Troubleshooting problems in control system

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 Questions
Question 1
Consider this control system, set up to maintain the temperature of a chemical reactor vessel at a
constant (“setpoint”) value. The reactor’s source of heat is a steam “jacket” where hot steam is admitted
through a motor-operated (M) control valve (TV) according to the temperature inside the reactor sensed by
the temperature transmitter (TT):

TIC
SP TT TI

Reactor

M
Steam jacket
TV
From steam
supply (boiler)
To condensate
return

You arrive at work one day to find the operator very upset. The last batch of product emptied from
the reactor was out of spec, as though the temperature were too cold, yet the controller (TIC) displays the
temperature to be right at setpoint where it should be: 175 o F.
Your first step is to go to the reactor and look at the temperature indicating gauge (TI) mounted near
the same point as the temperature transmitter. It registers a temperature of only 137 o F.
From this information, determine what is the most likely source of the problem, and explain how you
made that determination.

Suggestions for Socratic discussion

• Why was it a good decision to consult the temperature gauge (TI) on the reactor as a first diagnostic
step?
• Suppose a fellow instrument technician were to suggest to you that the problem in this system could be
a controller configured for the wrong action (e.g. direct action instead of reverse action). Do you think
this is a plausible explanation for the symptoms reported here? Why or why not?
• Could the problem be that someone left the controller in manual mode rather than automatic mode as
it should be? Explain why or why not.
• Based on the P&ID shown, are the instruments pneumatic or electronic?
• Given the fact that we know this reactor is steam-heated, is it possible to conclude that the chemical
reaction taking place inside it is either endothermic (heat-absorbing) or exothermic (heat-releasing)?
• Safety shutdown systems often use a “two-out-of-three” (2oo3) voting algorithm to select the best
measurement from three redundant transmitters. Explain how this same concept may be applied by the
instrument technician in the course of troubleshooting the problem.
file i00137

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Question 2
On the job, you are sent to troubleshoot a brand-new control system, consisting of a pneumatic liquid
level transmitter connected to a pneumatic controller, which in turn drives a pneumatic control valve. The
process vessel, piping, control valve, controller, and level transmitter are all brand-new: they even sport a
fresh coat of paint.

LT LIC
LG
74 74

According to the unit operator, this level control system has never worked. As she shows you, the liquid
level inside the vessel is so low that the level gauge (LG) registers empty, yet the controller is commanding the
valve 100% open, which of course continues to drain the vessel and prevent any liquid level from accumulating.
Being versed in process control theory, you decide to check how the controller is configured. Looking
inside the controller case, you notice the controller is set for direct action: an increasing PV results in an
increasing output signal (MV), which will move the air-to-close valve more toward the “closed” state.
Realizing how to fix the problem, you reach inside the controller and move a lever that switches it into
reverse action mode.

Explain why this fixes the problem.

Suggestions for Socratic discussion

• Explain the significance of the “newness” of this process. How would your assumptions differ if you saw
this process vessel was old and rusted instead of shiny-new?
• How do you suppose the controller got to be mis-configured in the first place?
• What would have to be different in this control system to permit a direct-acting controller instead of a
reverse-acting controller?
• Suppose you did not discover the controller’s action set for direct action. If the controller had been
left in manual mode instead of automatic mode, could this account for the problems exhibited by this
system?
file i00140

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Question 3
Consider this control system, set up to maintain the temperature of a chemical reactor vessel at a
constant (“setpoint”) value. The reactor’s source of heat is a steam “jacket” where hot steam is admitted
through a motor-operated (M) control valve (TV) according to the temperature inside the reactor sensed by
the temperature transmitter (TT):

TIC
SP TT TI

Reactor

M
Steam jacket
TV
From steam
supply (boiler)
To condensate
return

You arrive at work one day to find the operator very upset. The last batch of product emptied from
the reactor was out of spec, and the temperature displayed by the indicating controller (TIC) shows it to be
197 o F. The setpoint is set at 175 o F, and the controller is in the automatic mode as it should be.
Your first step is to look at the indication on the controller showing the output signal going to the motor-
actuated steam valve (TV). This output signal display (the “manipulated variable”) shows 0 %, which means
“valve fully closed.”
Next, you decide to check the temperature shown at the temperature indicator (TI) located near the
temperature transmitter (TT) on the reactor. There, you see a temperature indication of 195 o F.
From this information, determine what is the most likely source of the problem, and explain how you
made that determination.

Suggestions for Socratic discussion

• Why is it important for us to know that the controller is in automatic mode? Would it make a difference
if it were in manual mode instead?
• Explain why the first two diagnostic steps were to check the controller’s output display, then to check
the TI on the reactor. What do each of these checks tell us about the nature of the problem?
• Suppose a fellow instrument technician were to suggest to you that the problem in this system could be
a controller configured for the wrong action (e.g. direct action instead of reverse action). Do you think
this is a plausible explanation for the symptoms reported here? Why or why not?
file i00138

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Question 4
Consider this control system, set up to maintain the temperature of a chemical reactor vessel at a
constant (“setpoint”) value. The reactor’s source of heat is a steam “jacket” where hot steam is admitted
through a motor-operated (M) control valve (TV) according to the temperature inside the reactor sensed by
the temperature transmitter (TT):

TIC
SP TT TI

Reactor

M
Steam jacket
TV
From steam
supply (boiler)
To condensate
return

While doing some clean-up work near the reactor, you receive a frantic call from the operator on your
two-way radio. He says that the controller (TIC) is registering a temperature of 186 o F, which is 11 degrees
higher than the setpoint of 175 o F. A temperature this high could ruin the product inside the reactor. He
wants you to check the temperature indicator on the side the reactor (TI) and let him know what it reads.
You look at the TI, and see that it registers a temperature of 172 o F, which is a bit too cold if anything,
not too hot. You immediately report this to the operator using your radio, who then asks you to check out
the system to see why he’s getting a false reading on the controller display.
Fortunately, you have your multimeter and tool set with you, so you proceed to the temperature
transmitter to measure the milliamp signal it is outputting. Removing a cover from a round junction
box on the conduit where the transmitter’s wires are routed, you see a terminal block inside with a 1N4001
rectifying diode placed in series with the circuit:

Conduit To transmitter
Conduit

To controller

Setting your multimeter to measure milliamps, you connect the red and black test leads across the diode.

