1.

How do you carry out piping for a Different pressure flow transmitter on liquids,
Gas and steam services Why ?
Liquid lines : On liquid lines the transmitter is mounted below the orifice plate because
liquids have a property of self draining.
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Orifice plate

Flow direction

Primary isolation valve

( LIQUID SERVICE )

3 way manifold valve

Flow transmitter
+ -

2.Draw and explain any flow control loop ?

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C/v
Positioner
Orifice plate

Primary isolation valve

AIR SUPPLY FRC

3 way manifold valve

Flow transmitter
AIR SUPPLY

3. An operator tells you that flow indication is more, How would you start checking?
• First flushing the transmitter. Flush both the impulse lines. Adjust the zero by
equalizing if necessary. If still the indication is more then.
• Check L.P. side for choke. If that is clean then.
• Check the leaks on L.P. side. If not.
• Calibrate the transmitter.
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4. How do you do a zero check on a D.P. transmitter ?
Close one of the valve either H.P. or L.P. open the equalizing valve. The O/P should read
zero.
5. How would you do Glycol filling or fill seal liquids in seal pots 7 Draw and explain.
• The procedure for glycol filling is :
• Close the primary isolation valves.
• Open the vent on the seal pots.
• Drain the used glycol if present.
• Connect a hand pump on L.P. side while filling the H.P. side with glycol.
• Keep the equalizer valve open.
• Keep the L.P. side valve closed.
• Start pumping and fill glycol.
• Same repeat for L.P. side by connecting pump to H.P. side, keeping equalizer open and
H.P. side isolation valve closed.
• Close the seal pot vent valves.
• Close equalizer valve.
• Open both the primary isolation valves.

5. What are the primary elements for measuring pressure?

The primary elements used for measuring pressure are :

• Bourdon tube.
• Diaphragm.
• Capsule.
• Bellows.
• Pressure Springs.
The above are known as elastic deformation pressure elements.
Type of Bourdon tubes.
• ' C ' type.
• Spiral.
• Helix.
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Diaphragm : The diaphragm is best suited for low pressure measurement.
Capsules : Two circular diaphragms are welded together to form a pressure capsule.
Material Used : phosphor bronze, Ni-spanc stainless steel.
Bellows : Bellows is a one - piece, collapsible, seamless metallic unit with deep folds
formed from very tin walled tubing.
Material used : Brass, phosphor bronze, stainless steel. Used for high
pressure.
Pre.spring : Pressure springs of helical or spiral shape used for measuring high pressures.

6. Briefly explain the different methods of level measurement ?

There are two ways of measuring level :
1. Direct
2. Indirect.
TAPE MEASURE
1.Direct level measurement :
( a ) Bob and tape:
TANK
Heighest point reached by
A bob weight and measuring liquid
tape provide the most simple
and direct method of
measuring liquid livel. Distance to be measured
LIQUID after tape is taken out of
 Tank.

Bob (weight)

( b ) Sight glass :
This consists of a graduated glass tube mounted on the side of the vessel. As the level of the
liquid in the vessel change, so does the level of the liquid in the glass tube.

Indirect level measurement :

( a ) Pressure gauge :
This is the simplest method, for pressure gauge is located at the zero level of the liquid in
the vessel. Any rise in level causes an increase of pressure which can be measured by a
gauge.
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( b ) Purge system :
In this method a pipe is installed vertically with the open and at zero level. The other end of
the pipe is connected to a regulated air r supply and to a pressure gauge. To make a level
measurement the air supply is adjusted so that pressure is slightly higher than the pressure
due to height of the liquid. This is accomplished by regulating the air pressure until bubbles
cab be seen slowly leaving the open end of the pipe.

Pressure gauge
As level gauge

Air regulator
N2 purge
Air supply rotameter

The air pressure to the bubbler pipe is minutely in

excess of the liquid pressure in the vessel, so that
air pressure indicated is a measure of the level in
the tank.

The method above are suitable for open tank applications. when a liquid is in a pressure
vessel, the liquid column pressure can't be used unless the vessel pressure is balanced out.
This is done through the use of different pressure meters.

