20mA DC P = 3 to 15 psi
 - 
4.00mA AFR 3.0psi (zero)
8.00mA 6.0psi
12.00mA AS= 20 psi 9.0 psi
16.00mA = 1.4 kg/cm2 12.00 psi
20.00mA 15.0 psi (span)
PROCEDURE:
 Connect mA source at (+) and (-) terminal of I to P converter.
 Apply 20 psi Air supply (AS) to P converter.
 Connect test gauge at output.
 Apply 4.00mA and check 3.0 Psi. If it is disturbed then adjust using Zero pot.
 Apply 8.00mA and check 6.0 Psi.
 Apply 20.00mA and check 15.0 Psi. If it is disturbed then adjust it using Span pot.
Calibration Table:
mA Input PSI output

4.00 3.0 (Z)
8.00 6.0
12.00 9.0
16.00 12.0
20.00 15.0 (S)

Page 79 of 137
CONTROL VALVE
Company: Fisher
Masoneilan
Demla
Rotark
Samson
Valtek
What is control valve?

Control valve is a final control element which is used to regulate material flow in the process.
OR
Control valve is used to control the flow of pipeline.
What are the types of control valve depending on body?

1 Single seated v/v.
2 Double seated v/v.
3 Angle v/v.
4 Three way v/v.
5 Globe v/v.
6 Butterfly v/v.
7 Ball v/v.
8 Needle v/v.
9 Pinch v/v.
What are the parts of control valve?

1 Positioner
2 Actuator
3 Spring
4 Diaphragm
5 Stem
6 Yoke
7 Scale
8 Indicating edge
9 Feedback link
10 Plug
11 Valve body
12 Plug seat
13 Gland packing
14 Gland nut
15 Gland pusher
16 Bonnet
17 Three gauge Air supply
3 to 15 psi (from I to P Converter)
Positioner to actuator

Page 80 of 137
CONTROL VALVE DIAGRAM
Actuator
Spring
Diaphragm
Positioner 100%
To actuator Stem
Air signal 75%
Yoke
50%
Positioner Scale
25%
Indicating edge
Air supply (AS) 0%
Feedback link
3 to 15 psi
From I to P Plug
Converter
Gland packing
(Gland nut)
Bonnet
Valve body
I/L O/L
Plug seat Flange

Page 81 of 137
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 - FC)
What is air to open control valve?

Air to open
 Actuator
Fail to close (FC)
 Air
Reverse action
 When air pressure applied from bottom of the actuator the stem moves upwards and opening the
valve. This action is called Air to open.
 When air pressure will fail, valve will get close that is called Fail to close (FC).
What is air to close control valve?

Air to close Air

Fail to open (FO) Actuator

Direct action
 When pressure applied from top of the actuator the stem moves downwards and closing the valve.
This action is called Air to close.
 When air pressure will fail, valve will get open that is called Fail to open (FO).
What are the uses of valve positioner?
Positioned to actuator
Air Supply P/P from I to p

(AS) 3 to 15 Psi
How much air to be given to positioner?
 Not fix
 Printed on tag plate
C/V
1. Zero and Span can be adjusted using positioner.

2. Quick action of control v/v. (control v/v stem travelling will be fast)
3. Valve hysteresis will be zero (opening error zero)
4. Valve can be use for viscous liquid.
5. If line pressure suddenly changes there will be no effect on control v/v.
6. Valve action can be change from FC to FO and FO to FC.

Page 82 of 137
What is CV of control valve?
CV: Coefficient of Value.

CV is the capacity of valve.
“Number of US gallons per minute of water which passes through fully open control v/v” at pressure drop of 1
psi.
100 % open v/v.
Inlet outlet
Max GPM Haw
(Water)
What are the types of valve positioner?
There are three types of valve positioner.

1. Pneumatic positioner (P/P)
2. Electro pneumatic positioner (E/P)
3. Electro pneumatic positioner smart.
Control valve with Pneumatic Positioner (P/P): -
AFR
From + I P/P AS
DCS - P
(4.00mA to 20mA)
AS
C/V
Control valve with Electro Pneumatic Positioner (E/P):-
From + + AFR
DCS (4.00mA to 20.00mA) E/P AS
- -
Inbuilt I to P
C/V

Page 83 of 137
How to calibrate control V/V?
+ + AFR
mA source _ E/P AS
(4.00mA to 20.00mA) -
Scale
4.00mA 0 % (Z)
8.00mA C/V 25 %
12.00mA 50 %
16.00mA 75 %
20.00mA 100 % (S)
PROCEDURE:
 Connect mA source at (+) and (-) terminal of positioner or I to P converter.

 Apply air supply to positioner and I to P converter.
 Apply 4.00mA and check 0% at control valve. If it is disturbed then adjust is using positioner.
 Apply 8.00mA and check 25% at control v/v.
 Apply 20.00mA and check 100% at control v/v. If it is disturbed then adjust it using positioner.
How to calibrate control valve infield / online?

 Take control v/v bypass from line.
 Disconnect cable from positioned which is coming from DCS.
 Connect mA source at (+) and (-) terminal of positioner.
 Apply 4.00mA and check 0% at control v/v. If it is disturbed then adjust is using positioner.
 Apply 20.00mA and check 0% at control v/v. If it is disturbed then adjust it using positioner.

Page 84 of 137
How to check stroke of control v/v?
C/R Positioner to actuator

From DCS
OR + + AFR
mA source E/P AS
(4.00mA to 20mA) - -
scale
0% 4.00mA 0%
25% 8.00mA C/V 25%
50% 12.00mA Field 50%
75% 16.00mA 75%
100% 20.00mA 100%
 Connect mA source at (+) and (- ) terminal of positioner.

