Relation between flow and differential pressure.

Answer
#1

Flow is a continuous process of flowing of any liquid. Differential pressure

is the pressure difference between Suction pressure and Discharge pressure.

If we are using "restricted type flow measurement principle such as Orifice,

venture, V-Cone flow meters, anu-bar etc. then the Pressure drop across the
element i.e. let P, then Flow is proportional to the square root of
differential pressure.
flow is directly proportional to the square root of
#3
differential pressure(f=k*sqrt(p1-p2))
If pressure difference is high definitely the flow will high and if
#4
DP(differential press.) became low or zero, means line is partially/ fully
chocked. and as we know Flow = square root(DP.
Why three wires are using with a RTD?
#2

Answer
#1

#2

Resistance Temperature Detector(RTD)incorporates two basic concepts

1) Variation of temperature varies the resistance of Pt wire.
2) Variation in resistance affects the balancing of DC Bridge circuit.
For measurement purposes lead wires are brought out to make external
connections. These lead wires have some resistances which affect the bridge
balancing. Since we cannot reduces the resistances of lead wire to zero. So,
either 3 wires or 4 wire connection is employed to ELIMINATES THE IMBALANCING
TO THE BRIDGE CIRCUIT caused by resistances of lead wires so that an accurate
measurement can be made. These wires (3 or 4) are called compensating leads.
You are right, and the temperature indication does not increase so
significantly that it is worth the effort to use a 3 or 4 wire RTD.
It might increase with something like 0,001Deg C so that is so small you
might as well say there is no difference in the accuracy of a 2,3 and 4 wire
RTD, using a local or smart transmitter.
In the old days we use to use a 2 wire RTD in the field and then run a cable
say 200m to the temperature indicator. By the time it gets to the indicator
the temperature is completely different from what it was in the field due to
the cable resistance that add itself the RTD resistance.
We compensated for that by installing a 3de wire for the sole propose to
measure the resistance of the cable itself and deduct that from the total
resistance measured at the temperature indicator. So the actual resistance of
the RTD as measured at the temperature indicator is RTD - RLine1.(or
(Rline1/2)x2]if you want)With the 4 wire it makes it more accurate in that
you can now measure line one and line 2. The theory is that the one line
might have a small difference compare to the other line. So the actual RTD
resistance at the temperature indicator is measured RTD - [(RLine1/2)+
(RLine2/2)]But since we all use the small compact local and smart temperature
transmitters these days, 3 and 4 wires are no longer needed since the
distance from the RTD to the
transmitter is only from about 50 to 500mm and but it seems it have stayed

due to some design engineer always saying, why buy a 2 wire if you can get
the 3 and 4 wire for just about the same price. It will make the indication
just more accurate, but they never say by how much (0,001Deg C).
how to calibrate a new i/p converter
Answer
#1

#2

3
#4

#5

Connect the input air supply of around 5 to 7 Bar Feed 4 mA

through the calibrator; the output air pressure gauge shall
indicate 3 psi. Feed 20mA through the calibrator, the output air
pressure gauge shall indicate 15 psi.
I follow your above procedure
I use 0-30 psi pressure gauge
When I feed 4 mA gauge show 3 psi, gradually I increase mA simultaneously
pressure increase. At 10 mA gauge shows max 20 psi. I little adjust the range
screw but no change on gauge. now what will I do.
Hope you are adjusting 4mA with "Zero" screw and 20mA with "Span/range"
screw. I feel that you might have adjusted the 3 psi with range screw.
FIRST SEE ITS PRESSURE RANGE APPLY INPUT PRESSUR 5PSI MORE THEN MAXIMUM
RANGE OF OUTPUT PRESSURE AND SEE ITS OUT PUT THEN APPLY 4MA AND SEE OUTPUT
SIGNAL 3 PSI NOW ADJUST 3 PSI FROM ZERO ADJUSTMENT SCREW NOW 8
12
16
& 20MAAPLY AND CHECK MAX PRESSURE RANGE NOW ADJUST FROM SPAN SCREW
( RANGE CAN BE DIFFERENT FROM 3
TO 15 PSI )
1. AIR SUPPLY
I/P input
- 1.4kg/cm2
Output - 0.2 to 1kg/cm2 ok
2.input signal= 4-20 mA
i.connect the air supply to input with the hepl of REGULATOR i.e 1.4kg/cm2
ii.connect the MASTER GAUGE to OUT PUT ok
Apply the signal
i. 4mA- 0 kg/cm2 (if not Zero/0.2kg/cm2 Adjust Zero
adjustment Screw)
ii. 20mA-1 kg/Cm2 (if not 1kg/cm2 Adjust Span adjustment
Screw) ok.
then 8, 12, 16mA.
min. and max. is ok the remaining will perfect automatically i.e 8,12,16mA.

