Professional Documents
Culture Documents
Fault Tolerant Ethernet (FTE) is the industrial control network of the Experion Process Knowledge System (PKS). Combining Honeywells
expertise in designing robust control networks with commercial Ethernet technology, it goes beyond providing fault tolerance. FTE ensures the
performance, determinism and security required for industrial control applications.
What Is It?
The FTE network connects clusters or groups of nodes such as servers and stations, typically associated with the same process unit. It provides
multiple communication paths between these nodes so the network can tolerate all single faults and many multiple faults.
FTE ensures rapid detection and recovery in case of communication failures with a switchover time of less than a second. It allows normal
Ethernet nodes to connect to the FTE control network and benefit from its highly available communications environment. With FTE, users can
leverage commercial Ethernet technology found in IT networks to lower the costs of the FTE control network infrastructure, connections to IT
networks and third-party Ethernet devices, and ongoing maintenance and support.
How Does It Work?
FTE ensures that the switchover time in case of a communication failure is less than one second. This is because it uses a single network and does
not require a server or station to re-establish its network connection. In addition, the nodes in the FTE control network continually check the
status of each communication path to ensure high availability.
Conventional Ethernet redundancy schemes employ two separate Ethernet networks with each node connected to both networks. If a
communication failure occurs, the elapsed time for a particular node to switch to the other network can be over 30 seconds, depending on
network equipment and how the system is configured for network failover.
What Problems Does It Solve?
With FTE industrial control network, users benefit from efficient fault tolerance as well as fast response, determinism and improved security. The
solution does not require purpose-built network switches as it uses commercial, off-the-shelf (COTS) technology. FTE is simpler to operate and
manage since it allows seamless connection to non-FTE Ethernet nodes and online additional/removal of nodes.
For all releases prior to R310, users must download the DD from the Honeywell website
For R310 and above, users should download the DD directly from the FOUNDATION Fieldbus website
In case of any DD or device-related issues, users should contact their local Technical Assistance Center (TAC)
What Problems Does It Solve?
By accessing and downloading the required DD, EDDL, and Firmware files, users can seamlessly integrate Fieldbus devices into their
Experion systems.
HART Integration
HART is an open protocol that delivers the benefits of smart field devices while offering the simplicity and ease-of-use associated with traditional
I/O. Experion Process Knowledge System (PKS) integrates HART devices to improve system performance, process availability, safety and
throughput, while reducing lifecycle costs for upgrading and maintaining smart field devices.
What Is It?
Honeywell ensures seamless integration with Experion with its HART enabled I/O modules. Available in the Chassis-A, PMIO, and Series-C
form factors, the modules enable the effective use of HART digital data for control, display, diagnostics, parameterization and asset management.
Users can improve availability by implementing the modules in an optionally redundant fashion.
Experion PKS provides the freedom to communicate with HART devices removing barriers such as scan rate limitations. Access to detailed
device performance and abnormal condition information lets users report device malfunction or failure and information about process-related
abnormalities. In addition, the HART solution provides plant operators and maintenance personnel full access to all field device information
directly through Experion.
How Does It Work?
Experions best-in-class, open HART solution automatically populates HART process and status data through the I/O cards into the C200 and
C300 process controllers, and finally into standard operator displays. Absolutely no additional configuration is required. The I/O cards also
provide a pass-through capability that enables full asset management using the Honeywell Field Device Manager (FDM) application.
The complete solution is based on open standards and is fully compliant with the HART protocol specification. The handheld solution is available
on open pocket PC-based platforms and works equally well with devices from all vendors. All device-specific data is gathered from the HART
standard device description (DD) files and no special vendor files are required to integrate the device with the Honeywell solution. If no DD file
is available, the HART universal and common practice data and diagnostics can be utilized.
What Problems Does It Solve?
Smart field devices provide valuable process and diagnostic information that enhances every facet of the process and improves plant
operations and availability. Experion HART integration allows users to access and utilize this valuable information in a cost-effectively manner,
using a technology that is easy to implement. This results in improved process availability and enhanced safety management of the process, plant
and personnel.
Application of Magnetic Flow Meters : Magnetic Flow meter measures the volumetric rate of flow any liquid that has adequate electrical
conductivity. Most petroleum hydrocarbons have insufficient conductivity to be measured with a magnetic flow meter. It is rarely used in
Petroleum Industry.
