ALL ABOUT INSTRUMENT MECHANIC

 WIKA INDUCTIVE SYSTEM

Operating Principal:
Heart of the wika inductive system is non contact sensor attached to an indicating device. Both sensor
and indication are adjustable over the full length of the scale contact actuation is actived by means of a metal
plug linked to the pointer of the instrument. The metal plug affects the electric filed of the sensor when the
instrument pointer over Lapps with the contacts indicator. Contact auction is made without any mechanical
force that would affect accuracy of the instrument.
Below scheme reflects the operating principal in comparison with conventional mechanical contacts

R < 1.7 KΩ R=0

SW (-) 1

8V Equals
Red (+) 2

R > 7 KΩ
R=α
SW (-) 1
8V
Red (+) 2
Operating temp – 25 to 70 o C
*Advantages of inductive system
 Long service life by means of non contact sensor.
 Very little effect on gauge accuracy.
 Fully suitable in corrosive or hazardous atmosphere.
Components of the inductive system
 Line transformer
 Amplifier Circuit
 Relay to switch external circuit

Model 1151 DP/HIDP Press. Trans.

Bubbler System in open Vessels:

A bubbler system that has a top mounted pressure trans. can be used in open vessels. This systems
consist of an air supply press. Require constant flow meter, PT & tube that extends down in to vessels.
1
 Bubbler air through the tube at constant flow rate. The pressure required to maintain flow equal the
liquid specific graving the multi ply by vertical height of the liquid above the tube opening.

T
Air

Let X equal the vertical distance between the minimum and max. measurable level.(100 in)
Let SG equal SG of fluid (1.1)
Let h equal the max. head press. to be measured in inches of water
Let Range equal Zero to h
Then h = (X) (SG)
= 100 x 1.1
= 110 inH2O
Range = 0 ~ 110 inH2O

20

MA DC

4
0 110

Open Vessels:
A pressure transmitter mounted near a tank bottom measures the press. to the liquid above.
Make connection to high pressure side of the transmitter and vent low press. to the atmosphere press.
head equal the liquid S. G. multiply by the liquid height above the tap.
Zero range suppression is required if the transmitter lies below the Zero point of the desired level
range figure show liquid level measurement.

Example:

2
 X

Y
T

Let X equal the vertical distance between the mini & max measurable level (500 in).
Let Y equal the vertical distance between trans. datum line & min. measurable level (100 in).
Let SG equal the SG of the fluid (0.9)
Let h equal the max head press to be measure in inches of water
Let e equal the head pressure produced by Y expressed in inch of water

Let Range equal e to e + h

Then h = (X) (SG)

= 500 x 0.9
= 450 inH2O
e = (Y) (SG)
= 100 x 0.9
= 90 inH2O
Range = e to e + h
= 90 ~ 90 + 450
= 90 ~ 540 inH2O

20
Zero
Suppression

MA DC

4
0 90 540

Closed Vessels:
Pressure above a liquid affects the press. measured at the bottom of closed vessels. The liquid’s S.G.
multiply by the liquid height plus the vessel pressure equals the press. at the bottom of the vessel.
The measure true level the vessel pressure must be subtracted from the vessel bottom pressure to do
this make a pressure tap at the top of the vessels and connect this to low side of DPT. Vessels press. is than
equally applied to both high & low side of transmitter the resulting D.P. is proportional to liquid height
multiplied by the liquid’s S. G.
3
 (Low side for Vessels Pressure balance)

X Z

Y
LT

H L

Let X equal the vertical distance between the min & max measurable level (500in).
Let Y equal the vertical distance between the transmitter Datum line and mini measurable level (50in).
Let Z equal the vertical distance between the top of the liquid in the wet leg and trans. datum line (600in)
Let SG1 equal the S.G. of the fluid (1.0)
Let SG2 equal the S.G. of the fluid in the wet leg (1.1)
Let equal the max head press. to be measured in inH2O
Let e equal the head press. produced by Y exposed in inches of water
Let S equal the head press. produced by Z expressed in inches of water
Let Range equal = e – S to h + e – S
Than h = (X) (SG)
= 500 x 1 = 500 inH2O
e = (Y) (SG)
= 50 x 1 = 50 inH2O
S = (Z) (SG2)
= 600 x 1.1 = 660 inH2O
Range = e – S to h + e – S
= 50 – 660 to 500 + 50 – 660
= -610 to -110 inH2O

Zero elevation
20

4
-610 -110
8 Cell Sensors:
4
  Isolating Diaphragm
 Lead wire
 Capacitor plates
 Sealing Diaphragm
 Rigid insulation
 Oil fill
(1) 8 cell sensor
(2) Demodulator
(3) Oscillator control Amplifier
(4) Oscillator
(5) Current control Amplifier
(6) Current control & current Detector
(7) Current µ meter
(8) Reverse polarity protection
(9) Voltage regulator
(10) Zero elevation & suppression
(11) Damping Adjustment
(12) Span Adjustment
(13) Linearity Adjustment
The capacitance between the sensing diaphragm & either capacitor plate is approx 150 PF
20

600% Zero Elevation

4

-150 -125 -100 -75 -50 -25 0 25

20

500% Zero Suppression

4

0 25 50 75 100 125 150

8 Cell Sensors:
5
 The 8 Cell is a variable capacitance Sensing module in the Rosemount model 1151 Series Alpha line
Pressure transmitter.
This sensor is complete sealed module that allows direct electronic sensing of pressure induced
diaphragm deflection Diff. capacitance between the sensing diaphragm & capacitor plates is electronically
converted to a two wire 4-20 or 10-50 ma dc signal.
This approx is based on following concepts.

C1 – C2
P=K
C1 + C2
Where:
P- is the process Diff. Pressure.
K- is a constant.
C1- Capacitance between the high pressure side & sensing Diaphragm.
C2- is the capacitance between low pressure side & sensing diaphragm.