5
This shorts past the diode, forcing all the current to go through the meter instead of the diode, allowing
you to “break in” to the 4-20 mA circuit without having to physically break a wire connection anywhere.
Making a mental note to thank your instrumentation instructor later for showing you this trick, you see that
your multimeter registers 15.683 mA.
Given a calibrated temperature transmitter range of 100 to 200 degrees F, determine what this current
measurement tells you about the location of the problem in this temperature control loop, and explain how
you made that determination.

Suggestions for Socratic discussion

• Why is it important for technicians to be able to easily convert milliamp signal values into corresponding
process variable (PV) values?
• How does the diode perform this useful function of allowing current measurement without breaking the
circuit?
• Supposing there were no diode in this loop circuit, how would you suggest we measure the transmitter’s
output current?
• Is it possible that the fault in this system could be something to do with the control valve? Why or
why not?
file i00139

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Question 5
In this process, two chemical streams are mixed together in a reactor vessel. The ensuing chemical
reaction is exothermic (heat-producing) and must be cooled by a water cooling system to prevent overheating
of the vessel and piping. A temperature transmitter (TT) senses the reaction product temperature and sends
a 4-20 mA signal to a temperature indicating controller (TIC). The controller then sends a 4-20 mA control
signal to the temperature valve (TV) to throttle cooling water flow:

Feed A Feed B

Reactor

TV

Hot water out

Cold water
in

TT Reaction product out

New recorder

TIR

TIC

Suppose an instrument technician adds a temperature-indicating chart recorder (TIR) to the

temperature transmitter circuit, necessitating the addition of a 250 ohm resistor to the 4-20 mA circuit
to provide a 1-5 volt voltage signal which the recorder can read. Now the 4-20 mA temperature circuit has
more resistance in it than it did before.

Describe in detail the effect this circuit modification will have on the performance of the cooling system.
file i02931

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Question 6
This water filter level control system uses an ultrasonic level transmitter to sense the level of water in
the filter, and a controller to drive a motor-actuated valve introducing raw water to be filtered:

Setpoint

LIC

M LT

Ultrasonic H
Influent LIR

Filter L

Filtering
media
Effluent

Assuming a direct-acting level transmitter (increasing filter level = increasing signal), and a signal-to-
open control valve (increasing controller output signal = wider open valve), determine whether the level
controller needs to be configured for direct-action or reverse-action, and explain your reasoning. Annotate
the diagram with “+” and “−” symbols next to the PV and SP controller inputs to show more explicitly
the relationships between the controller inputs and output.

Next, determine the response of the controller to the following situations. In other words, determine
what the controller’s output signal will do when this water level control system is affected in the following
ways:
• A sudden increase in effluent flow rate (clean water demand)

• Level transmitter fails high (indicating 100% full water level)

• Control valve actuator fails, driving valve fully open (ignoring controller signal)

Suggestions for Socratic discussion

• Re-draw the diagram for this water filter level control system, replacing the controller (circle) with an
op-amp symbol (triangle), determining the “+” and “−” input assignments on the opamp for PV and
SP.
• Explain why level control is important in a water filter such as this.
• What do the “H” and “L” symbols near the LIR represent?
file i02370

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Question 7
There is a problem somewhere in this liquid flow control system. The controller is in automatic mode,
with a setpoint of 65%, yet the flow indicator and the flow controller both register 0.3%: (nearly) zero flow.
A P&ID of the loop appears here:

FIR FIC

I
/P

FY

FT

Pump

Explain how you would begin troubleshooting this system, and what possible faults could account for
the controller not being able to maintain liquid flow at setpoint.

Suggestions for Socratic discussion

• Explain how you could divide this control system into distinct areas or zones which you may then begin
to refer to when “dividing and conquering” the problem.
file i02518

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Question 8
In this process, two chemical streams are mixed together in a reactor vessel. The ensuing chemical
reaction is exothermic (heat-producing) and must be cooled by a water cooling system to prevent overheating
of the vessel and piping. A temperature transmitter (TT) senses the reaction product temperature and sends
a 4-20 mA signal to a temperature indicating controller (TIC). The controller then sends a 4-20 mA control
signal to the temperature valve (TV) to throttle cooling water flow:

Feed A Feed B

Reactor

TV

Hot water out

Cold water
in

TT Reaction product out

TT
TIR
TIC

Suppose operators decide to increase production in this process reactor. This means the incoming feed
flow rates will be increased, producing more heat.

Describe in detail how the cooling system will respond to this change in process operations.
file i02933

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Question 9
In this process, maple syrup is heated as it passes through a steam heat exchanger, then enters an
evaporator where the water boils off. The purpose of this is to raise the sugar concentration of the syrup,
making it suitable for use as a food topping. A level control system (LT, LIR, LIC, and LV) maintains
constant syrup level inside the evaporator, while an analytical control system (AT, AIR, AIC, and AV)
monitors the sugar concentration of the syrup and adjusts steam flow to the heat exchanger accordingly.

Steam
supply Vapor compressor

Water vapor out

Level gauge shows
50% level in evaporator
PV = 52%
LG Evaporator
AV LT LIR
85% open
PV = 52%
LIC SP = 50%
Out = 22%

LV
Heat 24% open
exchanger Concentrated
syrup out
Condensate Laboratory tests syrup
return to boiler at 66% concentration
AT
Liquid pump
Syrup in

FT
AIC AIR

PV = 34% PV = 34%
SP = 34%
Out = 86%

Examine the live variable values shown in the above diagram, and then determine where any problems
may exist in this syrup concentrating system.

Suggestions for Socratic discussion

• A valuable principle to apply in a diagnostic scenario such as this is correspondence: identifying which
variables correspond at different points within the system, and which do not. Apply this comparative
test to the variables scenario shown in the diagram, and use the results to defend your answer of where
the problem is located and what type of problem it is.
file i02934

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Question 10
Examine this P&ID for a level control system in a vessel where two different fluids (Feed A and Feed
B) are mixed together:

Motor
M

Feed A Feed B

Mixing
vessel
Level
LG gauge

LT

LV

LIC

Determine the effect on the control system’s regulation of liquid level inside the vessel if an instrument
technician accidently mis-calibrates the control valve such that it opens 2% more than it should (e.g. when
the controller sends a 50% signal to the valve, it actually opens to 52% stem travel). Assume all other loop
components are properly configured and that the controller is well-tuned.
file i04391

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Question 11
Examine this P&ID for a level control system in a vessel where two different fluids (Feed A and Feed
B) are mixed together:

Motor
M

Feed A Feed B

Mixing
vessel
Level
LG gauge

LT

LV

LIC

Determine the effect on the control system’s regulation of liquid level inside the vessel if an instrument
technician accidently mis-configures the controller for the wrong type of action (e.g. direct action when it
should be reverse, or vice-versa). Assume all other loop components are properly configured and that the
controller is well-tuned.
file i04393

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Question 12
In this process, two chemical streams are mixed together in a reactor vessel. The ensuing chemical
reaction is exothermic (heat-producing) and must be cooled by a water cooling system to prevent overheating
of the vessel and piping. A temperature transmitter (TT) senses the reaction product temperature and sends
a 4-20 mA signal to a temperature indicating controller (TIC). The controller then sends a 4-20 mA control
signal to the temperature valve (TV) to throttle cooling water flow:

Feed A Feed B

Reactor

TV

Hot water out

Cold water
in

TT Reaction product out

TIC

Suppose something fails in the control valve mechanism to make it incapable of opening further than
80%. From 0% to 80% position, however, the valve responds normally.