#7

and MAIN IMP POINT is ON the I/P's Ckt board Side 4 adjust ment buttons is
there and adjust that buttons Direct and Revese Actions ok
Friends, plz understand the question first. The interviewer has mentioned
"how to calibrate a NEW i/p Converter?"
"Sir, the new i/p would be factory calibrated with high accuracy master
instruments, so before we commission it in the plant we have can check its
output by applying proper signal, unless we have good accuracy masters we no

need to disturb the calibration. If yes, we can do the calibration using the
30psi regulated supply, 4-20 mA source, and receiver gauge."
What is the difference between sensor and transducers?
Answer
#1
#2

#3

#4

Sensor is a receiving a signal. Transducers is a transmitting a data a data

one device to another device.
Sensor is an element which Receives a signal that is to be measured. Where as
a transducer is a device or a sensor which converts a physical data to an
electrical data.
a sensor is one which measures a physical variable. a transducer is one which
transforms the physical variable into some other form which can be easily
processed by the remaining measurement system. if it is converting the signal
Into electrical form it is called electrical transducers.
Sensor can only sense the element but transducer can convert physical energy
to another form. So sensor is not transducer but transducer is sensor.

#5

Sensor is a device which converts any physical quantity into electrical

quantity. But the transducer converts one form of energy into another form of
energy; it may either electrical or any other physical quantity.

#6

Sensor can only sense the physical quantity and convert into electric signal
(24v). But transducer senses the physical quantity then converts it into other
form of energy as type of transducer.

#7

Sensor is a device which can only sense the physical Quantity like
temperature, pressure etc. FOR PRESSURE BELLOWS IS A SENSOR
Transducer is a device which senses the physical quantity and converts that
physical quantity into electrical quantity eg. THERMOCOUPLE

#8

sensor is only used to measure the physical quantity such

as (temp, flow, level, pressure) but transducer is a device used to measure
the physical quantity and convert the electrical energy.

Can anybody will tell me about PID controller.

Answer
#1

#2

#3

PID CONTROLLER is a proportional integral differential controller that

may b used at any electrical control application as the response of any
system is resulting from
the multiplication of any gain "prop" , differentiate it "diff" and then
integrate it.PSS is the most device at which we design it by PID either
with FLC or using POLE Placement can make a small pid using OPERATIONAL
AMPLIFIER OR SIMPLE RLC CIRCUIT.
For PID controller the actuating signal consists of proportional error
signal added with derivative and integral of the error signal. Therefore
the actuating signal for PID control is
ea (t)=e(t)+Td de(t)/dt + Kt}e(t)dt
Its a one type of feedback system. PID controller try to correct the
error between a measured process variable and desired set point by
calculating and then it generates the corrective action accordingly

#4

Actually we can make it simple:

# P:
Its controller gains which modify the controller o/p proportional to the
error.
# I:
Its a controller gain which modifies the controller o/p proportional to
the integral of the error.
# D:
Its a controller gain which modify the controller o/p Proportional to
error rate of change.
We have 4 parameters in our control loop to focus on:
1 - the rise time: the period of time during which the pv get 90% of the
desired sp value
2 - max overshoot
3 - Settling time: the period of time during which the pv gets the
desired sp value and saturate.
4 - error/offset
we can get it clear from this pic:
Now we will take a look about the effect of each controller gain on these
parameters:
# P gain:
Decrease rise time increase max. over shoot increase settling time
decrease error (but not eliminate)
# I gain:
Decrease rise time increase max over shoot increase settling time
eliminates error.
# D gain:
no effect on rise time
decrease max over shoot
decrease settling time
Decrease error.

How u measure flow? Orifice measurement? Why all ft in square root?

There are several ways to measure the flow of fluid & gas like magnetic flow
meter, mass flow meter, based on measurement of differential pressure like
venture, orifice
etc, turbine flow meter, positive displacement flow meter, vortex flow
meter.
Measurement of flow with the help of orifice is based on the measurement of
differential pressure across the orifice plate. Tapings are either on the
supporting flange or at D & D/2 m away for upstream and downstream of the
orifice respectively where D id Pipe diameter in which plate is installed.
Not all the transmitters are square root. Those transmitters which are based
on differential pressure are square root. We can use square root at the
transmitter itself or we can make the calculation in the DCS/PLC program.
Since Q(flow) is directly proportional to square root of the differential
pressure we do the square root extraction to measure the flow.
what should be the distance of vibration sensor & to the point where vibration to be measured Ex turbine axial
displacement
The distance of vibration sensor and the point where the vibration is to
Answer
be measured is should be 1.5 mm.
#1
The philosophy is different for Axial and Radial measurement. For radial
#2
measurement the AC component voltage is directly proportional to the
magnitude of vibration so the gap is fixed based on the probe linearity
Answer
#1

(usually 10vdc for Bentley Nevada probes).For axial measurement the AC

component voltage is not important and only the DC component is
considered which varies proportional to the distance between the probe
and the shaft. Conversely, the shaft is centered and the probe voltage is
adjusted to 10Vdc and the same voltage is also referenced in the system
for shaft zero position. While the unit/turbine is running the position
of the shaft is proportional to the dc component measured.
What is DCS architecture? Can u give example?
Answer
#1