Formula for linear output:

O/P = 4ma + 16ma f
f = factor of Value in 100%
(2) Suppose O/P = 8ma
(1) Suppose O/P = 4ma OP = 4ma + 16ma f
OP = 4ma + 16ma f 8ma = 4ma + 16ma f
4ma – 4ma = 16ma f 8ma – 4ma = 16ma f
0ma – 16ma f 4ma = 16ma f
f = 0ma/16ma f = 4ma/16ma = ¼
= 0 x 100 f = 0.25 x 100
f = 0 % output f = 25 %
4ma = 0 % 8ma = 25 %
(3) Suppose O/P = 12ma (4) Suppose O/P = 5ma
O/P = 4ma + 16ma f O/P = 4ma + 16ma f
12ma = 4ma + 16ma f 5ma = 4ma + 16ma f
12ma – 4ma = 16ma f 5ma – 4ma = 16ma f
8ma = 16ma f 1ma = 16ma f
f = 8ma/16ma = ½ f = 1ma/16ma = ½
f = 0.50 (0.50 x 100) f = 0.06 (0.06 x 100)
f = 50 % f=6%
12ma = 50 % 5ma = 6 %
Formula for Square Root output: (2) Suppose O/P = 12ma
O/P = 4ma + 16ma f 2
O/P = 4ma + 16ma f 2 12ma = 4ma + 16ma f 2
12ma – 4ma = 16ma f 2
(1) Suppose O/P = 8ma 8ma = 16ma f 2
O/P = 4ma + 16ma f 2 f 2 = 8ma/16ma = 1/2
8ma = 4ma + 16ma f 2 f 2 = 0.5
f = 0.707 (0.707 x 100)
f = 70.7 % 6
12ma = 70.7 %
 8ma – 4ma = 16ma f 2
4ma = 16ma f 2
f 2 = 4ma/16ma = 1/4
f 2 = 0.25
f = 0.5 (0.5 x 100)
f = 50 %
8ma = 50 %
(4) Suppose O/P = 16ma
O/P = 4ma + 16ma f 2
16ma = 4ma + 16ma f 2
16ma – 4ma = 16ma f 2
8ma = 16ma f 2
f 2 = 8ma/16ma = 3/4
f 2 = 0.75
f = 0.866 (0.866 x 100)
f = 86.6 %
16ma = 86.6 %

Convert to 4 ~ 20 ma to 1 ~ 5 V Dc
I = V/R
20 = 5/R

5 x 10 x 10 x 10
R= = 1ma = 10-3
20
R = 250 Ω
o
o
F o
o
C 100o K o
R
212 373.2o 671.7o Steam Point

32o 0o 273.2o 491.7o Ice Point

-459.4 273.2o 0oC 0o Absolute Zero

o
C = 5/9 (F – 32)
= 5/9 (F – 32) F = 140
= 5/9 (140 – 32)
= 5/9 (108)
= 60 oC
= 140 oF = 60 oC
o
F = 9/5 C + 32
= 9/5 60 + 32
7
 = 9 x 12 + 32
= 140 oF = 60 oC
RTD Formula:

Rt = Ro (1 + α t)
= 100 (1 + 385/100000 x 100oC)
Rt = 100 (1 + 0.385)
Rt = 100 x 1.385
Rt = 100 x 1385/1000 = 138.5 Ω
100 oC = 138.5 Ω
CV Stame Desided:

Pressure = Force x Area

Calibrated an Absolute Pressure Transmitter:

Range = 0 ~ 400 Abs mmHg
Apply 760 mmHg Vacuum Adj. Zero
Apply 360 mmHg Vacuum Adj. Span

(Alkaline) 14 PH
(Basic) |
|
Neutral 7 PH
|
|
Acidic 0 PH

Mercury = 849.0 Density

= 13.6 Sp Gravity

Question – Answers:

(1) What is CV of Valve.

CV=

Q GP
∆P

No of US gallon/ min of H2O which pass through a fully open valve at pressure drop of 1 PSI at 60 oF.

Three wire RTD System:

8
 B
R2
R1
G C
D
A
R3

Third wire is used for

compensation of lead wire
4 4 4
Resistance.

Note: install the transmitter so that the minimum level is at least 45mm above the center axis of the
transmitter.

Mini

See Note

Differential Pressure Range:

Open Tank:

9
 Maxi Span = XGL
Zero Suppression = YGL + ZGS
GL = SP. Gravity of liquid in Tank
GS = SP. Gravity of liquid in connecting line
Example:
h X h=X h X = 80 inches
e=Y e Y = 5 inches
s=Z s Z = 10 inches
(GL) SP. Gravity of tank = 0.8
Mini
Range = e + s ~ h + e(GS)
+ s SP. Gravity of connecting line = 0.9
e Y h Span = X GL
= 80 x 0.8
= 64 inH2O
Zero Supp. = Y GL + Z GS
s Z = 5 x 0.8 + 10 x 0.9
LT =4+9
= 13 inH2O
Range = 13 To 64 +13
= 13 To 77 inH2O

Differential Pressure Range with dry leg:

Close Tank:

10
 Span = X GL
Maxi Dry leg
Zero Supp. = Y GL + Z GS
Span = 80 x 0.8 = 64 inH2O
Zero Supp. = 5 x 0.8 + 10 x 0.9
X =4+9
= 13 ~ 64 inH2O

Mini

Z
LT

Differential Pressure Range with wet leg:

Close Tank:

Span = X GL
Wet leg
Zero Supp. = Y GL – d GS
Maxi Span = 80 x 0.8 = 64 inH2O
Zero Elev. = 120 x 0.9 – 20 x 0.8
= 108 – 16
X = -92 inH2O
d
-92 To – 92 + 64 = -28
Mini -92 ~ -28 inH2O
Y

LT

11
Differential Range with close Tank (capalary Type):
LO Span = X GL
Zero Elev. = d GS – Y GL
Maxi Span = 80 x 0.8 = 64 inH2O
Zero Elev. = Y GL – d GS
= 20 x 0.8 – 120 x 1.07
X = 16 – 128.4
d = -112.4
Mini Range = Zero To Zero + Span
HI = -112.4 ~ -112.4 + 64
Y = -112.4 ~ -48.4 inH2O

LT

Calculate the output current as a function of Pressure using the formulas below DC output between 4~20ma.
Reference Pressure. – Lower Range Limit+ 4
O/P(ma) 16 x
Upper Range Limit – Lower Range Limit

Range to be Calibrated = 30 ~ 150 PSI

Reference Pressure = 50 PSI ma ?