Describe in detail the effect this fault will have on the performance of the cooling system.
file i02932

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Question 13
In this process, maple syrup is heated as it passes through a steam heat exchanger, then enters an
evaporator where the water boils off. The purpose of this is to raise the sugar concentration of the syrup,
making it suitable for use as a food topping. A level control system (LT, LIC, and LV) maintains constant
syrup level inside the evaporator, while an analytical control system (AT, AIR, AC, and AV) monitors the
sugar concentration of the syrup and adjusts steam flow to the heat exchanger accordingly.

Steam
supply Vapor compressor

Water vapor out

Evaporator
AV LT

LIC

LV
Heat
exchanger Concentrated
syrup out
Condensate
return to boiler
AT
Liquid pump
Syrup in

FT
AC AIR

Suppose the syrup analyzer (AT) suffers a sudden calibration problem, causing it to register too low
(telling the analytical controller that the sugar concentration of the syrup is less than it actually is).

Describe in detail the effect this calibration error will have on the performance of the analytical control
system.

Suggestions for Socratic discussion

• What economic effect will this mis-calibration have on the process? In other words, does the process
become more or less profitable as a result of this change?
• Suppose someone shuts the manual block valve on the steam line just a little bit, so that it is about 80%
open instead of 100% open. How will this process change affect the control systems in this process?
file i02936

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Question 14
In this process, maple syrup is heated as it passes through a steam heat exchanger, then enters an
evaporator where the water boils off. The purpose of this is to raise the sugar concentration of the syrup,
making it suitable for use as a food topping. A level control system (LT, LIC, and LV) maintains constant
syrup level inside the evaporator, while an analytical control system (AT, AIR, AC, and AV) monitors the
sugar concentration of the syrup and adjusts steam flow to the heat exchanger accordingly.

Steam
supply Vapor compressor

Water vapor out

Evaporator
AV LT

LIC

LV
Heat
exchanger Concentrated
syrup out
Condensate
return to boiler
AT
Liquid pump
Syrup in

FT
AC AIR

Suppose the steam tubes inside the heat exchanger become coated with residue from the raw maple
syrup, making it more difficult for heat to transfer from the steam to the syrup. This makes the heat
exchanger less efficient, which will undoubtedly affect the process.

Describe in detail the effect this heat exchanger problem will have on the performance of the analytical
control system.

Suggestions for Socratic discussion

• Suppose the operations personnel of this maple syrup processing facility wished to have an automatic
method for detecting heat exchanger fouling. What variable(s) could be measured in this process to
indicate a fouled heat exchanger?
• What economic effect will this fouling have on the process? In other words, does the process become
more or less profitable as a result of the heat exchanger fouling?
file i02937

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Question 15
Pictured here is a P&ID (Process and Instrument Diagram) of a liquid flow control “loop,” consisting of a
flow transmitter (FT) to sense liquid flow rate through the pipe and output an electronic signal corresponding
to the flow, a flow controller (FC) to sense the flow signal and decide which way the control valve should move,
a current-to-air (I/P) transducer (FY) to convert the controller’s electronic output signal into a variable air
pressure, and an air-operated flow control valve (FV) to throttle the liquid flow:

I
/P

4-20 mA signal FC 4-20 mA signal

FY

FT 3-15 PSI signal

FV
Pump Pipe

The actions of each instrument are shown here:

• FT: increasing liquid flow = increasing current signal
• FC: increasing process variable (input) signal = decreasing output signal
• FY: increasing current input signal = increasing pneumatic output signal
• FV: increasing pneumatic signal = open more
Describe what will happen to all signals in this control loop with the controller in “automatic” mode
(ready to compensate for any changes in flow rate by automatically moving the valve) if the pump were to
suddenly spin faster and create more fluid pressure, causing an increase in flow rate.
Also describe what will happen to all signals in this control loop with the controller in “manual” mode
(where the output signal remains set at whatever level the human operator sets it at) if the pump were to
suddenly spin faster and create more fluid pressure, causing an increase in flow rate.

Suggestions for Socratic discussion

• Explain the practical benefit of having a “manual” mode in a process loop controller. When might we
intentionally use manual mode in an operating process condition?
file i00124

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Question 16
An operator reports a high level alarm (LAH-12) displayed at the control room for the last 13 hours of
operation, in this sour water stripping tower unit (where sulfide-laden water is “stripped” of sulfur compounds
by the addition of hot steam). Over that time period, the sightglass (level gauge LG-11) has shown the liquid
level inside vessel C-406 drifting between 2 feet 5 inches and 2 feet 8 inches:

V-10 P-201 P-101 P-102 P-103 C-7 E-2 E-9

SOUR WATER TANK SOUR WATER TANK EJECTOR COOLING WATER PUMP SOUR WATER PUMP STRIPPED WATER PUMP SOUR WATER STRIPPER SOUR WATER HEATER STRIPPED WATER COOLER
8’-0" Dia 12’-0" Sidewall 85 ACFM @ 1" H2O 20 GPM @ 80 oF 5 GPM @ 80 oF 8 GPM @ 150 oF 12" x 40’ SS Rated duty: 300 MBTU/HR Rated duty: 50 MBTU/HR
DP Atmosphere Rated head: 80 PSI Rated head: 75 PSI Rated head: 60 PSI DP 55 PSIG Shell design: 70 PSI @ 360oF Shell design: 150 PSI @ 350 oF
DT 190 oF DT 350 oF Tube design: 125 PSI @ 360 oF Tube design: 150 PSI @ 350 oF
Each bed 10’ of 1" pall rings

P-201
FI Slope
37
Slope To flare header
ST Dwg. 13320

PG PC
316 NC ST 115
PG
Set @ TT TIC 312
50 PSI
21 21 PG
PG 438
406
Set @ PV
PG PSV PSV TIR 115
75 PSI
315 PG TG 352 353 21 To incinerator
402 345
ST Dwg. 13319
TG
ST 344 TG
ST

26
PAH PSH H
FIC
202 202
27 PG LP cooling water
L I
/P 441 Dwg. 31995
ST
FQ
FY
TV Cond
27 27
C-7 21 AIT
FT FV
27 342
27
NC
Liquid dist.