 Apply 4.00mA and check 0 % at control v/v.
Note:
To check the stroke that means to check the opening of control v/v that is 0%, 25%, 50%, 75% and 100%.
Check from DCS or give input by mA source.
Note:
Above same procedure we can do by using DCS. Here we have to enter percentage from DCS that is 0%,
20%, 50%, 75% and 100%, we have to check percentage on control v/v that is 0%, 20%, 50%, 75% and
100%.
In running plant suddenly control v/v stop working or stuck up than how will you start checking?
From + AFR
DCS E/P AS
(4.00mA to 20mA) - O O
I/L isolation v/v c/v isolation v/v O/L

C drain v/v C
C

Page 85 of 137
PROCEDURE:

 First take control valve bypass from line using bypass valve.
 Check 4.00mA to 20.00mA DC signal which is coming from DCS (Safety barrier).
 Check output of I to P converter that is 3to15 Psi.
 Check air supply of I to P converter and positioner.
 Check air signal from positioner to actuator.
 If above all signals are OK then problem may be in control v/v.
 Now disconnect stem and plug of control v/v.
 Apply air signal to actuator and check actuator operates or not .if not than diaphragm may got
punctured.
 If actuator operates then connect stem and plug. Apply air to actuator.
 If it does not operate then loose gland nut and hammer little bit and check it operates.
 If it does not operate then control v/v is to be remove from line and send to workshop for repairing
purpose.
 Install spare control v/v and check stroke.
 Take coop in Auto DCS.
How to calibrate Fisher make fieldvue DVC 6000 SMART positioner control v/v?
(DVC = Digital valve control)
Model: 657 = ATC = FO

: 667 = ATO = FC
From DCS
Or DVC 6000
SMART
mA Source 100
80
4.00mA to 20.00mA Loop POSITIONER
60
40
20
0
HART

Page 86 of 137
PROCEDURE
Connect HART at loop (+) and (-)

Configure / setup

Calibrate

Travel Calibrate

Auto travel calibrate

Instrument mode is IN SERVICE continue
To place OUT OF SERVICE

OUT OF SERVICE

Calibration will come sudden change in
Instrument output

Manual

Auto calibration progress
Seeking high drive stop (0%)
Seeking low drive stop (100%)
Adjust output bias (50%)

Ok

IN SERVICE

Enter

Ok

Auto calibration complete

Home
IN SERVICE = AUTO
OUT OF SERVICE = MANUAL
(When Calibrate have to put on manual)

Page 87 of 137
How to check stroke of fisher control valve using HART 375 and HART 475?
Connect HART to loop (+) and (-)


Device diagnostic

Stroke valve

Instrument mode is IN SERVICE continue
In place OUT OF SERVICE

OUT OF SERVICE

Step to target

Enter 0% from HART and check 0% at control v/v.

Done

Enter

Stroke v/v. is completed

Home
Calibration Table:
HART mA Source % of C/V
0% 4.00 0%
20% 7.2 20%
40% 10.4 40%
60% 13.6 60%
80% 16.8 80%
100% 20 100%
Where is air to open and air to close valve used?
Air to open Air to close

 Steam line ( heating limit) * Flair line (Access gas line) (Exhaust gas burning)
 Feed line (food making) * Cooling water line ( Motor cooling)

Page 88 of 137
SOLENOID VALVE
Company: Rotex (Indian)

Asco (US) (Automatic Switch Co.)
 SOV is an electrically (voltage) operated v/v.

 SOV is used to control liquid and gas flow.
 SOV controlled by electrical voltage which is applied to coil.
 When voltage applied to coil, magnetic field will generate. So that plunger inside the coil moves
up and down.
 SOV having the main parts are coil, plunger, plug and spring.
 Depending on design of v/v, plunger will open and close the v/v.
 Generally 24V DC SOV v/v is used.
 There are two types of SOV.
 Normally open
 Normally close
USE (Application)
1. SOV is used to operate ON – OFF control v/v.
2. SOV is used for emergency shutdown (ESD) system.
S Supply (DCS, PLC, Switch)

1 Bulb
AS
LMS Bulb
Exhaust
FS/PS
I/L O/L
ON – OFF C/V
2 ESD System (Emergency Shut Down)
S Supply
AFR
From DCS
4.00mA to 20.00mA DC AS
C/V
 ESD stands for emergency shutdown.

 ESD requires in plant for safety purpose.
 ESD is used for shutdown the total plant or control v/v or particular process in case of an
emergency.

Page 89 of 137
LOOP DIAGRAM
What is loop?
The loop which having sensor, transmitter, DCS and control v/v for measurement and controlling of process
variable that is temperature, pressure, level and flow.
What are the types of loop?

There are two types of loop.
1. Open loop
2. Close loop
What is open loop?

 The loop which having only indication of process variable those loop is called open loop.
 Open loop which having sensor, transmitter and DCS for indication.
 For example pressure transmitter is measuring pressure of tank and DCS is indicating pressure in
control room.
PT DCS
Field C/R
Open loop diagram
+
Junction box Safety barrier Marshalling
Tx AI DCS
(JB) (ZB) panel (M/R)
-
Transmitter --------AI
Switch --------------DI
What is close loop?

 The loop which having both indicating and controlling of process variable those loop is called
close loop.
 Close loop which having sensor, transmitter, DCS and control v/v for controlling.
 For example pressure transmitter is measuring pressure of tank and controller in DCS controlling
pressure by operating control v/v.
PT DCS
Field C/R
C/V
Field

Page 90 of 137
Close loop diagram
Field Field C/R C/R C/R

+
Junction box Input safety Marshalling
Tx AI DCS
(JB) barrier panel (M/R)
-
+ -
Field AO
Field C/R C/R

Junction box Output safety Marshalling
E/P
AS (JB) barrier panel (M/R)
C/V
SAFETY BARRIER
Company: Pepperl + Fuchs

MTL
Phoenix
 Safety barrier is used to protect field instruments those are transmitter, positioner, switch in
hazardous area.
 Safety barrier works as a fuse in loop.
Safety
Tx 24V DC
barrier 4.00mA to 20mA DC DCS
+ -
24V DC supply (SMPS)
What are the types of safety barriers?