50 - 30
O/P(ma) 16 x +4
150 – 30
= 16 x 50 – 30 / 150 – 30 +4
= 16 x 20 / 120 + 4
= 16 / 6 + 4
= 6.67 ma Dc

1 bar = 1000mbar = 750.062 mmHg = 1.019 kg/cm2 = 401.463 inH2O

1 kg/cm2 = 28.959 inHg = 393.701 inH2O = 14.223 PSI = 735.55 mmHg
1 kg/cm2 = 10,000 mmwc = 735.6 mmHg = 0.9807 bar = 980.7 mbar

O/P Formula Pressure Transmitter Range –2 ~ +10 kg/cm2 :

(2) How much ma O/P at -2 kg/cm2 = ? 0 kg/cm2 = ? 1 kg/cm2 = ? 7 kg/cm2 = ?

12
 -2 – (-2)
O/P(ma) 16 x +4 0 – (-2)
10 – (-2) O/P(ma) 16 x +4
10 – (-2)
= 16 x 0 / 123 + 4
=4x0+4 = 16 x 20 / 12 + 4
=0+4 =8x1/3+4
= 4 ma =8/3+4
2
-2 kg/cm = 4 ma = 2.66 + 4
= 6.66 ma
0 kg/cm2 = 6.66 ma
1 – (-2)
O/P(ma) 16 x +4
10 – (-2) 7 – (-2)
O/P(ma) 16 x +4
= 16 x 3 / 12 + 4 10 – (-2)
=4x1+4
=4+4 = 16 x 9 / 12 + 4
2
1 kg/cm = 8 ma =4x3+4
= 12 + 4
= 16 ma
7 kg/cm2 = 16 ma

13
 N

FLOW

Linear Input Square Root O/P

Ma (%) (%)
4 0% 0%
5 7.9 %
6 35.3 %
7 43.3 %
8 25 % 50 %
9 55.9 %
10 61.2 %
11 66.1 %
12 50 % 70.7 %
13 75 %
14 79.05 %
15 82.91 %
16 75 % 86.60 %
17 90.13 %
18 93.54 %
19 96.82 %
20 100 % 100 %

RTD Pt – 100 S 10oC)

(0.39 Ω = 1oC or 3.9 Ω =
0oC = 100 Ω I
30oC = 111.67 Ω O
50oC = 119.40 Ω M
100oC = 138.50 Ω
200oC = 175.84 Ω
300oC = 212.02 Ω

Model 1151 14
Samart P. T.
399oC = 248.69 Ω
- 1oC = 99.61 Ω
- 10oC = 96.09 Ω
- 30oC = 88.22 Ω
- 50oC = 80.31 Ω
- 100oC = 60.28 Ω
- 200oC = 18.48 Ω

 Resistances of pure metallic conductor vary a use proportional to the temp.

Control Valve Safe Failure:

The generalization are that in heating application the valve should be fail to closed and cooling
application valve should be fail to open.
 The control valve actuator always o ring air to push down actuator this is know as the direct actuator, a
direct actuator preferred because there is no steam seal to cause possible leakage and thus reduce
maintenance costs.
% Flow O/P
Valve Characteristic
100

75
Quick
Opening

50
Linear

25

Equal
Percentage

0
0 25 % 50 % 75 % 100 %
Lift (Valve Opening)

ST.001 Table Status Number

Symbol Rule No. 1 2 3 4 5

15
 Step No.
Comments
SignalAction SignalCondition

% DI – 1 Start P. B. Y Y
% DI – 2 Switch A N Y Y
% DI – 3 Switch B N N
% DI – 4
% DI – 5
% DO – 1 Valve A Y N
% DO – 2 Valve B Y N
% DO – 3
% DO – 4
% DO – 5
Sequence Table Entry Exam:

Start MFCD
PB

Valve A

Switch A

Tank

Switch B

Valve B
Control Valve:
Single Seated Valves:
A Single seated valve should always be installed with flow tending to open to insure dynamic
Stability of the trim (High press. drop).
Double Seated Valves:
For higher pressure drop and large valve size (Tight shut off).
 Type of Body Design:

16
  Globe valve: Single or double seated.
 Angle valve: Butterfly valve
Three way valve
Pinch valve
Saunders valve
Ball valve
Angle valve
Que: Why transmitter out put signal start from 3 ~ 15 PSI or 4 ~ 20 ma?
Ans: Linear and can check up whether it’s “Live Zero” or dead band.
Que: Why is ma signal preferred for signal transmission?
Ans: noise Reduction and no current drop for long transmission line.
Que: Why is flow measured in square root?
Ans: flow varies directly as the square root of DP. Since this flow varies directly the open does not indicate
flow directly the flow can be determined by taking the square of the pen F α √DP.
 Linear:
The valve opening to flow rate is a linear cure.
 Equal percentage :
Equal increment of valve opening it will give equal in flow rate range at small opening the
flow will also be small.
 Quick opening:
At small opening the increment in flow rate higher opening the rate becomes stead.
 Use of valve positnor:
1. Quick action & positioning of control valve.
2. Valve hysterics.
3. Valve used on viscous liquid.
4. Split Range.
5. Line pressure changes on valve.
6. Valve bench set not STD.
7. Reversing & direct action
8. Spring legs actuator.
9. Changing valve characteristics.
Ratio Control loop:
Flow A

17
 FT

FY

FY × or ÷
(Ratio Station)
Set Point

FIC

FY I
P

FT

Flow B

Mainly Used for blending application. System maintaining flow B to wild flow B

Boiler Drum Level Control:Bois

18
 Set
FT
Steam Turbine
FIC
P&R
Steam Flow Out

I
P

FT FIC
P&R
BFW LT

Tree Element Control:

A simple electronic control system in show in figure the water level in drum is to be controlled, not
only water level but steam flow out of the boiler and water flow in to drum the three measured variable feed in
to one master controller which control the water to the drum.
Show in figure how the three signals steam flow, BF water flow and water level are combined the first
two (steam flow & FW flow) are introduced directly into the feed water flow controller the water level called
BAIS comes from level controller, the errors signal in this controller is the difference between steam flow out
and water flow in series with level controller signal, the resultant error signal is fed through the feed water
controller to provided the feed water flow signal to the Pinal controller element. (Control valve).

P3 = R (P2 – P1 – K) + P4 + K0
R = gain
K1 = Adj. Suppression
K0 = Adj. BAIS
Cascade Control (Two Distinct Advantages):
1. Disturbance affecting the secondary variable can be corrected by the secondary controller
before a pronounced influence is fell by the primary variable.
2. Closing the control loop around the secondary part of the process reduces the phase lag seen by
the primary controller resultant in increased speed of response.

Que: when can a by pass not be used on a positnor.