ST
AAH
10’ packed bed
PG 342
Set @ Cond
401 100 PSI AIT AAH
341 341
FIC NC PG
From 50 PSI 28 TG 422
PSV
steam header I
/P 343
Dwg. 13301 FIR 351
FY 10’ packed bed
28 L 1/2"

ST
28
From nitrogen FT 2" thick
header FV insul
28 28 LAH LAL
Dwg. 13322 3/4"
1 1/2" 12 12
FT FIR TG TG
29 29 Steam dist. 477 480
Set @ PSV LAL LSH LSL
2" vac. 1"
355 TI 11 1"
FI 2" press. HLL 340 12 12
29 LG Set @ Mag
19 60 PSI
NC NLL LSL LG LT
From acid gas E-9
separator V-10 LSLL 11 11 12
Dwg. 25311 ST
LLL 1"
203

PCV
HLL 10 4’-1" 1" P
/I
From sour water 1 1/2" LY
flash drum PG PG PG
299 300 405 2’-6" TG
Dwg. 25309 ST
12
ST

478 TG
TG 1’-3" 479
3/4"
20 LIR LR
12a 12b
2" thick 10’-6"
insul 24" MH
E-2 M
ST
LLL
FI Set @
LT 97 100 PSI LV
1’-0" FT
18 30 12
LIC
PSV ST
NC
LIR 12
354 FIR H
18 Strainer
30 L
LI FI
18 98 ST
To water treatment
PAL Dwg. 45772
LSH LAH ST

201
18 18
ST

pH
AIT PG
M
LSL LAL PG 348 PG 463
18 TG PSL 459 461
18 pH
346 201 FT FIR
AIT AIR
LP cooling water I 347 347 31 31 L
AIR L
Dwg. 31995 ST ST
348 L
PSLL
204
P-101 P-102 P-103
Slope
ST ST

Identify the likelihood of each specified fault in this process. Consider each fault one at a time (i.e. no
coincidental faults), determining whether or not each fault could independently account for all measurements
and symptoms in this process.

Fault Possible Impossible

LT-12 miscalibrated
LG-11 block valve(s) shut
LSH-12 switch failed
LSL-12 switch failed
Leak in tubing between LT-12 and LIC-12
LIC-12 controller setpoint set too high
LV-12 control valve failed open
LV-12 control valve failed shut

file i03540

18
Question 17
In this process, steam is introduced into “stripping” vessel C-7 to help remove volatile sulfur compounds
from “sour” water. The temperature of the stripped gases exiting the tower’s top is controlled by a pneumatic
temperature control loop. Unfortunately, this loop seems to have a problem.
Temperature indicating recorder TIR-21 registers 304 degrees Fahrenheit, while temperature indicating
controller TIC-21 registers 285 degrees Fahrenheit. The calibrated range of TT-21 is 100 to 350 degrees
Fahrenheit. A technician connects a test gauge to the pneumatic signal line and reads a pressure of 12.8
PSI:

V-10 P-201 P-101 P-102 P-103 C-7 E-2 E-9

SOUR WATER TANK SOUR WATER TANK EJECTOR COOLING WATER PUMP SOUR WATER PUMP STRIPPED WATER PUMP SOUR WATER STRIPPER SOUR WATER HEATER STRIPPED WATER COOLER
8’-0" Dia 12’-0" Sidewall 85 ACFM @ 1" H2O 20 GPM @ 80 oF 5 GPM @ 80 oF 8 GPM @ 150 oF 12" x 40’ SS Rated duty: 300 MBTU/HR Rated duty: 50 MBTU/HR
DP Atmosphere Rated head: 80 PSI Rated head: 75 PSI Rated head: 60 PSI DP 55 PSIG Shell design: 70 PSI @ 360oF Shell design: 150 PSI @ 350 oF
DT 190 oF DT 350 oF Tube design: 125 PSI @ 360 oF Tube design: 150 PSI @ 350 oF
Each bed 10’ of 1" pall rings

P-201
FI Slope
37
Slope To flare header
ST Dwg. 13320

PG PC
316 NC ST 115
PG
Set @ TT TIC 312
50 PSI
21 21 PG
PG 438
406
Set @ PV
PG PSV PSV TIR 115
75 PSI
315 PG TG 352 353 21 To incinerator
402 345
ST Dwg. 13319
TG
ST 344 TG
ST

26
PAH PSH H
FIC
202 202
27 PG LP cooling water
L I
/P 441 Dwg. 31995
ST
FQ
FY
TV Cond
27 27
C-7 21 AIT
FT FV
27 342
27
NC
Liquid dist.

ST
AAH
10’ packed bed
PG 342
Set @ Cond
401 100 PSI AIT AAH
341 341
FIC NC PG
From 50 PSI 28 TG 422
PSV
steam header I
/P 343
Dwg. 13301 FIR 351
FY 10’ packed bed
28 L 1/2"

ST
28
From nitrogen FT 2" thick
header FV insul
28 28 LAH LAL
Dwg. 13322 3/4"
1 1/2" 12 12
FT FIR TG TG
29 29 Steam dist. 477 480
Set @ PSV LAL LSH LSL
2" vac. 1"
355 TI 11 1"
FI 2" press. HLL 340 12 12
29 LG Set @ Mag
19 60 PSI
NC NLL LSL LG LT
From acid gas E-9
separator V-10 LSLL 11 11 12
Dwg. 25311 ST
LLL 1"
203

PCV
HLL 10 4’-1" 1" P
/I
From sour water 1 1/2" LY
flash drum PG PG PG
299 300 405 2’-6" TG
Dwg. 25309 ST
12
ST

478 TG
TG 1’-3" 479
3/4"
20 LIR LR
12a 12b
2" thick 10’-6"
insul 24" MH
E-2 M
ST
LLL
FI Set @
LT 97 100 PSI LV
1’-0" FT
18 30 12
LIC
PSV ST
NC
LIR 12
354 FIR H
18 Strainer
30 L
LI FI
18 98 ST
To water treatment
PAL Dwg. 45772
LSH LAH ST