1. Zoner safety barrier (ZB)
2. Diode safety barrier
What are the types of safety barrier used in control loop?

1. Analog input safety barrier (Tx----SB----DCS)
2. Analog output safety barrier (DCS----SB----C/V)
3. Digital input safety barrier (switch)

Page 91 of 137
Analog input safety barrier
STC4/CR
AI
Tx 24V DC
Safety 4.00mA to 20.00mA DC DCS
Barrier
+ -
24 V DC Supply (SMPS)

Page 92 of 137
Analog output safety barrier
SCD
AO
E/P 4.00mA to 20.00mA
Safety 4.00mA to 20.00mA DC DCS
AS
barrier
C/V
+ - 24V DC Supply (SMPS)

Page 93 of 137
Digital input safety barrier
SR2
C DI C C
NO 8V DC NO DCS
PS Safety NO
Barrier
NC NC
+ -
24V DC Supply (SMPS)
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. Hot loop checking
2. Cold loop checking
Cold loop checking Hot loop checking

 Without supply  With supply
 Cable continuity  Indication and alarm on DCS
 Multimeter  Source or HART communicator
Cold loop checking

 Cold loop checking is to be check without applying supply to the loop.
 In cold loop checking we have to check cable signal continuity from transmitter to DCS and DCS
to control valve.
 Cable continuity is to be check using multimeter.
JB ZB
Multi meter

Page 94 of 137
Hot loop checking

 Hot loop checking is to be check with applying supply to the loop.
 In hot loop checking we have to check indication and alarm of process variable on DCS.
 Hot loop checking is to be check using source or HART communicator.
DCS
Range:
AI C/R
0oc to 200oc
0oC
50oC
100oC
ZB 150oC
200oC
JB
4.00mA
8.00mA
12.00mA
16.00mA
20.00mA
TTx Resistance
o o
R= 0 C to 200 C Source
Field
RTD
HART
Pipeline
T
mA DC (output)
What are the instruments used for loop checking?

 Multi meter
 Source / calibrator
 HART communicator
 Communication device (walkie talkie)
 Necessary tools
What are the contents of loop folder?
 Loop checking data sheet
 Location layout
 Punch list
 ILD – instrument loop diagram
 P & ID – piping & instrument diagram
 Termination diagram
 ESD value, Alarm value

Page 95 of 137
How to do loop checking using HART 375?
Connect HART to Tx

Switch ON HART

HART Application

Model no. X
Online
Device setup
PV = T, P, L, F Home
AO = 4 to 20mA
LRV
URV Tx Range

Device setup

Diagnostic /service

Loop Test

Choose Analog output values
 4mA
 20mA
 Others
 End

Enter on 4 MA check indication on DCS
Enter on other, enter valve 8 MA and check reading on DCS
Same for other valve that is 12MA, 16MA, 20MA

End/Abort (Exit from loop checking)

Home

Page 96 of 137
How to check loop checking using HART 475?
Connect HART to Tx

Switch ON HART

HART

Service tools
 Home
Simulate

Loop test

Choose Analog output values
 4mA
 20mA
 Others
 End

Enter on 4mA and check indicator on DCS
Enter on other; enter value of 8mA and check indicator on DCS
Same for other values 12.00mA, 16.00mA and 20.00mA

ABORT (Exit from loop checking)

Home
Loop checking from DCS to control valve
DCS C/R
% C/V = 0 % AO (safety barrier)

+ +
E/P
- 4.00mA to 20.00mA DC - AS
A M
Scale
Auto Manual C/V

0% Field 0%
Take loop manually 25% 25%
(Compulsory) 50% 50%
75% 75%
100% 100%

Page 97 of 137
4.00mA to 20.00mA SYSTEM
Work station
DCS C
(System P
Cabinet) U
KEY BOARD
M Card
DCS
C 24V DC SUPPLY
P A A A D D
P
S I I O I O
U + - + -
Marshalling 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Panel
(M/R)
Z Z Z Z Z Z Z Z Z
B B B B B B B B B
Pair cable P P P P P P P P
A A A A A A A A
(Primary cable) I I I I I I I I
(Ex.12p/1.0mm2 R R R R R R R R
C C C C C C C C
A A A A A A A A
B B B B B B B B
L L L L L L L L
E E E E E E E E
Junction Box
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Secondary cable
Field Instrument (Single pair cable)

Page 98 of 137
FIELDBUS FOUNDATION SYSTEM
C
P
G Work Station
KEY BOARD M
H1 Interface Card
H1 H1
P C P C C C
P P A A
FIELDBUS
S S R R
U U POWER SUPPLY
D D
(FBPS)
Trunk Cable
(Single pair cable)
(1900 meter)
(Speed 31.25 kbps)
(Orange color)
Digital 2 way cable
Terminator
Zone 0/ Zone 1
Segment Field Field Segment Segment Segment
T
Protector Barrier Barrier Protector Protector Protector
Spur cable (120 meters)

Page 99 of 137

Page 100 of 137
FIELDBUS FOUNDATION
What is fieldbus?
Fieldbus is a digital, two ways, multi drop data bus for communication with field instrument.
HISTORY OF INSTRUMENTAION
Pneumatic Instruments
3 to 15psi

Electronic Instruments

HART SMART

Wireless Tx (HART)

Fieldbus (FF)
 Fieldbus was first introduce in the year of 1996 by instrument society of automation.
 Fieldbus is a one type of communication protocol to communicate with field instruments.
 Fieldbus is a digital, two ways, multi drop data bus for communicate with field instruments.
 Output of fieldbus is a digital (not 4.00mA to 20.00mA).
 Fieldbus data transfer speed is 31.25 kbps.
 Like 4.00mA to 20.00mA system, fieldbus is also use two wires for power and signal but signal is
digital.
 Fieldbus always multiple instruments to use single cable single wire pair carries both power and
digital communication signal.
 Instead of running individual cable in 4.00mA to 20.00mA system fieldbus allows multiple
instruments to use single cable.
 Fieldbus use twisted single pair cable with shield.
Twisted pair cable
 Fieldbus communication cable color mostly preferred is orange.

 Generally fieldbus power supply (FBPS) generates 24V DC.

Page 101 of 137
What are the components of fieldbus system?
1. DCS (H1 fieldbus card)

2. FBPS (fieldbus power supply)
3. Segment protector
4. Field barrier
5. Trunk cable
6. Spur cable
7. Temperature multiplexer
8. Terminator
Trunk cable
Trunk cable is a main cable between control room (DCS H1-card) to segment protector (junction box) in field.
Spur cable
Spur cable connects trunk cable to field instruments that is transmitter and control valve.
DCS (H1 fieldbus Card)
H1 fieldbus card is a device in control room that control and monitor the field network.
Temperature multiplexer
Temperature multiplexer is used to communicate with temperature sensor those are RTD and T/C.
Temperature multiplexer is directly connected to segment protector or field barrier.
Trunk in 8 channel Temp. Mux

Page 102 of 137
Advantages of fieldbus
1. Reduce cable (wiring) and installation cost.