Ans: 1. split range operation.
2 . Reversing action positnor.
3. Valve bench set not std.
Que: How will you check Zero of DP level Transmitter while line.
Ans: Close both Isolation valve on HP & LP leg, open Equalize a valve and check & Adjust
Zero.

19
Que: what type bonnet use on high temp. & low temp.?
Ans: High temp.: With Radiating fin low temp.
Low temp.: Extended bonnet.
TYPE OF THERMOCOUPLE:
TYPE RANGE
Iron constantan (J) -210 – 1200oC
Chromel Alumal (K) -270 – 1900oC
Chromel constantan (E) -270 – 1000oC
Cupper constantan (T) -270 – 400oC
Platinum pt-Rhodium 10% (S) -50 – 1700oC
Platinum pt- Rhodium 13% (R) -50 – 1700oC

Que: How will you change the action of control valve?

Ans: If control valve without bottom flange the actuator needs to be changed. If the bottom flanged is provided
disconnect steam, separate body from bonnet remove the bottom flange and the plug from body, detach the plug
from the steam by removing the pin, fix the steam at other end of the plug and fix the pin back, turn the body
upside down. Connect it back to the bonnet after inserting the plug & steam, connect back the steam & couple it
fix back the bottom flange calibrate the valve.
Que: What are the diff. type of orifice plates and its use?
Ans: Internal orifice: small flow rate mounted directly secondary device.
Concentric: Liquid steam, Gas.
Eccentric: Viscous, Slurry flow.
Segmental: Slurry, colloidal flow.
Quadrant: Viscous flow.
Que: How do you calibrate DP ‘X’ meter in line?
Ans: procurement of work permit cont. in man mode if trip exists disable, close main Isolating valve (HP & LP)
Equalize & drain the liquid if and adjust Zero of Transmitter & required span by applying max cal. Span.

EXPLAIN CASCADE CONTROL LOOP:

SV
MASTER PV TIC Set point
TT TIC
Steam
Remote
PIC SP
PT
Feed Water
Slave

PV
Cascade means two controller in series, one of them is master or primary & secondary is the secondary slave,
the O/P of the slave controller operates the final control elements.

20
 T:1 T:2
TON
T:1 (EN)
DN Preset. 0.35 (DN)
DN Acc…….

T:1
TON
T:2 (EN)
DN Preset. 0.35
Acc……. (DN)
T:2

(0.25 Flash)
TT
Abnormal
T:2 output
( )
TT
Lamp blinking indication leader logic.

1oC 10oC 30oC 50oC 100oC 200oC 300oC 400oC 1200oC

Iron Constantan J 0.050 0.501 1.536 2.583 5.268 10.777 16.325 57.942 69.536
Chromel Alumal K 0.039 0.397 1.703 2.022 4.095 8.137 12.207 41.269 48.828
Chromel Constantan E MV Output
Copper constantan T 0.039 0.391 1.196 2.035 4.277 9.286 14.860
Pt-Pt-Rhodium 10% S 0.005 0.55 0.173 0.299 0.645 1.440 2.323 9.585 11.947
Pt-Pt-Rhodium 13% R 0.005 0.054 0.171 0.296 0.647 1.468 2.400 10.503 13.363

Bit = 0 or 1
Byte = 8 bit
Kilobyte = 1024 bytes/bit
Mega byte = 1024 KB
Giga byte = 1024 MB

Reset PB

R1 Accept PB
R1

R1
Hooter

Kg/cm2 MMHg Bar M. BAr MMWC PSI KPA

2
Kg/cm 1 735.56 0.9807 980.7 10.000 14.25 98.066

21
MMHg 0.001359 1 0.00133 1.3332 13.5951 0.01934 0.13332
Bar 1.01972 750.062 1 1000 10197.16 14.5038 100
M.Bar 1.01972x10-3 0.7501 0.001 1 10.197 0.0145 0.1
MMWC 0.0001 0.07355 0.000098 0.098 1 0.00142 9.8067x103
PSI 0.7031 51.715 0.6895 68.950 703.07 1 6.8947
KPA 0.0101972 7.50662 10-2 10 101.9716 0.145338 1

Concentric Orifice Plate:

Most flow meter installation are made with concentric orifice plates, the advantages are
reproducibility, low cost ease of installation and removal and high accuracy.
The disadvantages are it can be used fro only clean fluids not suited for viscous fluids wet steam liquid
with vapor and its also creates high pressure drop.
Capacitance Level Detector:
A capacitor consists of two conductor isolated by an insulator. The conductor are called plates and
insulator is referred to as di-electric, the characteristic nature of the capacitor is its ability to store electric charge
when potential is applied to a capacitor current flow in the circuit till the capacitor is fully charged the larger
capacitor more current flow in the circuit if an alternating voltage source is used the current in the circuit flows
in one direction and then in the other direction the magnitude of the flow is direct proportional to the size of
capacitor.
Gauge Pressure:
Absolute Press – Atm Press.
Absolute Press. = Gauge Press + Atmost. Press.

Figure: Magnetic Flow Meter

Magnetic Inductive Compact Flow Meter:

Conductivity of fluid = 20 µ/S
Electrodes = platinum
Model-f/200 delta flux
Measuring Principle: The flow meter is designed for electrically conductive fluids measurement based is on
faraday’s law of induction, according to which a voltage is induced in an electrically conductive body which
passes through a magnetic field. The following expression is applicable to the voltage.
U = K x B x V x D Where:
U = induced Voltage
K = an instrument Constant
B = magnetic field strength
V = mean velocity
D = Pipe diameter
Thus the induced voltage is proportional to the mean flow velocity when the field strength is constant
inside the flow meter the fluid passes through a magnetic field applied vertically to the direction of flow an
electric voltage is induced by the movement of the fluid (which must have a minimum electrical
conductivity). This is proportional to the mean flow velocity and thus to the volume of flow. The induced
voltage is pick up by two electrodes which are in conductive contact with the fluid and forward to signal
converter for standardized output.
ADVANTAGES:
- No pressure drop through pipe construction.
- Only the pipe liner and the electrode are in contact with fluid.
22
 - Output signal expect linear function with of mean flow velocity.
Application: Flow meter are used for the accurate determination of flow of conductive fluids in sealed pipes
the flow of most liquids saltwater acids, alkalis, milk, slurries, frodanimal feed etc.