Magnetic Flow meters are widely used on slurries
Static Head
Static Head = pgh
p= Density of the liquid
g= Gravity
h= height of the liquid column
Type J Thermocouple - Iron Constantan
Type T Thermocouple Copper Constantan
Type K Thermocouple Chromel Alumel
Type N -Nicrosil Nisil
Type E - Chromel Constantan
Type S- Platinum 10 % Rhodium
Type R - Platinum 13% Rhodium
Type Cu - Uncompensated
Type C - Tungsten Rhenium
For Europe
CENELEC in process of being transferred to IEC/EN (European Committee for Electrical Standardization)
IEC
(International Electrotechnical Commission)
North America
NEC 500
NEC 505
(National Electric Code)
Hazardous Area Zoning For Gases Vapor & Mists (CENELEC & IEC)
Zone 0 - Explosive gas atmosphere is present continuously or for long periods
(typically > 1000 hours/year)
Zone 1 - Explosive gas atmosphere is likely to occur under normal operating condition
Zone 2 - Explosive gas atmosphere is not likely to occur in normal operation and if it occurs, will only exist for a short period (typically < 10
hours/year)
Hazardous Area Zoning For Dusts (CENELEC & IEC)
Zone 20 - Explosive gas atmosphere in the form of a cloud of combustible dust in air is present continuously or for long periods or frequently
Zone 21 - Explosive gas atmosphere in the form of a cloud of combustible dust in air is likely to occur in normal operation occasionally
Zone 22 - Explosive gas atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but if it occurs,
will only exist for a short period
HAZARDOUS AREA ZONINGFor Gases, Vapors & Mists (NEC 500)
Division 1
An area in which an explosive atmosphere exist continuously or some time under normal operating conditions
Division 2
An area in which explosive atmosphere is not likely to exist under normal operating conditions
EXPLOSION MEDIUM CLASSIFICATION (NEC 500)
There are 3 general classes which define the flammable materials present in the atmosphere :
Class I Mixture of Gas/Vapor with atmosphere
Class II Mixture of Dust with atmosphere
Class III Mixture of Fibers with atmosphere
LOCATION TERMINOLOGY(NEC 500)
CLASS 1, DIVISION 1
Location where ignitable concentrations of flammable gases, vapours or liquids
Can exist under normal operating conditions
May exist continuously, intermittently, or periodically because of repair or maintenance operations or because of leakage
May exist because of equipment breakdown that simultaneously causes the equipment to become a source of ignition
CLASS 1, DIVISION 2
DCS Engineer Interview Questions - Fundamentals (Refinery ,Power Plant, Chemical Plant ,Paper)
Some of the Interview questions for Control System Engineers - DCS (Distributed Control System )
Q) Definition of DCS?
A microprocessor based control and Data acquisition system consisting of number of modules operating over a network.
Q)Typical functions available in DCS
1 PID Control
2 Discrete control
3 Advanced control capability
4 Alarm management
5 Graphical and Schematic displays
6 Trending of real time and historic data
7 Communication between other device and subsystem
8 Data acquisition
9 Report generation
10 Data Historization
Q) Different type of PID function included in DCS?
PID Basics controller
PID Ratio
PID cascade
PID Bias
PID Differential gap
PID adaptive gain
PID non linear
Manual station
PID self tuning
External output tracking
Reset limiting
Q)Math functions included in DCS?
ADD
Subtract
Multiply
Division
Summation
Difference
Square root
Square
Absolute Value
Logarithm
Exponential
Polynomial
Q) Dynamic functions included in DCS?
Lead/Lag
Dead time
Velocity limit
Totalize
Q) Logic controls included in DCS?
And
OR
Exclusive OR
On/Off Delay
Inverter
Flip-Flop
Pulse
Nand
Nor
Upstream and downstream straight length run is essential for an orifice plate flow measurement
The upstream can be identified by the orifice plates Tag number markings. Tag numbers are always marked on the upstream of the orifice plate.