201
18 18
ST

pH
AIT PG
M
LSL LAL PG 348 PG 463
18 TG PSL 459 461
18 pH
346 201 FT FIR
AIT AIR
LP cooling water I 347 347 31 31 L
AIR L
Dwg. 31995 ST ST
348 L
PSLL
204
P-101 P-102 P-103
Slope
ST ST

Which instrument is faulty: the transmitter, the recorder, or the controller, or is it impossible to tell
from what little information is given here?
file i03541

19
Question 18
This P&ID shows an incinerator stack used to safely burn poisonous gases. The high temperature of the
gas flame reduces the poisonous compounds to relatively harmless water vapor, carbon dioxide, and oxides
of sulfur and nitrogen.
The incinerator was recently out of service for three full weeks being rebuilt. Following the rebuild,
operations personnel have attempted to start the incinerator’s burner on plant fuel gas with no success.
They can get it started with natural gas, but the burner management system keeps tripping whenever they
switch to fuel gas. They call you to investigate.

F-1
INCINERATOR
DP Atmosphere
DT 1650 oF
Res Time 1.5 sec minimum

(3) - 3" nozzles

90o apart at
elev. 50’ 6"
67’ above
grade SO2

AE AT AAH
35 35 35
1" 1"
NOTES: O2
AE AT AIR
1. Gas safety vent pipes to extend 10 feet above grade, 34 34 34/35
situated at least 30 feet from any source of ignition. 1"x1/2" 1/2"
2. Burner management system supplied by vendor, located ET

in NEMA4X enclosure at base of incinerator tower. See

drawing 17003 for wiring details.
3. Gas chromatograph supplied by vendor, located in Rain shield
analyzer shack at base of incinerator tower. See TIR TAL TAH from 24’ to 67’
drawing 17059 for wiring and tubing details. 36 36 36

3/4" 3/4"
TT TE TE TT TIC
36 36 37 37 37
PG
41
34’ 6"
Waste stream #1 above grade 1"
Dwg. 12022 ST
2"
PG 2" thick
42 from grade

ET
to 24’ 0"
Waste stream #2
Dwg. 12022 ST 1" 1"
2" F-1
PG
43
6"x2" 6"x2"
Waste stream #3
Dwg. 12022 ST ET
2" 6"x2" 1" 1"

2"x3/4"
2"
24" MW
SV NE
115
BAL
106
SV BE
101 PSH D I RSP
/P
107 108 GC

FY FIC AT RS-485

Vent 2" PSH 38b 38 Modbus

BE 33
(Note 1) 110 (Note 3)
109
SV SV SV FV Gateway

102 SV 111 112 38 AY

103
2" 33
Ethernet

2" FC
PG
PSL BMS SV
104
105 (Note 2) 113 BMS AIR AIR AIR AIR AIR
PCV (Note 2) 33a 33b 33c 33d 33e
PG PSL H2S C2H2 NH3 HNO3 CH4
39
44 Vent 114
From natural
gas header (Note 1)
Dwg. 32915 2"
2"x1" 2"x1" 2"

HART
FY HART to analog DIR
ZS
From fuel 38 FT 38c 38
gas header
Dwg. 32915 38
2"
PCV FIQ TIR
40 38 38
FY
38a

20
 Identify the likelihood of each specified fault in this process. Consider each fault one at a time (i.e. no
coincidental faults), determining whether or not each fault could independently account for all measurements
and symptoms in this process.

Fault Possible Impossible

SV-115 leaking air
PSL-105 failed
PSL-114 failed
PCV-39 pressure setpoint too low
PCV-39 pressure setpoint too high
PCV-40 pressure setpoint too low
PCV-40 pressure setpoint too high
ZS-38 failed
Blind inserted in natural gas header
Blind inserted in fuel gas header

file i03500

21
Question 19
The compressor emergency shutdown system (ESD) has tripped the natural gas compressor off-line
three times in the past 24 hours. Each time the operator goes to reset the compressor interlock, she notices
the graphic display panel on the interlock system says “Separator boot high level” as the reason for the trip.
After this last trip, operations decides to keep the compressor shut down for a few hours until your arrival
to diagnose the problem. Your first diagnostic test is to look at the indicated boot level in the sightglass
(LG-93). There, you see a liquid level appears to be normal:

V-65 P-8
COMPRESSOR INLET SEPARATOR COMPRESSOR
Size 3’ 5" ID x 12’ 0" length 50 MSCFH @ 315 deg F disch
DP 450 PSIG and 175 PSID boost pressure
DT 100 deg F FIR
75
FSL
AND
75
Set @
30 MSCFH

FY
HS H 75
TIR PIR
From natural gas 12"x6" I
91 88 89 L
source A-3
Dwg. 38422 PG PT FT PG
Vent stacks 20’ above grade 132 74 75 RTD 135
TE TG
M
73 72
From natural gas 12"x6" 12"x8" To gas cooling
source A-2
Dwg. 10921
Dwg. 38422

M
PSV PSV PSV TT
From natural gas 12"x6" 11 12 13 88
source A-1 PG PT 12"x8"
Dwg. 38422 131 89
RTD

Set @ Set @ Set @ TE

405 PSIG 408 PSIG 410 PSIG
88
12" 4" 4" 4" 1/2" 1" 12" Anti-surge

XC XA
76 76

1" V-65 1"

Slope

Slope

ET
ET

I
/P
2" XY
IAS
1"x1/2" 1"x1/2" 76a
2" HHLL = 2’ 6"
(ESD)

PDT 2" L 1:1

HLL = 1’ 11"
LSHH LT LG
93 XY
231 92 93 IAS
NLL = 1’ 4" 76b
2"
LLL = 0’ 7"
2"
PDSH P

93
Set @ 2" RTD
0.9 PSID
PDIR
H TE TT
2" 232 232
93 LIR H
LIC
H
JAHH JIR
92 92 220 220 PDT
L L
PG 77 PG
FC 134 133
JT
ET ET
220 12" 8"
2"
Rod out

OWS
LV
TSH Set @
92 325 deg F
232
VZE M P-8
221
NDE

SV
RTD
92
RTD
TE
TE 229
IAS VXE VYE 224 VXE VYE VXE VYE
DE 222 223 225 226 227 228
vent

To motor controls
Dwg. 52331 Vibration monitor
ESD

I Bently-Nevada 3300 series

(See dwg. 58209 for wiring details)

HS
230

First, explain why this first diagnostic test was a good idea. Then, identify what would your next
diagnostic test be.