Sensor

Level Trol Calibration by weight System:

Displacer length = 650mm
Displacer Diameter = 48.6mm
Displacer weight = 2648gms
Specific Gravity of liquid = 0.73
Displacer Volume = πr2h
= 22/7 x 24.3 x 24.3 x 650
= 1205 M3
Loss of Weight =
= 1205 x 0.73
= 879.65/4
= 219.9
= 2648gms – 879
Loss of weight at = 1769

Valve Positnor:
Working Principle: positnor is pneumatic force balance device. Which ensures the control valve
plug position is always directly proportional to the valve of the controller signal pressure.
SIOM communication cable

Increase the controller signal pressure to the diaphragm creates an unbalance

condition the pilot move cover vent increase positnor out put pressure to the actuator
diaphragm until to the force of the positnor spring and diaphragm are equilibrium the positnor
output is stabilized at an amount necessary to maintain the desired valve plug position.

23
 PH indicator
PH
Amplifier

RTD
Glass
(PH)
Reference
PH Measurement:
The measurement of PH requires the use of specially designed electrodes two electrodes are used for
each installation one produces a change in voltage as the PH of the Solution the other electrodes maintains a
constant voltage the most common ph sensitive electrodes is the glass electrodes and the most common
reference electrodes is the calomel electrodes.
Together these electrodes form an electrolytic cell whose O/P equal the some of voltage produced by
the two electrodes this voltage is applied as the input to a null balance mill volt potentiometer similar to that
used with a thermocouple included in the circuit is temperature compensating resister this is immersed in the
solution its resistance changes with temperature of the solution so that the ph measurement is correct at the
operating temperature.
PH means Percentage of hydrogen, Ions, Ph is useful of given solution as acidic basic.
Conductivity:
All ions in a solution however affect its ability to pass an electric current measurement of the ability
(conductivity) useful in many industrial process, such a measurement can be made by immersing a pair of
electrodes of know area a certain distance apart and then measuring the resistance between them,
conductivity is expressed in mhos measured between two electrodes each having are of 1squre centimeter and
place 1cm apart.
A mho equals 1/1ohm
The conductivity cell can be used with an A. C. Wheatstone bridge as with PH measuring system a
temperature compensating resistor is used in the circuit to correct for variation in temp. of the solution.
Meter
Electrodes

1cm

1cm 1cm

Conductivity: means to ability to pass of current from the solution the conductivity is used in plant for
defined the dissolved gases in the water specially NO2 & CO2.
24
Flow control: normally equal percentage valve is used.
Pressure control: normally linear valve is used to constant pressure drop.
Temp. control: normally equal percentage use.
Level: normally linear valve used.
Que: What is the used of single seated valve?
Ans: The single seated valve use on smaller size & in valves of larger size where an absolute shut- off is
required the use of single seated valve is limited by pressure drop across the valve in the almost closed
position.
Que: What is used of double seated valve (size: 150mm To 400mm Single & double seated Valve)
Ans: Double seated valve always give some leakage but splits the flow between is balanced across the two
plugs hence good for high pressure drop. It is used on bigger size valve & high pressure system.
Que: What is the use of angle valve?
Ans: Very high pressure drop required.
Que: What is use of butter fly valve? (size 50mm ~ 800mm)
Ans: Small pressure drop across the valve is allowed the butter fly fully open when the dies rotates by 90o a
drawback of this valve that even a very small angular displacement produced a big change in flow.
Que: What is the three way valve used?
Ans: Where a dividing or mixing of flows according to a controlled ration is required.
-Saunders (Rubber lined valve) on corrosive materials.
Que: What are the different type of plug?
Ans: V port plug, contoured plug.
V port plug: used on double seated valve have a more constant off balance are.
Contoured plug: single seated valve with small trim size.

V Port

Contoured

Que: How will you change valve characteristic with positnor?

Ans: A positnor contain different type of comes in it by selection of the prrpa cam
Primary element used for flow measurement:
1. Orifice plate
2. Venture tube
3. Pitot tube
4. Anubar

Que: Why is the Orifice tab provided?

Ans: 1. Indication of the orifice plate in the line.
2. The orifice diameter marked Unit.
3. The material of the orifice plate.
4. The mark of the inlet.
Que: What are the primary element for measuring pressure?
Ans: 1. Bourdon tube (C type, Spiral, helix)
2. Diaphragm
25
 3. Capsule
4. Bellows
5. Pressuring spring

 Explain the working an electronic level troll?

Reful
ator

Pe
RVDT mod CA2 Q
+
Osci
lator
Zero
Span

Ans: The variation in buoyancy resulting level varies the net all of the displacer increasing or decreasing the
load on the torque arm this changes is directly proportion to the change in level and Sp. Gravity of the liquid
the resulting torque tube movement varies the angular motion of the rotor in the RVDT (Rotary Variable Diff.
Transformer) providing a voltage change proportional to the rotor displacement which is contorted and
amplified to a D. C. current.
 Different types of temp. measurement.
- Mercury in glass thermometer
- Bimetallic thermometer
- Pressure spring thermometer
- Thermocouple
- RTD
- Pyrometer: Radiation / Optical
 Different types of pressure measurement.
- U Tube manometer
- Diaphragm
- Bellows
- Capsule
- Bourdon tube
- Spiral and Helix
Used of Posinor:
1. Speed up valve response, specially for long pneumatic signal line and large volume actuator.
2. Over comes valve hysteresis.
3. Over come high forces on steam e.g. High pressure in line gland packing friction etc.
4. “Bench set” i.e. to mach valve spring range to controller output signal e.g. valve spring may be
0.3 ~ 1.1, 6.30 PSI etc. positnor give O/P to valve to 0.3 ~ 1.1, 6 ~ 30 PSI as required for input
of 3 ~ 15PSI.
5. Split range
6. Reverse action
7. After valve characteristic with came

26
Que: What is interface level? How do you calibrate it?
Ans: When a vessel in filled with two liquid of tag different specific gravities the level measurement refers to
as interface level
DP = H (D – d)
On a level set different of tag Sp gravity
Que: How will you calibrate a level troll in the field?
Ans: 1. first close both the primary Isolation valve and drain the liquid inside the chamber.
2. Adjust the Zero.
3. Connect a PVC tube to the drain point as show in hook up.
4. Fill it to the center if the top flange.
5. Adjust the SP. Gravity or span adjustment.
6. Fill up to 50% check linearity.
Que: How will you calibrate an interface level troll?
Ans: on an interface level troll there are two liquid of two different SP. Gravity.
1. The level will be Zero when it is full of lighter liquid
Zero % level = H & D.
= 500 x 1
2. the level will be 100% when it is full of heavier liquid
100% level = H x D
Que: What is Absolute Pressure?
Ans: Absolute Pressure is the total pressure present in system
Absolute press = Gauge Press + Atmospheric press. ?
Que: What is Abs. Zero Pressure?
Ans: The abs. Zero = 760mmhg.
Que: What is maximum Vacuum?
Ans: the maximum vacuum = 760mmhg.
Que: What is the Vacuum?
Ans: any pressure below Atm. Pressure is Vacuum.