2. Cable requires less in fieldbus than 4.00mA to 20.00mA DC system.
3. Fieldbus system is saving in total installation cost. This saving comes from reduces wiring,
installation, terminations, connections, junction box, marshalling panel, cable tray, conduit and
support.
4. Many parameters (process variable) can be communicated in fieldbus network where as only one
parameters can be transmitted in 4.00mA to 20.00mA DC.
5. Reduce number of drawings.
6. Reduce control room spaces.
Disadvantages of fieldbus
1. Fieldbus components are more expensive than 4.00mA to20.00mA DC system.

2. Trouble shooting is difficult in fieldbus.
3. Skill technician and engineer require to maintain the fieldbus system.
Difference between 4.00mA to 20.00mA DC system and Fieldbus system
4.00mA to 20.00mA DC system Fieldbus system

1. 4.00mA to 20.00mA DC communication is 1. Fieldbus communication is digital.
Analog.
2. 4.00mA to 20.00mA DC system use 2. Fieldbus system use one cable for multiple
individual cable for each instrument. instruments.
3. 4.00mA to 20.00mA DC system requires 3. Fieldbus system requires FBPS (fieldbus
general purpose power supply (SMPS). power supply).
4. 4.00mA to 20.00mA DC system requires 4. Fieldbus system requires segment protector
safety barrier to connect field instruments. OR field barrier to connect field instruments.
5. 4.00mA to 20.00mA DC system uses I/O 5. Fieldbus system uses H1 fieldbus card to
card (AI, AO, DI, DO) in DCS to connect connect field instruments.
field instruments.
6. More cables are require. 6. Less cables are require.
7. More wiring, cabling and termination 7. Less wiring, termination and cable costing.
costing.
8. More man power require. 8. Less man power require.
9. Project cost is more. 9. Project cost is less.
10. Point to point wiring. 10. Multi drop wiring.

Page 103 of 137
CONTROL LOOP DIAGRAM
FLOW CONTROL LOOP
-
AS E/P +
I/L O/L
H L
DP FCV
DCS
FIC
DPT Type
FT
FIC 504
SP = 10 LPM X
Set point Close Tab
PV = 0 LPM
Process value
% C/V = 100%
A M Confi. Trend
Auto Manual Configuration Graph

Page 104 of 137
TEMPERATURE CONTROL LOOP
DCS / TIC 501

SP = 100OC X
PV = 53OC
% C/V = 100%
A M Confi. Trend
TCV
100OC
RTD TTx
Tank
Steam Outlet
LEVEL CONTROL LOOP
DCS / LIC 502

SP = 40% X
PV = 30 %
% C/V = 100%
A M Confi. Trend
LT (GWR)
LCV
DRAIN POINT

Page 105 of 137
PRESSURE CONTROL LOOP
DCS / PIC 503
SP = 5 Bar X
PV = 3 Bar
% C/V = 100%
A M Confi. Trend
PT
5.0 Bar
PCV
NITROGEN
TANK

Page 106 of 137
TEMPERATURE CONTROL LOOP
TTx DCS
+ + + +
JB SB M/R AI TIC AO M/R SB JB E/P AS
- - - -
T C/V
PRESSURE CONTROL LOOP
PTx DCS
+ + + +
JB SB M/R AI PIC AO M/R SB JB E/P AS
- - - -
P C/V

Page 107 of 137
LEVEL CONTROL LOOP
LTx DCS
+ + + +
JB SB M/R AI LIC AO M/R SB JB E/P AS
- - - -
L C/V
FLOW CONTROL LOOP
FTx DCS
+ + + +
JB SB M/R AI FIC AO M/R SB JB E/P AS
- - - -
F C/V

Page 108 of 137
HART COMMUNICATOR
H = Highway
A = Addressable
R = Remote
T = Transducer
Company: Emerson model – 375 & 475

Yokogawa BT 200
What is HART communicator?
 HART communicator is used to communicate with the SMART instruments.

 HART communicator is connected to the supply terminal of transmitter.
 HART communicator is not directly connected to the supply terminal, when it is used in lab. It
should be connected with 250 Ω resistance in series.
Where to connect HART communicator?
HART communicator is connected at (+) and (-) terminal of 24v DC supply transmitter.
2 WIRE TRANSMITTER 4 WIRE TRANSMITTER

Supply Supply
s
S
output
4.00 to 20.00mA DC
HART
HART
What are the uses of HART communicator?
1. To change of 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 (zero 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.
10. To check and make the configuration of transmitter.

Page 109 of 137
How to connect HART communicator with transmitter while using in Lab and Field?
LAB FIELD
Tx. Tx.
24V DC supply 24V DC supply
DCS
Offline Online
HART HART
Note:
In Field: HART is getting 250 Ω load from DCS, so HART will communicate with transmitter.
In Lab: HART is not getting 250 Ω load from loop, so we have to connect loop resister of 250 Ω in series
with supply.
HOW TO ONLINE AT LAB
24V DC
Supply 250 Ω
Loop resister
Transmitter
HART
Online
How to switch off HART?
HOME

Enter on close tab

HART Application

Switch OFF HART
 Standby
 Shut down
(Enter on shut down HART will switch off)

Page 110 of 137
How to loop checking using HART 375 & 475?
Connect HART to transmitter


Switch ON HART

HART Application
 (Delete)
MODEL No.
ONLINE
1. DEVICE SETUP
2. PV = (T, P, L, F) HOME
3. AO = 4.00mA to 20.00mA
4. LRV =
5. URV =
SAVE BACK

Device setup

Diagnostic / Service

Loop test

Choose analog output value
 4mA
 20mA
 Other
 End

Enter 4mA and check reading on DCS
Enter on Other, enter value 8mA and check reading on DCS
Same for other values those are 12mA, 16mA and 20mA

Abort (exit from loop checking)

HOME

Page 111 of 137
How to change UNIT of transmitter with HART 375 & 475?