Finally, comment on the decision by operations to leave the compressor shut down until your arrival.
Do you think this was a good idea or a bad idea, from a diagnostic perspective? Why or why not?
file i03502

22
Question 20
The overhead pressure control system in this fractionator seems to have a problem. The controller
(PIC-33) indicates the pressure being over setpoint by a substantial margin: the pressure reads 48 PSI while
the setpoint is 37 PSI:

E-5, E-6, E-7 E-8 E-9 P-10 P-11 P-12 P-13 P-14 P-15 C-5 V-13
FEED HEAT RECOVERY EXCHANGERS OVERHEAD PRODUCT CONDENSER BOTTOMS REBOILER MAIN CHARGE FEED PUMP BACKUP CHARGE FEED PUMP MAIN BOTTOMS PRODUCT PUMP BACKUP BOTTOMS PRODUCT PUMP MAIN OVERHEAD PRODUCT PUMP BACKUP OVERHEAD PRODUCT PUMP MAIN FRACTIONATION TOWER OVERHEAD ACCUMULATOR
80 MM BTU/hr 55 MM BTU/hr 70 MM BTU/hr 2100 GPM @ 460 PSID 1900 GPM @ 460 PSID 2880 GPM @ 70 PSID 2880 GPM @ 70 PSID 2350 GPM @ 55 PSID 2350 GPM @ 55 PSID Dia 10’-3" Height 93’ DP 81 PSIG
Shell 500 PSIG @ 650 oF Shell 120 PSIG @ 650 oF Shell 630 PSIG @ 800 oF DP 57 PSIG DT 650 oF
Tube 660 PSIG @ 730 oF Tube 165 PSIG @ 400 oF Tube 600 PSIG @ 880 oF DT 650 oF top, 710 oF bottom

NC

Note 2
RTD FO To LP flare
Dwg. 62314
IAS
FT TT PV
33b
68 PT 68 3 to 9 PSI PG
H
PY PIC PY
68 PG 135
33a 33 L 33b
110
NOTES: PAH PV
FY Modbus RS-485 FIQ 33a
1. Backup (steam-driven) pumps automatically started by 2oo2 trip 66 9 to 15 PSI
logic, where both pressure switches must detect a low-pressure 68 68 PR
Cooling water
condition in order to start the backup pump. 33 return
FO Dwg. 11324
2. Transit-time ultrasonic flowmeter with pressure and temperature
compensation for measuring overhead gas flow to flare line. PSH PG PT
NC
66 108 33

FIR
67

FOUNDATION Fieldbus
PG
109 FT
E-8
67

HP cooling water
M
Dwg. 11324
Set @ 52 PSI Set @ 52 PSI FOUNDATION Fieldbus

PG RTD Overhead product

111 Dwg. 28542
Set @ 55 PSI Set @ 55 PSI
H
IAS FC LIC FOUNDATION Fieldbus
FOUNDATION Fieldbus FOUNDATION Fieldbus FT FT TT
31 31 30 L
FV Set @ 69 PT 69
P 31 73 PSI 69

FO

NC
LG LT FY FIR
V-13
32 30 69 69
AIC FY
42 40c

Lead/Lag Lead/Lag

FY FY
40a 40b
FOUNDATION Fieldbus FC FY
34 34
FT PG
40 134 FT IAS
AIC FV
34
36 34
IAS P
Distillate product
FIC FY FC Dwg. 28543
35 35
PG AT
136 36 FT NC

35 FV
35
FOUNDATION Fieldbus FFC PG
Sidedraw product
41 127
Dwg. 28545
C-5
FOUNDATION Fieldbus PG PG
NC

FT IAS 130 131

41 FV
41
P
600 PSI steam
Dwg. 10957 FC

NC
AIT
42 TT TIR
FT
53 53 37
PG PG
138 137
Bottoms product TIR TT
Dwg. 28544 50 50

LAH
E-5 58 Radar Magnetostrictive (float) PG
LT LT 132
TIR TT TT TIR 38b 38c PG
LSH HLL = 7’-2"
51 51 54 54 133
58 E-9
Fractionator feed LT
from charge heater LG NLL = 5’-4"
38a
Dwg. 27004 39
E-6 LSL LLL = 3’-8" Condensate return
57 Median
select
Dwg. 10957
LY H
TIR TT TT TIR LIC FIC
52 52 55 55 38 38 L 37
IAS
FV
E-7 37
LAL P
57
TT TIR FO

56 56
NC
PG TIR TT
106 PG 59 59 PG PG
107 HC 140 HC 141 HC
142 143 144
Set @ Set @ Set @
410 PSI IAS PG 500 PSI IAS 100 PSI IAS
139

S
S

PSL PSL PSL

60 62 64

PSL I PSL I PSL I

S
S

61 63 65
R

R
R

Note 1 Note 1 Note 1

PG PG PG PG PG PG
123 124 119 113 116 118
FO FO FO

RO RO RO RO RO RO

PG PG PG PG PG PG
M M M
122 125 120 112 115 117

P-10 P-11 P-12 P-13 P-14 P-15

PG
114

PG Condensate return
121 Dwg. 10957

1000 PSI steam

Dwg. 10957

Identify the likelihood of each specified fault in this process. Consider each fault one at a time (i.e. no
coincidental faults), determining whether or not each fault could independently account for all measurements
and symptoms in this process.

Fault Possible Impossible

PT-33 calibration error
PY-33a calibration error
PY-33b calibration error
PV-33b block valve closed
PV-33b bypass valve open
Instrument air supply to PY-33b failed
Instrument air supply to FV-34 failed

file i03533

23
Question 21
Inspecting the trends of PV and SP on a process chart recorder, you notice the poor quality of control:

100
95
90
85
80
75
70
65
60
55 PV
% 50
45 SP
40
35
30
25
20
15
10
5
0

Time

The “wandering” of the process variable (PV) around setpoint may be due to excessive action on the
part of the controller, or it may be due to load fluctuations in the process itself. In other words, the instability
may be the fault of the controller reacting too aggressively, or it may be that the controller is not working
aggressively enough to counter changes in process load.
Identify a simple method to determine which scenario is true. Hint: the way to check is as simple as
pushing a single button, in most cases.
file i01646

Question 22
A very useful technique for testing process control loop response is to subject it to a “step-change” in
controller output. In other words, the process is perturbed (the highly technical term for this is “bumped”)
and the results recorded to learn more about its characteristics.
What practical concerns might surround “bumping” a process such as this? Remember, the process
variable (PV) is a real physical measurement such as pressure, level, flow, temperature, pH, or any number
of quantities. What precautions should you take prior to perturbing a process to check its response?
file i01652