 Explain the working of an electronic PID Controller?

Set point
Manual
Deviation
M
Σ To final
Amplifier Element
A

P D
+
Gain
Reset
input from measurement Transmitter is compared with the set point. Voltage is produce a deviation
signal the deviation signal is combined with a characterized feedback signal to provide the input for the
27
function generator amplifier. This amplifier output is delivered to the feed back network and this final output
this is 4 ~ 20ma dc signal for actuator of final operator. (PID detail page no.)
Que: What is the type of tap used orifice plate?
Ans: Flange Tap: those are most commonly used on pipe size of 2 inches or larger. They are located in the
orifice flange which from up stream and 1 inches down steam from the flange of orifice plate.
Corner Tap: on pipe size less than 2” common tap located directly at the flange of the orifice plate.
Vana Contract: located at 1 pipe diameter up steam and at point of minimum pressure down steam these most
widely used for measurement of steam.
Que: What is the use of link connector of the valve position?
Ans: The link service as the feedback to the valve any valve movement is sensed by this link some time due
to line pressure changes on H. P. service the valve position may be change the link in turn senses this change
& the positnor will produced an output which will operate the valve to the original position.
Que: What is emergency shutdown system in boiler and furnaces?
Ans: Boiler: 1. High, low level
2. Fuel low pressure
3. At. Steam low pressure
4. Drum pressure high
5. Return oil pressure high
6. Fan trip
7. Flame failure
Furnaces: 1. Fuel pressure high, low
2. Feed low
3. Flame failure
4. Fan trip
Que: What does a transmitter output start from 4 ~ 20ma?
Ans: the transmitter output start from what knows as “live Zero” this system has specific adjustment.
1. The system automatically alarm when the signal system becomes inoperative.
2. the output curve in linear (Ratio 1:5)
Que: Why do you have small hole some times above or below the orifice plate?
Ans: 1/8” hole in orifice plate installed in horizontal lines, bottom of line gas or hydrocarbon liquids contain
traces of meter, top of line for liquid traces of vapors as non condensable.
Hole

 Pneumatic control Relay:

A relay is a pneumatic amplifier the function of the relay is to convert a small changes in the input signal
to a large change in output signal.
Principle: The air supply enters the relay through a port on the surface of the instrument on which the
relay is mounted the input signal (nozzle press.) enter the relay thought another port & acts on the
diaphragm since diaphragm in is contact with a steam valve the two more in unison at the input signal
increase the steam pushes against ball valve which in turn moves a flat spring allocating the supply air to
enter the relay body further motion of the steam valve causes it is close of the exhaust port thus when
input pressure increase the steam (exhaust) valve closes & the Supply valve open when input decreases
the steam valve open & supply valve closes this varies the pressure to output.
28
 Input

Diaphragm

Supply Steam
Valve
Ball Valve

Output
Spring
Exhaust

Que: How will you work on a control valve while it is line.

Ans: while control valve in line the control valve has to be got by pass and secondary the line has to be
drained & depressurized.
 Explain Tuning of controller: Tuning basically involves adjustment of P.I.D parameters to achieve good
control the gain time content & dead time around the loop will dictale the setting of various parameters of
the controller tuning method are broadly classified in to two 1.) Closed loop method (Ultimate gain
method) 2.) Open loop method (Process reaction curve)
 Thermocouple: It is a simple device consisting of two dish similar metal wire joined t there ends, which an
end of each wire is connected to a measuring instrument the thermocouple be comes an accurate &
sensitive temperature device.
Principle: Thermal energy is converted to electrical energy.
Que: Draw a potentiometer temp. measuring circuit & explain it?
Ans: the input to the instrument is a measurement of some variable in the process using a sensing element
(such on T/C) or a device to a produce direct voltage which is the unknown voltage this voltage is subtracted
from voltage developed by a know constant voltage in a potentiometer measuring circuit.
The subtraction occurs by connecting the two voltage in series with the opposing polarity. The
difference the two voltage produce an error signal the voltage going to the amplifier the error will be positive
or negative depending which of the there voltage is grater when amplified the error signal will drive the servo
balancing motor in appropriate to adjust the circuit (actually drive the slide wire) until the difference between
the feedback voltage & the input voltage in balanced out an error signal equal to zero results c null point.

29
 Amplifier
TC

Motor
Unknown Signal
Signal
Slide wire
Measuring
CKt

Constant
Voltage
Signal
(Known Signal)
Resistance Thermometer: At the temperature of the resistance bulb Rt rises, it resistance rises because of this
bridge Un-balance. This unbalance is detected by the mill voltmeter cell sing it to defect third wire to a point
that will used to compassion restore balance to of lead wire the circuit when calibration to the circuit precision
resistor is substituted for the temperature bulb and the battery voltage is adjust by varying Rb until the meter
reads the correct temperature for this resistance for instance if a platinum bulb is to be used a press ion of 100
ohms would require that the meter reading 32o F (0oC).
The resistance bulb has there leads. This is necessary so that the same amount of lead wire is used in
both branches of the bridge this arrangement is generally preferred because the lead length may be lengthened
or shortened with out affecting the meter reading.

RY
R1
V

Rb
Rt1 R2

Rt1 = Rt2

Rt

 Three scale of pressure measurement: 1. Gauge Pressure scale

2. Absolute Pressure scale
3. Vacuum scale
Different between Gauge pressure scale & Absolute Pressure scale is the location of Zero point.
 Gauge pressure scale the zero point is at the atmospheric.

30
 On the absolute pressure scale the zero point is at the absolute zero pressure point.
 The vacuum scale has its zero at atmospheric pressure and its maximum point at absolute zero.
The pressure scale in figure notice that the absolute pressure scale includes the gauge pressure scale &
vacuum scale thus a pressure of 10” of mercury absolute may also be expressed as vacuum of 20in/Hg or
Gauge pressure -20in/Hg.