#2

DCS ARCH:- it means total dcs system , it includes engineering

station , operating station , dcs panel like analog panel(AO&AI) ,
digital panel (DO & DI), system cabinet , pdb cabinet , and all DI,
DO, AI , AO
from Field terminals , also from mcc , from drive
panel . this is
whole dcs arch.
DCS ARCHITECHTURE IS RELATED WITH "FIELD CONTROL STATION"
(FCS) AND HUMAN INTERFACE SYSTEM (HIS).
FIELD SIGNAL FOR EG.(DI,DO,AI,AO) IS CONNECTED WITH FCS
PANEL AND IN FCS USED NEST,VLNET,VNET, DEPEND UPON TYPES ON
DCS.

Why OPC server is used in DCS?

Answer
#1

#2

OPC server is used to hook up or share the

information across third Party DCS into the
EXISTING DCS.
For Eg. I want to have CS3000 (Yokogawa) sharing
some information exchange on EXPERION PKS
(Honeywell) System, I will Need OPC integrator for
the same.
OPC stands for OLE for Process control, again OLE stands for Object
Linking and Embedding, to link the different objects from different user
and make it used or available in DCS for process a task, OPC server is
used.

what is the reason for flow fluctuations happen on differential flow transmitter during in service
Change in process pressure, restriction in one of the sensing lines,
rapid change in temperature, and noise in the signal being returned to
the source of indication. (Check for noise in the shielding-blow down
sensing lines-check if the process media is at the correct operating
temp.-make sure the equalizer valve is closed and the sensing (hi and lo)
lines are open.
We have ZR22G-100-S-A-E-T-T--E-A/CV/F1 Model Zirconia Oxygen analyzer which is Yokogawa make. I kept the
analyzer in Flue gas path at Air pre heater area. My plant is 7.5MW Biomass power plant. For a particular fuel, Coconut
Husk which contains Sodium and Potassium chlorides iam not getting proper reading, Analyzer output always Zero. I
calibrated the analyzer and it is OK. For Other fuels like Wood chips, Cholam waste, DOB, Ground nutshells, Ply wood
waste and all iam getting actual percentage of Oxygen. What is the main reason behind this draw back?
please check your heater which is used in zirconia change your load air
Answer
percentage in firing and observe changing or not if changing means actual
#1
is zero
Pls. set your fuel temperature bcs. Normally zirconia o2 analyzer work on
#2
800-900 deg. centigrade temperature.
Answer
#1

So set the temp. Still you not get result then pls regulate your flow and
also with your process gas you have to provide atmospheric air with set

pressure (>=1kg/cm2).
How u measure rooms temp? Is it possible 2 measure room temp by RTD or thermocouple? Between RTD n
thermocouple which is more regard?3 measure diff. between RTD n thermocouple?
RTD is low range temp. Sensor (0-300) but
Answer
thermocouple is for high range temp. (0-1400)RTD
#1
measures temp. With change in resistance,
thermocouple measures temp. With reference of
cold junction, its output in mV.
Functions of electro pneumatic valve positioner?
Answer
#1
#2

To reduce and to control the flow of the service which is passing through
All valve cannot be actuate directly using I to P converter. Using
electro pneumatic valve positioner we can boost the air signal to the
required level to actuate valve and position it such that the flow of
material passing through line is maintain.

What is difference between two wire &three wire pt 100?

Answer
#1

two wire RTD use for short

distance, three wire RTD use for
long distance because of
resistance compensation.

What is DCS and PLC scanning time?

Answer
#1
#2

Scan time is time required for checking i/p, to executive

Program and give output. generally 5msecfor plc
SCANNING TIME OF PLC DEPENDS ON THE NUMBER OF RUNGS, JUMP COMMANDS, SUB
ROUTINES, AND INTERFACING DRIVER CONFIGURATION. THERE IS NO FIXED SCAN
TIME FOR PLC.

WHAT IS CV OF CONTROL VAVLE

Answer

#1
#2
#3

The Cv is actually the Flow Coefficient of control valves. It actually

measures the friction experienced by a fluid as it moves through some
pipe / valve. The standard definition of Cv is:"the flow of water through
a valve at 60 oF in US Gallon/minute at a pressure drop of 1 lb/in2."
Coefficient valve one cv equal the flow of one u.s galleon (3.8
litter)per minutes of water at 60 F under a pressure drop of value of
1psi.
flow coefficient of control valve.its calculated by the
given below formula:
CV = Q/(P/SG)^1/2
where:
CV -flow coefficient
Q -flow of liquid
P-pressure drop across the flow
SG-specific gravity of the liquid
CV=1.17KV

=>

KV=.86CV

KV is metric unit of CV
The flow of water through a valve at 60 oF in US gallon/minute at a
pressure drop of 1 lb/in2.

what is full form of SMART

Answer Self-Monitoring, Analysis, and Reporting Technology
#1