Switch ON HART

HART Application
 (Delete)
MODEL No.
ONLINE
1. DEVICE SETUP
3. AO = 4.00mA to 20.00mA
4. LRV =
5. URV =
SAVE BACK

Device setup

Basic setup

Units

List of units come
Select which is require

SEND Warn = loop manual = ok
 Warn = loop Auto = ok
HOME
(UNIT HAS BEEN CHANGED)

Page 112 of 137
How to change Range of transmitter with HART 375 & 475?


Switch ON HART

HART Application
 (Delete)
MODEL No.
ONLINE
1. DEVICE SETUP HOME
2. PV = (T, P, L, F)
3. AO = 4.00mA to 20.00mA
4. LRV =
5. URV =
SAVE BACK

Enter on LRV
Enter the value of LRV

Enter on URV
Enter the value of URV

 Warn = loop Auto = ok
HOME
(RANGE HAS BEEN CHANGED)

Page 113 of 137
How to do ZERO TRIM of transmitter with HART 375 & 475?


Switch ON HART

HART Application
 (Delete)
MODEL No.
ONLINE
1. DEVICE SETUP
2. PV = (T, P, L, F)
3. AO = 4.00mA to 20.00mA
HOME
4. LRV =
5. URV =
SAVE BACK

Device setup


Calibration

Sensor trim

Zero trim

Apply “0” input to sensor

Ok

Zero adjusted (Trimed)

Page 114 of 137
How to change Transmitter output from Linear to Square root and Square root to Linear with
HART 375 & 475?


Switch ON HART

HART Application
 (Delete)
MODEL No.
ONLINE
1. DEVICE SETUP
3. AO = 4.00mA to 20.00mA
4. LRV =
5. URV =
SAVE BACK

Device setup

Basic setup

Transfer Function
* Linear
* Square Root

Select which is require

 Warn = loop auto = ok
HOME

Page 115 of 137
How to change SENSOR TYPE from RTD to T/C and T/C to RTD with HART 375 & 475?


Switch ON HART

HART Application
 (Delete)
MODEL No.
ONLINE
1. DEVICE SETUP
HOME
2. PV = (T, P, L, F)
3. AO = 4.00mA to 20.00mA
4. LRV =
5. URV =
SAVE BACK

Device setup

Configuration

Sensor Configuration

Connections select T/C or RTD

FOR RTD FOR T/C

Select PT100 * K Type
α = 0.00385 * J Type
 * R Type
* 2 Wire * S Type
* 3 Wire * T Type
* 4 Wire 
 OK
OK

Page 116 of 137
How to do calibration of transmitter with HART 375 & 475?


Switch ON HART

HART Application
 (Delete)
MODEL No.
ONLINE
1. DEVICE SETUP
2. PV = (T, P, L, F)
3. AO = 4.00mA to 20.00mA
HOME
4. LRV =
5. URV =
SAVE BACK

Device setup


Calibration

Sensor trim

Lower sensor trim Upper sensor trim

 
(Zero) (Span)
 
Apply low pressure Apply high pressure
 
Ok Ok
 
Enter applied pressure value Enter applied pressure value

Page 117 of 137
How to check battery status of HART 375 & HART 475?
Switch ON HART

Setting

Power status
 80%
Fill Empty
What is the difference between HART 375 & HART 475?
HART 375 HART 475

1. HART 375 is not color display. 1. HART 475 having color display.
2. HART 375 is not touch screen.(joy stick) 2. HART 475 is fully touch screen.
3. Battery backup is less. 3. Battery backup is more.
4. Slow in working (operationally). 4. Fast in working (Operationally).
5. Graphical display is not available. 5. Graphical display is available.
TYPE OF DRAWINGS
There are mainly five types of drawings…
1. Hook up drawing
(Instrument installation)
2. ILD – Instrument loop diagram
(Single loop diagram – T, P, L, F)
3. P & ID – Piping and instrument diagram
(Whole unit / plant diagram)
4. Instrument location diagram
5. PFD – Process flow diagram

Page 118 of 137
VIBRATION MONITORING SYSTEM
Company: Bentley Nevada, USA

3500 & 7200 model
What is vibration?
Vibration is a static and dynamic imbalance of equipments.
What are the types of vibration?

1. Axial vibration
2. Radial vibration
3. Seismic vibration
4. Key phaser
What is vibration monitoring system?

Vibration monitoring system is used for machinery protection.
Where vibration monitoring system used?

Vibrating monitoring system used in rotating equipments, those are turbine, compressor, machine, pump,
generator, cooling tower fan etc.
What is the principle of vibration monitoring system?

Eddy current loss.
What are the units of vibration?

Mils, Microns.
1 Mils = 0.001 inch

1 Mils = 0.254 mm
1 Mils = 25.4 microns
1 mils = 200mv DC
What are the components of vibration monitoring system?

1. Vibration probe.
2. Extension cable.
3. Proximitor. (Transducer)
4. Display
Vibration probe
Vibration probe used to convert the mechanical motion in to electrical signal.
Radial probe
Shaft Axial probe
Bently Nevada vibration monitoring system uses eddy current technology to sense the distance between probe
tip and rotating shaft.

Page 119 of 137
Proximitor (transducer)
Proximitor is used to generate voltage which is proportional to the ‘Gap’ between the probe tip and rotating
shaft.
What is the supply voltage of vibration monitoring system?

-24V DC.
What is the ‘Gap’ voltage is to be set in 3500 model?

-10V DC.
-10V DC = 1.2mm
1.2mm = -10V DC
Vibration probe
Motor
Shaft Cable
Gap 1.2mm Proximitor (transducer)

3500 Model
- 24 V com out
-24V DC
Com.
MM
-10.00 V DC
What will be the Gap voltage when probe attach to the shaft?
0V DC
What will be the Gap voltage when probe is de attach the shaft?
-24V DC
Why negative voltage is used for vibration system?

 Negative voltage is used because circuit use PNP transistor and PNP transistor requires negative
bias voltage.
 Noise level is less in negative voltage.

Page 120 of 137
CABLE GLAND
What is cable gland?

A device designed to permit the entry of cable in to electrical equipments which provide sealing, retention,
earthing, bonding, grounding, insulation, strain relief of combination of all those.
What is the size of cable glands?

 20mm
 25mm
 32mm
 40mm
 50mm
 63mm
What are the types off cable glanding?