Absolute Pressure Scale

Gauge Pressure
Positive

20

To maximum
15
Gauge Pressure

10
5
0
Negative

0 Vacuum
20” 5
vacuum 10 Pressure
or 20” 15
Gauge 20
Press.
‘X’ 10” 25
30 0

Orifice Plate: The orifice plate is quite simple & inexpensive. It is the easy to install & replace. There is a
much data available for calculation of correct size. The orifice plate not so accurate as either the venture or
flow normally and does not have as good recovery. It cannot be used with high beta ratios functionally the
orifice plate is subject to erosion & damage, but it is easy replacement offset this hence it is most avidly used
for primary flow element.
VENTURI TUBE: The venture tube is most expensive & accurate. High beta ratios above (0.75) can be used
with good results the pressure recovery of the venture tube is excellent which means that there is little
pressure drop through it functionally the venture tube is good since it does not obstruct abrasive sediment in
fact because of its shape it resists wear effectively.
Venture tube is used for large pipelines it is more accurate than the orifice plate but considerably more
expansive & difficult to install.
FLOW CALCULATION: Rate of flow =
Q = EAo √2gh
Where: Q = flow rate (volume/units of inch)
E = efficiency Factor
Ao = area of orifice in square feet

31
 g = acceleration due to gravity
h = diff. pressure across orifice in feet
TURBINE METER: The pulse generating turbine flow meter consist of precision turbine wheel mounted on
bearings inside a length of pipe and an electromagnetic coil mounted on the pipe at the right angle to the
turbine wheel fluid passing through the pipe causes the turbine wheel to turn at the speed which varies with
the velocity of the flowing as each blades of turbine wheel pass the coil it interrupts the magnetic field of the
coil producing of an electrical pulse the frequency of the pulse very with the velocity of the fluid flow.
Orifice Plate:
Concentric: The concentric orifice plate is used for ideal liquid as well as gases & steam service, this orifice
plate has a hole concentric hence know as a concentric orifice plate
.

Eccentric Orifice Plate: The use of this is made in viscous & slurry flow measurement

Segmental Orifice Plate: The segmental orifice plate has the hole in the form of segment of a circle. This is
use for colloidal & slurry flow measurement.

 Explain the application of proportional, integral, derivative action (PID)?

 Proportional control: Proportional control only attempts to return a measurement to the set point after a
load upset has occurred however it is impossible for a proportional controller to return the measurement
exactly to the set point.
Use: it is normally used for level control. It reduces the effect of a load changes but it cannot eliminate.
 Propnt + Reset(Integral): Integral action is introduced to eliminate off set it will integrate any difference
between measurement & set point and cause the controller’s output to change until the difference between
the measurement & set point is Zero Reset will act long as the error exists.
Use: P + I controller are by far the common types used in industrial process control and where
predominant dead times occur.

32
 P + I + D: Derivate action help the controller overcome system inertia and result in faster, more precise
control derivation action occur when ever the measurement signal changes. Under steady conditions the
derivate action does not act, Derivate allows the controller to inject more corrective action.
Use: on temperature control.
 How do you carry out piping for DPT, on liquid, Gas, Steam service?
 Liquid line on liquid line transmitter mounted below the orifice plate since liquid have a properly of self
draining.

_
+

 Gas Service: on Gas service the transmitter mounted above the orifice plate because gas have property self
venting & secondary condensate formation.

_
+

 Steam Service: On steam service the transmitter is mounted blow the orifice plate with condensate pot the
pot should be at the same level.

33
 H L

 Explain antisurge control of a compressor?

 This method of surge control uses the ratio of compressor pressure rise to inlet flow rate to set the flow in
bypass root.

PD
T
Suction Remote Discharge
Line Set Ratio Line
FRC
FT FY

Ratio controller

When the suction pressure drops and discharge up the compressor start surging the PDT sensor
this & give the signal to the FRC which will open the by pass valve.
Que: What is SQ root extractor why it is used?
Ans: Sq root extractor extracts the square root of the input signal & produce and output signal.
Use: Flow measurement signal are normally SQ root which a produced from DPT so convert these in to linear
signal.
 An operator tells you that a control valve is struck up flow will you checking?
1. First of all get the control valve by passed from operations.
2. Check tight to the diaphragm of the control valve.
3. Disconnect if possible the actuator steam & from control valve steam.
34
 4. Stroke the actuator & see whether the actuator operates or not if not then the diaphragm may be
punctured.
5. if the actuator operates connect it back to the plug steam stroke the control valve if it doesn’t operate
loosen the glands nut & bolt & see. If it operates, if it doesn’t then the control valve has to be removed
from the line to w/s(work shop).
Que: Where is an air to close & air to open control valve used?
Ans: Air to closed 1. Reflux line
2. Cooling water
3. Relit service
Air to Open: 1. Feed line
2. Steam Service
Que: What is intrinsically safe system?
Ans: Intrinsic safety is a technique for designing electrical equipment for safe use in location made hazardous
by the pressure of flammable gas or vapors in air.
Defn: Intrinsically safe circuit in one in which any spark or thermal effect introduced either normally or under
specified fault condition is incapable of causing ignition of a specified gas or Vapors in air mixture at the most
easily ignited concentration.
 Displacer type level measurement: The level troll is one of most common instrument used for
measurement level in closed tanks this instrument works on ARCHIMEDES principle the loss in weight of
a body immersed in a liquid is equal to amount of liquid displaced.
 Draw & Explain flow Closed loop:

O/P

Orifice plate A/S

Signal

5D
O/P
Impulse line I
A/ P
S

FT O/P
+ FIC A/C Supply
_ I/P

Equalizing
Valve

 Given Q1= 200M3/hr, Q2 = 60 M3/hr ∆P1 = 2500mmH2O, ∆P2 =?