( c ) Differential pressure meter :

Connection are made at the vessel top and bottom, and to the two columns of the D.P. meter.
The top connection is made to the L.P. column of the transmitter and the bottom to H.P.
column of the transmitter. The difference in pressure in the vessel is balanced out, since it is
fed to both the column of the meter. The difference in pressure deducted by the meter will be
due only to the changing, level of the liquid.
( d ) Displacer type level measurement :
The leveltrol is one of the most common instruments used measuring level in closed tanks.
This instrument works of Archimedes principle. The displacer in immersed in the liquid due
to which there is loss of weight depending on the specified gravity of the liquid. This
displacer hangs freely on a knife transmitted to the pneumatic or electronic counterpart at the
other end.
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7. Explain the working of a leveltrol.

The leveltrol is used for measuring level of liquids in a closed vessel.

1. PRINCIPLE. : It works on Archimedes principle "The loss in weight of a body immersed
in a liquid is equal to amount of liquid displaced by the body". The leveltrol basically
consists of the following :
2. DISPLACER : It is consists of a cylindrical shape pipe sealed and filled inside with sand
or some weight. The purpose of this is to convert change in level to primary motion. The
variation in buoyancy resulting from a change in liquid level varies the net weight of the
displacer increasing or decreasing the load on the torque arm. This change is directly
proportional to change in level and specific gravity of the liquid.
3. RELAY : Amplifies pressure variations at the nozzles.
4. REVERSING ARC : It is used for the following purposes.

• Motion take of from Torque tube.

• Means of reverse control action.
• Adjustment for specific gravity.

PROPERTIONAL UNIT. : Converts primary motion to a proportional output air pressure.

5. CONTROL SETTING UNIT : Provides a motions of varying the set point.

8. Explain the working an electronic leveltrol.

REG
+
RVDT DC MOD
OSC
+ OP
+
AM
P
- - DC AMPLIFIER
SPAN

_ ZERO

The variation in buoyancy resulting from a change in liquid level, varies the net weight of the
displacer increasing or decreasing the load on the torque arm. This change is directly
proportional to the change in level and specific gravity of the liquid. The resulting torque
tube movement varies the angular motion of the rotor in the RVDT (Rotary Variable
Differential. Transformer) providing a voltage change proportional to the rotor displacement,
which is converted and amplified to a D.C. current.

9. How will you calibrate a leveltrol in the field?

Displacer chamber

Level transmitter.
 Transparent P.V.C tube

Calculation # 1 If the calibrating liquid is water: Process Liquid Density / 1* Displacer

height = mm of H2O.

Calculation # 2 If the calibrating liquid is Other liquid: Process Liquid Density / Calibrating
liquid density * Displacer height = mm of H2O. ( Calibrating liquid height in mm ).

1. First close both the primary isolation valves and drain the liquid inside the chamber.
2. Adjust the zero to get 0% output.
3. Connect a transparent PVC tube to the drain point as shown in hook up.
4. Fill it to the center of the top flange.
5. Adjust the specific gravity or span adjustment ( Electronic Level ).
6. Fill it up to 50 %, check linearity.

10. What is the used of Suppression and elevation ?

Suppression and elevation are used on Level applications where (1) transmitters are not
mounted on some level (2) Wet leg. i.e. condensable vapors are present
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11. What is burnout feature ? Explain.
Burnout provides the warning feature of driving indicator the end of scale if the input circuit
should open.
A burnout resistor is provided which develops a voltage drop between the measuring circuit
and the amplifier. The polarity of the signal determines the direction of the servo drive upon
an open circuit in the input.
Upscale burnout : R value 10 M
Downscale burnout : R value 2.2 M

12. What type of sensing element would you use to measure very low temperature ?
The sensing element used for measuring very low temperature is R. T. D.
( Resistance Temperature Detector )

13. What are skin temperature thermocouples ?

Skin thermocouples are those which are directly connected to the process without any
thermowell. Used for measuring the skin temperature of heaters furnaces, flue gas etc

14. Explain the application of proportional integral and derivative action?

Proportional control only :

Proportional control only attempts to return a measurement to the set point after a load upset
has occurred. How ever it is impossible for a proportional controller to return the
measurement exactly to the set point.
Use : It is normally used for level controls. It reduces the effect of a load change but it can
not eliminate it.
Proportional plus reset control:
Reset action is introduced to eliminate offset. It will integrate any difference between
measurement and setpoint and cause the controller's output to change until the difference
between the measurement and set point is zero. Reset will act as long as the error exists.
Use: Proportional + Reset controllers are by far the common types used in industrial process
control and where predominate dead times occur.
Proportional plus reset plus derivative:
Derivative or rate action helps the controller overcome system inertia and result in faster,
more precise control. Derivative action occurs whenever the measurement signal changes.
Under study conditions the rate action does not act. Derivative allows the controller to inject
more corrective action.
Use : On temperature controls.