1. Single compression cable glanding.
2. Double compression cable glanding.
What are the parts of cable gland?
1. Check nut
2. IP washer
3. Nipple entry part
4. Inner rubber
5. Cone
6. Ring
7. Main gland body
8. Outer rubber
9. Washer
10. Compression nut

Page 121 of 137
Where cable gland is used in industries?

 Transmitter
 Switch
 Positioned
 Junction box
 Panel
 RTD
 T/C
 Motor
CABLE LUG
What are the types of cable lugs?

1. Pin type
2. Ring type
3. U type (Fork type)
Ring type lugs Pin type lugs U type lugs

Page 122 of 137
What is the size of cable lugs?

 0.5mm2
 0.75 mm2
 1.0 mm2
 1.5 mm2
 2.5 mm2
 4.0 mm2
 6.0 mm2
 10.0 mm2
 16.0 mm2
What are the types of cables?
1. Armour cable
2. Non armour cable
3. Power cable
4. Communication cable
5. Pair cable (multi core)
Armour Cable Non Armour Cable
Pair Cable

Page 123 of 137
What is the size of cables?

 0.5mm2
 0.75 mm2
 1.0 mm2
 1.5 mm2
 2.5 mm2
 4.0 mm2
 6.0 mm2
 10.0 mm2
 16.0 mm2
CABLE TRAY
What is cable tray?

Cable tray is used to support electrical cables which are used for power distribution and communication.
What are the types of tray?

 Ladder tray
 Punching tray
What is the size of tray?

1. 50mm 6. 300mm 11. 550mm
2. 100mm 7. 350mm 12. 600mm
3. 150mm 8. 400mm 13. 650mm
4. 200mm 9. 450mm 14. 700mm
5. 250mm 10. 500mm
What is the material used for cable tray?
GI (Galvanized Iron), SS (stainless Steel), Fiber
TUBE
What is the size of tube?
 1/8” – one eight – 3mm

 1/4" – Quarter – 6mm
 3/8” – three eight – 10mm
 1/2” – Half – 12mm
 1” – one inch – 25mm

Page 124 of 137
INTERVIEW QUESTIONS FOR PREOCESS CONTROL INSTRUMENTS
What is instrument?
Instrument is a device which is use for measurement, monitoring, controlling and display of process variable.
What is instrumentation?
Instrumentation is a branch of an engineering which deals with measurement, monitoring, controlling and
display of process variable.
What are the process variable?

 Temperature
 Pressure
 Level
 Flow
What is the definition of temperature?

Temperature is the degree of coldness and hotness of the body. It is to be measured hotness and coldness of
process medium.
What is the definition of pressure?

Force acting per unit area.
What is the definition of level?

Difference between two heights of liquid in a tank or in a vessel.
What is the definition of flow?

Quantity of gas or liquid moving through the pipeline within a standard time is in minutes or hour.
What are the units of temperature?

 Degree Celsius
 Degree Fahrenheit
 Degree Kelvin
 Degree Ranking
What are the units of pressure?

Units of high pressure: kg/cm2
Bar
Psi (pounds per square inch)
Units of low pressure: Pascal
mmH2O
mmHg
InchH2O
InchHg

Page 125 of 137
What are the units of level?

 Percentage (0 to 100%)
 Meter
 Feet
 Inch
 Cm (centimeter)
What are the units of flow?

Units of liquid flow: Liter per minute (LPM)
Liter per hour (LPH)
Gallons per minute (GPM)
Gallons per hour (GPH)
Barrels per day (BPD) (I barrel = 158.98 liters)
Units of gas and air flow: m3min (miter cube per minute)
M3hour (miter 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 permits?

 Cold work permit
 Hot work permit
 Confined space entry permit
What is the cold work permit?

The work which does not creates heat, smoke and flame but there is possibility to create spark that work is
called cold work.
 Instrument installation
 Field calibration
 Loop checking
 Function test
 Trouble shooting (Fault finding)
What is the hot work permit?

The work which creates heat, smoke and flame that work is called hot work.
 Welding
 Cutting
 Drilling
 Grinding
What are the types of fire extinguishers?

 Water type
 DCP type (Dry chemical powder)
 Foam type
 CO2 type

Page 126 of 137
What is zone and types of zone?

Zones are used to define the presents of explosive gas in atmosphere.
There are three types of zone
Zone 0: An explosive gas mixed with air in atmosphere is continuously 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 use to measure voltage (AC /DC), current (AC/DC), resistance, mA, mV and
cable continuity.
How to measure voltage and current?

Voltage is always measured in parallel and current is always measured in series only.
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 electromechanical device which is used to change over the 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 on resistance mode.
If coil is ok ----- 150 Ω to 2000 Ω
If coil is not ok ----- open (OL) & Short (0 Ω)
Why 4 to 20mA DC signal used for signal transmitter?

Voltage will drop for long distance so that voltage signal will not used.
Using 0 to 20mA DC signal we cannot differentiate that actual process value is zero or there is open circuit.
Linear graph we can get (4, 8, 12, 16 and 20)
4mA is called “live zero”.
What is transmitter?
Transmitter is a device which is use to measure process variable those are temperature, pressure, level and
flow.
How to connect indicator, DCS, PLC and controller?

Always connected in series.
What is input and output of transmitter?

Transmitter supply voltage = 24V DC (worldwide)
Transmitter output = 4.00mA to 20.00mA DC (worldwide)
What are the formula conversion from 0C to 0F and 0F to 0C?

0
C = 0F-32 __________ (1)
1.8
0
F = (0C*1.8) + 32_______ (2)

Page 127 of 137
What are the temperature sensing elements?

RTD and Thermocouple (T/C).
What is mean by PT100?

When temperature is 0 degree Celsius, resistance is 100 Ω.
What is the sensing element in RTD?

Resistance bulb
What is output of RTD?

Resistance in ohms (Ω).
What is the principle of RTD?

Change in resistance.
What is the deference between two wire RTD and three wire RTD?
Two wire RTD used for short distance and three wire RTD used for long distance.
What is the use of four wire RTD?

Four wire RTD used for very long distance.
What will be the resistance at 100 degree Celsius?