 Alarm = 60 M3/hr
35
 = Q1 = K1√ ∆P1
Q2 K1√ ∆P2
= 200 = √2500
= 06 = √ ∆P2
= √ ∆P2 = √2500 x 60 = 50 x 6
200 20
= 30/2 = 15
∆P2 = (15)2 = 225mm
∆P2 = 225 x 100 = 9%
∆P1 2500
Alarm = √9
Unit flow = √9 = 3 Unit
PSI Conversion: 1% = 12/100 = 0.12 PSI
9% = 9 x 0.12 = 1.08 PSI
Alarm Setting = 3 + 1.08 = 4. 08 PSI
Kg/cm2 = 1% = 0.8/100 = 0.008
9% = 0.008 x 9
= 0.072 = 0.272
Que: What is a Reynolds number?
Asn: δVD or 3.54 x Qn x Pb
µ µxD
Qn = normal flow M3/hr
Pb = Density kg/m3
µ = Viscosity in poise
D = “I” Diameter of Pipe in mm
Que: What is feedback & feed forward control?
Asn: * Feed back control involves the detection of the controller variable & counter acting of changes it valve
relative to set point by adjustment of manipulated variable.
* Feed forward control is system in which corrective action is based on measurement of disturbance input in
to the process.
 Ultimate Gain Method: The turn ultimate way attached to this method becomes its gain (Sensivity) and
ultimate period. The ultimate sensivity Ku is the maxi allowed volume of gain (for controller with only
proportional mode) for which the system in stable. The ultimate period is the period of the response with
the fain set at its ultimate value.
 Process Reaction Curve: To determine the process reaction curve the following step are recommended.
1. Let the system come to steady start at the normally loud level.
2. Place the controller on manual.
3. Manual the output of the controller at the value of which it was operating in the automatic
mode.
4. Allow the system to reach to steady state.
5. With controller on manual change the O/P of controller which is a signal value.
6. Record the response the controller variable.
7. Return the controller O/P to its previous value and return the controller to auto operation.
 Proportional Action: It is obtained by adjustment the magnitude of feed back signal an increase in negative
feedback means loss effective gain and thus a border proportional bend.
 Integral Action: It is obtained by charging the reset capacitor at a rate determined by the value of reset
resister the reset resister is variable & constitutes reset adjustment.

36
 Derivative Action: The connection of the derivative capacitor across the feed back circuit delays feed back
until the capacitor is charged to a value approaching amplifier value of derivate resister. The resister is
variable and constitutes derivative adjustment.
 Short of Derivative Action: The derivative action have bad go to proportional controller so where the
process leg is high at that time the derivate controller is used generally the derivative controller is used in
temp. measurement.
The temp. measurement the sensing element sense the temp. of vessel but sometime is taken by it in
some process these lagging feature is not effective so the at that time the derivate controller is use.
 Conductivity meter: The conductivity meter have a hole tube made of plastic in which there ring is
provided the generally the ring are made of carbon so the maintenance is minimum. Two terminal is taken
out from the cash from which the supply is given no when fluid passes through the two ring the electrical
circuit is completed & the current is passes which is proportional at the conductivity of liquid.
 Turbine Supervisory System: Main three Section of system.
1. Vibration measurement
2. Axial shift measurement
3. Eccentricity measurement
h h h h h
h

Genra
HP IP LP tor
4
1 2 3 7
5 6 V
V V V
1. Horizontal Vibration
2. Horizontal Vibration
3. Horizontal Vibration
4. Horizontal Vertical Vibration
5. Horizontal Vertical Vibration
6. Horizontal Vertical Axial Vibration
7. Horizontal Vibration
Measuring Unit = Micro ohms
Vibration Measurement mi> measuring pickup slestnic velocity p\kir ni[ hi[y C[. j[mi>
cylindrical houring n) a>dr permanent magnet n) rcni kr[l) hi[y C[. ai permanent magnet siY[
moving coil j[iD[l) hi[y C[. Set frequency 14HZ riKvimi> aiv[ C[. jyir[ vibration aiv[ Ryir[
permanent magnet move Yiy C[. aiY) EMF measuring coil n) a>dr uRpn Yiy C[. ai pick up ni[
output vibration ni smp\miN mi> hi[y C[.
 Chemtrol level troll Weight calibration:
Displacer length = 650mm
Diameter = 48.6mm
Weight = 26489mg
Volume = πr2h
= 22/7 x 24.3 x 24.3 x 650
= 1205m3

37
Loss of weight = 1205 x 0.75 SPG
= 879.65

0% Loss of weight = 1205 – 0%

-219
986 – 25%
-219
767 – 50%
-219
548 – 75%
-219
329 – 100%
879.65/4 = 219.9
 Pressure measurement:
Manometers:
U Tube manometer
Inclined Tube manometer
Well type manometer
Pressure Elements:
Diaphragm Capsule
Bourdon tube Spiral
Bellows Helix
 Temperature Measurement:
Mechanical:
Thermometer:
Mercury in glass thermometer
Bimetallic thermometer
Pressuring spring thermometer
C shaped, Spiral, Helical.
Vapor filled thermometer
Liquid filled thermometer
Gas filled thermometer
Electrical:
Thermocouple
RTD
Pyrometers
Radiation Pyrometer
Optical pyrometer
 Level measurement:
Direct Liquid level measurement
Bob & Tap
Sight glass
Float type
Indirect Liquid level measurement
Bubble pipe
D. P. manometer
D. P. transmitter
Radioactive
38
 Ultrasonic system
Displacer type
 Flow measurement:
Rate of flow meter
D. P. type flow measurement
By orifice plate D. P. Transmitter
Venture tube Pitot tube
Flow nozzle
Rota meter
Flumes, Open Nozzles
Positive displacement meter
Turbine meter
Electromagnetic meter
Mass flow meter
Que: Why two plugs provided on a D. P. Transmitter?
Ans:

Vent Plug

Drain Plug

1. The top plug is a vent plug for venting the air entrapped side the cell.
2. The bottom is a drain plug for draining the liquid accumulated inside the cell.

 Valve Sizing:
FL = CLd2 = √(P1 – P2) Liquid
W
FG = CGd 2 = [√ (P1 – P2) (P2)]
2TQ
FS = CSd2 = √ (P1 – P2)
V
Where: FL = flow of liquid gal/hrs.
FG = flow of gas cu ft/hrs
FS = flow of Vapor lb/hrs
Cl, CG, CS the appropriate discharge co-efficient.
P1 = up stream pressure in PSIG
P2 = down stream pressure in PSIG
d = valve diameter in inches
W = density of liquid lb/w ft
V = specific volume of the vapor cu ft/w at the down stream condition.
T = absolute temp. of the following gas
Q = Specific gravity of dry gas relative to air in the same temp. & pressure.

39