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15. What is difference gap control ?
Differential gap control is similar to on off control except that a band or gap exists around the
control point.
Use: In industry differential gap control is often found in non critical level control
applications where it is desirable only to prevent a tank from flooding or drying. When a
measured variable exceeds the upper gap the control valve will open fully or be closed fully.
Similarly when it exceeds the lower gap it will open or close fully.

16. Where is on off control used ?

On off control is used when
1. Precise control is not needed.
2. Processes that have sufficient capacity to allow the final operator to keep up with the
measurement cycle.
3. It is mainly used in refrigeration and are conditioning systems.

17. Explain the working of Rotameter?

OUT LET

The flow rate varies directly

Tapered glass tube as the float rises and falls in the tapered tube.

Scale
IN LET

Variable area meters are special form of head meters. Where in the area of flow restrictor is
varied. So as to hold the differential pressure constant. The rotameters consists of a vertical
tapered tube through which the metered fluid flows in upward direction. A "float" either
spherical or cone shaped, actually more dense than the fluid being measured, creates an
annular passage between its maximum circumference and the weight of the tapered tube. As
the flow varies the "float" rises or falls to vary the area of the passage so that the differential
across it just balances the gravitational force on the "float" i.e. the differential pressure is
maintained constant. The position of the "float" is the measured of the rate of flow.
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18. Explain the working of a magnetic meter.
An electric potential is developed when a conductor is moved across the magnetic field. In
most electrical machinery the conductor is a "wire"; the principle is equally applicable to a
moving, electrically conductive liquid. The primary device of commercial magnetic meters
consists of a straight cylindrical electrically insulated tube with a pair of electrodes nearly
flush with the tube wall and located at opposite ends of a tube diameter. A uniform a.c.
magnetic field is provided at right angles to electrode diameter and to the axis of the tube.
The a.c. voltage developed at the electrodes is proportional to the volume flow rate of fluid,
and to a magnetic field strength. This device is limited to electrically conducting liquids. The
magnetic meter is particularly suited to measurement of slurries and dirty fluids, since there
are no location for solids to collect except the walls of the tube itself.

19. Explain the working of a turbine meter.

Turbine meters consist of a straight flow tube within which a turbine or fan is free to rotate,
about its axis which is fixed along the center line of the tube. Straightening vanes upstream
of the turbine minimizes possible rotational components of fluid flow. In most units a
magnetic pick-up system senses the rotation of the rotor through the tube wall. The turbine
meter is a flow rate device, since the rotor speed is directly proportional to flow rate. The
output is usually in the form of electrical pulses from the magnetic pick-up with a frequency
proportional to flow rate. Turbine meter are primarily applied to measurement of clean and
non-corrosive hydrocarbons.
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20. Explain the working of a Pitot tube.
The pitot tube measures the velocity at point in the conduct. If quantity rate measurement is
desired, it must be calculated from the ratio of average velocity to the velocity at the point of
measurement.
Principle : If a tube is placed with its open and facing into a stream of fluid, then the fluid
impinging on the open end will be brought to rest, and the kinetic energy converted to
pressure energy. This the pressure built up in the tube will be greater than that in the free
stream by the impact pressure or pressure produced by loss of kinetic energy. The increase in
pressure will depend upon the square of the velocity of the stream. The difference is
measured between the pressure in the tube and static pressure of the stream. The static
pressure is measured by a tapping in the wall of the main or by a tapping incorporated in the
pitot static tube itself. The difference between the pressure in the tube and static pressure will
be a measure of the impact pressure and therefore of the velocity of the stream oil.

21. Where is the integral orifice used ?

Integral orifice is used to measure small flow rates. It is mounted directly on the secondary
device. The integral orifice diameter varies between 0.020 inch and 0.250 inch diameter. The
integral orifice finds considerable use in laboratory and pitot plants.
Calculation of flow rate :
Qn / Fc = Ks x Cwi x Fa x Fm x Gp / Ge , hw

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