24
Question 23
In this process, sulfur-laden water is “stripped” of sulfur compounds by the addition of hot steam. A
level control system is supposed to maintain a constant level of liquid at the bottom of the stripping tower,
but it seems to have a problem:

V-10 P-201 P-101 P-102 P-103 C-7 E-2 E-9

SOUR WATER TANK SOUR WATER TANK EJECTOR COOLING WATER PUMP SOUR WATER PUMP STRIPPED WATER PUMP SOUR WATER STRIPPER SOUR WATER HEATER STRIPPED WATER COOLER
8’-0" Dia 12’-0" Sidewall 85 ACFM @ 1" H2O 20 GPM @ 80 oF 5 GPM @ 80 oF 8 GPM @ 150 oF 12" x 40’ SS Rated duty: 300 MBTU/HR Rated duty: 50 MBTU/HR
DP Atmosphere Rated head: 80 PSI Rated head: 75 PSI Rated head: 60 PSI DP 55 PSIG Shell design: 70 PSI @ 360oF Shell design: 150 PSI @ 350 oF
DT 190 oF DT 350 oF Tube design: 125 PSI @ 360 oF Tube design: 150 PSI @ 350 oF
Each bed 10’ of 1" pall rings

P-201
FI Slope
37
Slope To flare header
ST Dwg. 13320

PG PC
316 NC ST 115
PG
Set @ TT TIC 312
50 PSI
21 21 PG
PG 438
406
Set @ PV
PG PSV PSV TIR 115
75 PSI
315 PG TG 352 353 21 To incinerator
402 345
ST Dwg. 13319
TG
ST 344 TG
ST

26
PAH PSH H
FIC
202 202
27 PG LP cooling water
L I
/P 441 Dwg. 31995
ST
FQ
FY
TV Cond
27 27
C-7 21 AIT
FT FV
27 342
27
NC
Liquid dist.

ST
AAH
10’ packed bed
PG 342
Set @ Cond
401 100 PSI AIT AAH
341 341
FIC NC PG
From 50 PSI 28 TG 422
PSV
steam header I
/P 343
Dwg. 13301 FIR 351
FY 10’ packed bed
28 L 1/2"

ST
28
From nitrogen FT 2" thick
header FV insul
28 28 LAH LAL
Dwg. 13322 3/4"
1 1/2" 12 12
FT FIR TG TG
29 29 Steam dist. 477 480
Set @ PSV LAL LSH LSL
2" vac. 1"
355 TI 11 1"
FI 2" press. HLL 340 12 12
29 LG Set @ Mag
19 60 PSI
NC NLL LSL LG LT
From acid gas E-9
separator V-10 LSLL 11 11 12
Dwg. 25311 ST
LLL 1"
203

PCV
HLL 10 4’-1" 1" P
/I
From sour water 1 1/2" LY
flash drum PG PG PG
299 300 405 2’-6" TG
Dwg. 25309 ST
12
ST

478 TG
TG 1’-3" 479
3/4"
20 LIR LR
12a 12b
2" thick 10’-6"
insul 24" MH
E-2 M
ST
LLL
FI Set @
LT 97 100 PSI LV
1’-0" FT
18 30 12
LIC
PSV ST
NC
LIR 12
354 FIR H
18 Strainer
30 L
LI FI
18 98 ST
To water treatment
PAL Dwg. 45772
LSH LAH ST

201
18 18
ST

pH
AIT PG
M
LSL LAL PG 348 PG 463
18 TG PSL 459 461
18 pH
346 201 FT FIR
AIT AIR
LP cooling water I 347 347 31 31 L
AIR L
Dwg. 31995 ST ST
348 L
PSLL
204
P-101 P-102 P-103
Slope
ST ST

25
 Here is what the trend recording from LR-12b looks like during the time an operator placed the controller
in manual mode and then back to automatic mode:

100
95
90
85
80
75
70
65
60
PV
%
55 SP
50
45
40
35
30
25
20
Output
15
10
5
0

Time

A fellow technician tells you he thinks the controller is over-tuned (having too much gain). The operator,
who just did the manual-mode test, disagrees. Based on the information seen in the trend, what do you
think the source of the oscillation is, and how would you go about testing your hypothesis?
file i01902

26
 Answers
Answer 1

Answer 2

Answer 3

Answer 4

Answer 5
This circuit modification will have absolutely no effect on the performance of the system, as long as the
loop-powered transmitter receives its minimum terminal voltage for proper operation.

27
Answer 6
This controller needs to be reverse-acting:

Setpoint

Reverse-acting

LIC

M LT

Ultrasonic
Influent
Filter

Filtering
media
Effluent

This re-drawing of the control system uses an opamp symbol in place of the ISA-standard circle used
to represent a loop controller:

Setpoint

+
LIC
−

M LT

Ultrasonic H
Influent LIR

Filter L

Filtering
media
Effluent

• A sudden increase in effluent flow rate (clean water demand): controller output increases

• Level transmitter fails high (indicating 100% full water level): controller output decreases

• Control valve actuator fails, driving valve fully open (ignoring controller signal): controller output
decreases

28
Answer 7
One possible fault has to do with the control valve: perhaps something has happened to make it fail
closed (loss of air supply, signal, etc.). Other possible problems include the following:
• Pump not running (no source of fluid power to motivate flow)
• Very poor controller tuning
• Wrong controller action
• Valve failed closed (loss of air supply, signal, etc.)
• Transmitter failed, showing no flow when in fact there is
A good “first test” for troubleshooting the loop is to check the controller output: is it trying to open
up the valve?

Answer 8
The controller should still be able to maintain the process temperature at setpoint, but it will have to
open the cooling water valve further than usual to do so.

Answer 9
The one glaring discrepancy we see here is between the laboratory’s measurement of syrup concentration
and what the AIC and AIR indicate. Given that both the AIC and AIR agree with each other on PV value,
we may conclude that the signal to both of these instruments corresponds to a 34% measurement. The
problem is either the transmitter (AT) mis-measuring the syrup concentration, or else it is sensing the
concentration okay but outputting the wrong 4-20 mA signal nonetheless, or else the laboratory made a
measurement error of their own and incorrectly reported a syrup concentration that is too high.

We also see some minor discrepancies between controller output indications and actual valve stem
positions, but these are small enough to ignore. Likewise, the discrepancy between the level gauge (LG)
indication and the level controller/recorder indications is small enough that it does not pose a serious problem.