138.51 ohms (Ω)
What is calibration?
Calibration means “comparing measuring instruments with standard instruments for its best accuracy”.
OR..Calibration means the instruments under test is being compared with more accurate instruments 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 what purpose T/C is used?

For Measure high temperature.
What is the output of T/C?

Millivolts (mV)
What is the principle of T/C?

Seeback effect
What is Seeback effect?

When heat applied to the hot junction, millivolt generate at cold junction.
What are the sensing element of T/C?

Two different metals, those are Chromal and Alumel.

Page 128 of 137
Which type of T/C is mostly use in industries?

“K” type thermocouple.
What are the types 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 are the range, metal and color of “K” type thermocouple?
Range: = 1800C to 12600C
Metal : = Chromal Alumel
(+) (-)
Color: = Yellow Red
What is the specialty of thermocouple leads wire?

Lead wire should be the same material as the thermocouple metal material.
How to check TT (Thermocouple input) without connecting thermocouple or millivolts 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 thermocouples are those which are directly connected to the process without any thermo well. It is used
for measuring the skin temperature of heater, furnace and boiler.
What will be the millivolts at 100 degree Celsius for “K” type thermocouple?
4.069mV (according to chart)
How to calibrate RTD, T/C and Temp. Switch?

RTD, T/C and temperature switch is calibrated by using Temperature bath. (Sand bath or Oil bath)
What are the sensing elements for temperature switch?

Bellows.
What is the use of temperature switch?

Temperature switch use to heater control, alarm purpose and tripping circuit.
What is thermo well?

Thermo well is used to protect the temperature sensor against damage, corrosion and high pressure process.
What are the pressure sensing elements?

Bourdon tube (pressure gauge)
 C type bourdon type
 Helical
 Spiral
Bellows (pressure switch)
Diaphragm (pressure transmitter, DPT)
What is the principle of pressure sensing elements?

Pressure sensing elements works on the principle of “Shape change”.

Page 129 of 137
What is the range of “C” type bourdon tube?

Range: 0 to 100000psi
What are the three instruments to measure pressure?

 Pressure transmitter
 Pressure gauge
 Manometer
What is Absolute pressure?

It is pressure presents in atmosphere.
What is gauge pressure?

Gauge pressure = Atmospheric pressure + system pressure.
What are the parts of pressure gauge?

 “C” type bourdon tube
 Hairspring
 Pointer
 Gear sector & pinion arrangement
 Connecting link
 Zero & Span adjustment
 Scale
What is the principle of pressure gauge?

Pressure gauge works on the principle of Hooks law. Hooks law state that measuring pressure in elastic
medium.
What is the material used of bourdon tube?

 Stainless steel (for high pressure)
 Copper (for low pressure)
What is compound gauge?

Compound gauge is used to measure both gauge pressure and vacuum pressure.
What is vacuum pressure?

Any pressure below atmospheric pressure is called vacuum pressure or negative pressure.
What is maximum vacuum?

-760mmHg
What is deadweight tester?

Deadweight tester is used to calibrate the pressure gauge.
What is the principle of deadweight tester?

Deadweight tester works on the principle of Pascal law.
What is Pascal law state?

Pascal law state that “pressure applied on liquid, it (liquid) will be remains same in all direction”.

Page 130 of 137
What is pressure switch?

Pressure switch is a device which is use to change over the 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 use 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 4.00mA to 20.00mA DC.
Which calibrator/source are used to PT, PS and PG calibration?

Pressure source
What are the pressure source/calibrator is used?

There are two types of pressure source
 Pneumatic pressure source
 Hydraulic pressure source
What are the material of diaphragm and flange in pressure transmitter?

SS 316 L
What are the types of instruments used for level measurement?

DPT type level transmitter OR Hydrostatic head type level transmitter
Radar type level transmitter OR Non contact type level transmitter
Leveltrol OR Displacer type level transmitter
What are two types of level switch?

Float type level switch
Vibrating fork type level switch
What is the sensing element of float type level switch?

Float
What is leveltrol?
Leveltrol is one of the most common instruments used for measuring level in tank.
What is the sensing element of leveltrol?

Displacer
What is the principle of leveltrol?

Leveltrol works on the Weight loss principle of “Archimedes law”.
What is states Archimedes law?

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

Page 131 of 137
What is displacer?
Displacer is a cylindrical shape pipe scaled and filled inside 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 is 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 DC).
What will happen if displacer has a hole in it, while in live?

Output will be minimum (04.00mA DC).
What is the SG of water, oil, petrol, seawater and glycol?

 Water = 1.0
 Oil = 0.84
 Petrol = 0.73722
 Seawater = 1.023
 Glycol = 0.94
What is interface level?

When tank filled with two different specific gravity 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.
What is zero suppression?

Compensation of an unwanted pressure at HIGH SIDE of level transmitter.
What is zero elevation?

Compensation of an 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.

Page 132 of 137
What is the principle of Radar type level transmitter?

Time of flight system OR FMCW = Frequency modulated continuous waves.
Which measure distance from top of the surface of process liquid.
What are the sensing elements of Radar type level transmitter?

Electromagnetic waves
What are the types of Radar type level transmitter?

 Wave stick type.
 Horn OR Cone type
 Guided wave radar 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?

Bournolli’s theorem
What is state Bournoli’s theorem?

When there is restriction (flow sensor) in pipeline flow produces Differential pressure across the restriction.
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 square root mode.
Linear and square root is to be change by using HART communication.
What are the flow sensing elements?

 Orifice plate
 Venture tube
 Pitot tube
 Flow nozzle
 Annubar
What is orifice plate?

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

Page 133 of 137
What are the types of orifice plate?

 Concentric orifice plate
 Eccentric orifice plate
 Segmental orifice plate
 Quadrant orifice plate
 Integral orifice plate
What are the uses of concentric orifice plate?

This orifice plate has a hole in center so that it is called concentric orifice plate.
1. Ideal liquid flow
2. Gas or Air flow
3. Dry steam flow
What are the uses of eccentric orifice plate?

This orifice plate has a hole in eccentric so that it is called eccentric orifice plate.
1. Liquid containing solid
2. Oil containing water
3. Wet steam
4. Viscous liquid
5. Slurry liquid
What are the uses of segmental orifice plate?