Answer 10
There will be no adverse effect resulting from this mis-calibration, unless the valve is unable to achieve
a full-closed position when required. In such a case, the liquid level will slowly fall below setpoint.

Answer 11
The liquid mixing vessel will either drain empty or overflow, depending on which side of setpoint the
process variable was on at the time of the mis-configuration.

Answer 12
There will be no effect on the performance of this cooling system, except in circumstances where the
controller tries to open the valve further than 80%. In those cases, the process temperature will exceed
setpoint.

Answer 13
The syrup’s sugar concentration will eventually become excessive as the analytical controller (AC)
attempts to maintain setpoint.

29
Answer 14
The analytical control system should still be able to maintain sugar concentration at setpoint, unless
the heat exchanger fouling is so extreme that even a wide-open steam valve does not heat the incoming syrup
enough to sufficiently concentrate it.

Follow-up question: suppose the heat exchanger fouling really is this bad, but we cannot fix the heat
exchanger with the tools we have available. What would you recommend the operator do to make this system
produce on-spec syrup?

Answer 15
In automatic mode:
Process flow rate (increase) → FT output signal (increase milliamps) → FC output signal (decrease
milliamps) → FY output signal (decrease PSI) → FV position (moves further closed, pinching off liquid
flow).

In manual mode:
Process flow rate (increase) → FT output signal (increase milliamps) → FC output signal (remains
steady) → FY output signal (remains steady) → FV position (holds position).

The important part of this question is the difference in response between “automatic” and “manual”
controller modes. In automatic control mode, the controller takes action to bring the process back to setpoint.
In manual control mode, the controller just lets the process drift and takes no action to stop it.
At first, having a “manual” mode in a control system seems pointless. However, giving human operators
the ability to manually override the otherwise automatic actions of a control system is important for start-up,
shut-down, and handling emergency (unusual) conditions in a process system.
Manual mode is also a very important diagnostic tool for instrument technicians and operators alike.
Being able to “turn off the brain” of an automatic control system and watch process response to manual
changes in manipulated variable (final control element) signals gives technical personnel opportunity to test
for unusual control valve behavior, process quirks, and other behaviors in a system that can lead to poor
automatic control.

Answer 16

Fault Possible Impossible

√
LT-12 miscalibrated
√
LG-11 block valve(s) shut
√
LSH-12 switch failed
√
LSL-12 switch failed
√
Leak in tubing between LT-12 and LIC-12
√
LIC-12 controller setpoint set too high
√
LV-12 control valve failed open
√
LV-12 control valve failed shut

Answer 17
We know the indicating controller (TIC-21) must be miscalibrated, because the pneumatic signal
pressure of 12.8 PSI agrees with the recorder’s indication of 304 degrees F.

30
Answer 18

Fault Possible Impossible

√
SV-115 leaking air
√
PSL-105 failed
√
PSL-114 failed
√
PCV-39 pressure setpoint too low
√
PCV-39 pressure setpoint too high
√
PCV-40 pressure setpoint too low
√
PCV-40 pressure setpoint too high
√
ZS-38 failed
√
Blind inserted in natural gas header
√
Blind inserted in fuel gas header

Answer 19
Given the fact that the ESD system keeps indicating a high boot level, you know that it “thinks” the
liquid level inside the boot is higher than it should be. The next logical step is to determine whether or not
a high liquid level condition does indeed exist. If so, the trip is legitimate and there may be a problem with
the liquid level control system. If not, the LSHH-231 or its associated wiring may have a fault that sends a
false trip alarm to the ESD system.
However, the decision to leave the compressor idle for a few hours until your arrival was not a good one
for diagnosis. If indeed there is a problem with excessive liquid collecting in the boot, this would only be
evident during running operation. With the compressor idle and no new gas entering the separator vessel,
there will be no new liquid collecting in the boot, which will give the boot level control system ample time
to empty that liquid down to a normal level and make it appear as though there is no level problem. In
other words, leaving the compressor idle for a few hours “erases” the evidence, making it more difficult to
troubleshoot.
Aside from re-starting the compressor and watching it run, you could perform a test on the liquid level
control system by simulating a high-level condition inside the boot (e.g. applying pressure to one side of
LT-92) and observing how fast or slow the actual liquid drains out (as indicated by LG-93). If there is a
problem with the level control valve LV-92 or its associated components, you should be able to tell in the
form of a long (slow) drain time. The fact that the blind flange at the bottom of the boot drain line says “Rod
out” on the P&ID suggests this line is prone to plugging with debris, which could explain a slow-draining
condition and consequently the frequent high-level trips.

Answer 20

Fault Possible Impossible

√
PT-33 calibration error
√
PY-33a calibration error
√
PY-33b calibration error
√
PV-33b block valve closed
√
PV-33b bypass valve open
√
Instrument air supply to PY-33b failed
√
Instrument air supply to FV-34 failed

Answer 21
Place the controller in manual mode and observe the PV trend!

31
Answer 22
Some processes may not take well to “bumps,” especially large bumps. Imagine “bumping” the coolant
flow to a nuclear reactor or the fuel flow to a large steam boiler: the results could be catastrophic! Not only
is it a potential problem to exceed an operating limit (PV too high or too low) in a process, but it may be
dangerous to exceed a certain rate of change over time.
Short of catastrophe, unacceptable variations in product quality may result from perturbations of the
process. Again, these may be functions of absolute limit (PV too high or too low), and/or rates of change
over time.
Remember, the purpose of regulatory control systems is to maintain the PV at or near setpoint. Any
time the control system is disabled and the process purposely “bumped,” this purpose is defeated, if only
momentarily. It is essential that operations personnel be consulted prior to manually perturbing a process,
so that no safety or operating limit is exceeded in the tuning process.

Answer 23
This oscillation is clearly not the result of an over-tuned controller, because it persists even when the
controller is in manual mode. The source must be coming from somewhere else in the process.

At this point in time, it would be a good thing to note the frequency of this oscillation, and begin
searching for anything that could cause the level to go up and down at this frequency, or perhaps something
that could “fool” level transmitter LT-12 into thinking the level is oscillating at this frequency. If the
frequency is relatively high, local machine vibration could be the cause of it. This hypothesis makes a lot
of sense, based on the fact that the controller’s action in automatic mode doesn’t seem to be correcting
the oscillations at all: the oscillation amplitude seems to remain unchanged between automatic and manual
modes. This is what we might expect from a vibration-induced oscillation, where the frequency of the
oscillation is much faster than the liquid level can possible change, and therefore faster than the level control
system can physically compensate.

32