This orifice plate has a hole in from of segmental of circle so that it is called segmental orifice plate.
1. Liquid containing solid
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.
Why tab is provided with orifice plate?

Indication of an 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.
What is impulse line?

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

Page 134 of 137
How to do tubing or piping of impulse line for DPT for liquid line, air or gas line and steam line?
For liquid line DTP is mounted below the orifice plate.
For air OR gas line DPT mounted above the orifice plate.
For steam line DPT is mounted below the orifice plate with condensate pot.
In running plant suddenly flow is showing more, less or fluctuating than how will you start checking?
First drain or flush the DPT.
Check choking if there then flush both impulse lines.
Check leakages at both impulse lines.
Check zero of DPT, if disturbed then adjust it.
Check 24V DC supply voltage it should not 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 equalize 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 are the tapping used for orifice plate?

 Flange tapping
 Corner tapping
 Radius tapping
 Pipe tapping
 Vena contract tapping
What is corner tapping?

This is used on line size less than 2 inches they are directly located at the force of the orifice plate.
What is flange tapping?

Flange tapping is used on line size 2 inches or larger they are locked in the orifice flange 1 inch from upstream
and 1 inch downstream from face of the orifice plate.
What is the instrument (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?

Change in frequency of sound wave. OR Shift in frequency of sound wave.
What is the sensing element of magnetic flow meter?

Magnetic coil with electrode.
What is the principle of magnetic flow meter?

Faraday’s low of electromagnetic induction.
What is state Faraday’s law?

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

Page 135 of 137
What are the sensing elements of mass flow meter?

Oscillating tube.
What is the principle of mass flow meter?

Mass flow meter works on the principle of “Corioli’s effect”.
What is state 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 flow meter?

Bluff body/shedder bar.
What is the principle of vortex flow meter?

Vortex flow meter works on the principle of “Von Karman effects”.
Which type flow switch is mostly used in plants?

Paddle type flow switch.
What are the I/P, O/P and air supply for I to P converter?
I/P = 4.00mA to 20.00mA DC (That is coming for the DCS)
O/P = 3 to 15 psi (0.2 to 1 kg/cm2)
Air supply = 20 psi (1.4 kg/cm2 )
Which is a master signal for control valve?

Output 3 to 15 psi that is come from 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 use to regulate (control) material flow in the process.
What are the types of control valve depending on body?

1. Single seated valve. 6. Needle valve
2. Double seated valve 7. Ball valve
3. Angle valve 8. Globe valve
4. Three way valve 9. Pinch valve
5. Butterfly valve
What are the types of control valve depending on action?

1. Air to open (FC)
2. Air to close (FO)
What are the parts of control valve?

Positioner, Actuator, Spring, Diaphragm, Stem, Yoke, Indicator Edge, Scale, Feedback link, Gland nut,
Gland pusher, Gland packing, Bonnet, Plug, Plug seat, Valve body, Three gauges. (1) Air supply
(2) 3 to 15 psi
(3) Positioned to Actuator
Page 136 of 137
What is CV of control valve?

CV = Coefficient value
Number of US gallon per minute (GPM) of water which passes through fully (100%) open control valve is
pressure drop of 1 psi.
What is 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 for control valve.
 Valve hysteresis will be zero.
 Valve can be use for viscous liquid.
 If line pressure change suddenly then also there will be no effects 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 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
variable.
What is open loop?

The loop which having only indication of process variable those loop is called open loop.
Open loop which having transmitter and DCS for indication of process variable.
What is close loop?

The loop which having both indicating and controlling of process variable that loop is called close loop.
Close loop having transmitter, DCS and control valve of process variable.
What is safety barrier?

Safety barrier is used to protect the instruments 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.

Page 137 of 137
What are the types of loop checking?

There are two types of loop checking.
1. Cold loop checking
2. Hot loop checking
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
7. Piping & instrument diagram
8. Necessary tools
What is HART communicator?

HART communicator is a device which is used to communicate with SMART instruments that instrument and
positioner.
Where to connect HART communicator?

HART communicator is connected at (+) and (-) terminal of 24V DC supply of transmitter.
What are the uses 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 to use it?

 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
moves up and down.
 Depending on design of valve plunger will open and close the valve.
 Generally 24 V DC solenoid valve is used.
There are two types of valve:

Normally open
Normally close.
Application: To operate the ON-OFF control valve.

For Emergency Shutdown (ESD) system.

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Page 1 of 137

6. Relay & contactor….

7. Two wire & four wire transmitter system…

10. Level measurement…

11. Flow measurement…

13. Control valve…

14. Loop diagram, safety barrier and loop checking…

15. HART communicator…

16. Vibrating monitoring system…

17. Cable gland, Cable lug, Cable tray and Tube…

18. Interview questions for process control instruments…

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

Petrol Diesel Naphtha Kerosene Gasoline

What are the process variable?

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

: Transmitter (PT, TT, FT, LT, DPT)

T/I : Temperature Indicator (LI, FI, PI)

TIC : Temperature Indicating Controller (PIC, LIC, FIC)

PS : Pressure Switch (TS, FS, LS)

: RTD – (Resistance Temperature Detector)

: DCS Supply Voltage

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

: PLC (Programmable logic controller)

: DCS (Distributed control system)

: NO Push button (Normally Open)

: NC Push button (Normally Close)

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

: Air to open valve

: Air to close valve

: Electrical signal (ILD)

: Pipeline signal (P & ID)

: Air line or pneumatic signal

: Electrical signal continuous

: Internal data link

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

What is PPE? What are the PPE?

What are the types of work permit?

What is hazardous area?

What are the types of zone?

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

Company : Fluke, USA

Measurement Units Symbol

V A mA com. VΩ MA (micro ampere)

OFF Red Red Black Red

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

How to measure voltage and current?

 Voltage always measured in parallel.

How to check of Relay, Contactor and SOV?

 Simple circuit diagram using relay and bulb:-

Generally 24V DC and 230V AC contactor is used.

CREATED BY: DHIRAJ TANDEL, NAVSARI, GUJARAT- +91 94083 29327

Name Of Company Country Color of Instrument

TWO WIRE TRANSMITTER SYSTEM

Transmitter supply voltage = 24V DC

TWO WIRE TRANSMITTER DIAGRAM

 Generally all Transmitter works on two wire transmitter system.