An upstream of 28D and a down steam of minimum 7D is essential for an a
Zero check and static zero check on a DP flow transmitter
Zero check- A procedure for checking the transmitter output is equal to 4.00 mA when its HP & LP chambers are equalized and are at the
atmospheric pressure
Static zero check- A procedure for checking the transmitter output is equal to 4.00 mA when its HP & LP chambers are equalized and are at the
operating pressure.
2.
3.
4.
5.
6.
7.
8.
c) Paper
d) Can mica or polyester
9.
1/1000000Ampere will be? The sum of the voltage drops across the resistances of a closed circuit equals the total voltage applied to
the circuit
a) 1 lack ampere
b) Mille ampere
c) Mega ampere
d) Micro ampere
10.
The sum of the voltage drop across the resistance of a closed circuit equal to the total voltage applied to the circuit - statement is
related to . low ?
a) Ohms low
b) Lows of electro magnetic induction
c) Lows
c) Kirchhoff low
d) Charles low
11.
12.
13.
14.
15.
16.
17.
18.
a) High tension transformer is rated in ?
b) KWA
c) KVA
d) KWh
19.
20.
21.
22.
23.
24.
25.
Working of Leveltrol
A Leveltrol in and instrument used for measuring the liquid level between two known points. The Leveltrol works on the buoyancy principal.
Leveltrol has a float, which submerses proportionately with liquid level raise in the float chamber. The amount of submersion of the displacer
depends on the liquid density, which produces a torque. The amount of torque produced in measured in terms of % of level.
Parts of Leveltrol:
Float chamber, Float, Torque lever, Knife edge, Feedback Bellows, Air Relay, Restriction, Flapper, Nozzle, Feedback link, Density range, Action
change lever, HP and LP flange,
A differential pressure transmitter gives a linear output for the differential pressure measured across its HP and LP chambers.
Connect the transmitters HP leg to the bottom of the tank and its LP leg to the top of the tank. The transmitter will read the liquid level accurately
irrespective of the change in process pressure above the liquid surface.
Brief Idea About Thermocouple Extension and Compensation Cable?
Extension and compensating cables are used for the electrical connection between the open ends of a thermocouple and the reference junction in
those installations where the conductors of the thermocouple are not directly connected to the reference junction.
Extension cables are manufactured from conductors having the same nominal composition as those of the corresponding thermocouple. They are
designated by a letter "X" following the designation of the thermocouple, for example "JX".
Compensating cables are manufactured from conductors having a composition different from the corresponding thermocouple. They are
designated by a letter "C" following the designation of the thermocouple, for example "KC". Different alloys may be used for the same
thermocouple type, they are distinguished by additional letters such as, for example, KCA and KCB.
Cold junction. The cold junction is the ambient temperature (control room). Without cold junction compensation the temperature at the hot
junction will measure inaccurately.
Selection of a level switch for a particular process
While selecting a level switch, the following points are to be considered:
- The characteristic of process (corrosive or non corrosive)
- The process pressure
- The liquid density
- The flange ratings
- Proof pressure of the switch
- The micro switch contact rating
Type of orifice tapping is commonly used in P.D.O
PDO in general, is using the Flange Tapping. The upstream and downstream orifice tapping are taken from the flanges.
Contact selection on high and low pressure alarm switches
On a high pressure switch, the wiring is terminated on the common and the normally close contact terminals.
On a low pressure switch, the wiring is terminated on the common and the normally open contact terminals.
This type of contact termination is done to achieve a close contact from the switch during a normal (healthy) process condition which is a fail safe
method.
Why RTD measurement use 3 wires for a field signal connection
3 wire system is used in temperature measurement by an RTD to compensate the line resistance. Three wire system provides a Wheatstone Bridge
in the measuring instrument.
New flow factor if a DP transmitter is re-ranged from 25 kPa to 50 kPa
A simple calculation is as follows:
Q1/Q2 = Sq root of DP1/ Sq root of DP2
Q1 = Q2 * Sq root of DP1/ Sq root of DP2
Q1 = New flow factor, Q2 =Existing flow factor
DP1 = Transmitter new range, DP2= Transmitter existing range
Q1 = Q2*SQ ROOT OF 50/25
Q1 = 1.41*Q2
The new flow factor will be 1.41 times higher than the existing flow factor.
Process Instrumentation : Flow Measurement Application Advantages and Disadvantages of Turbine Meters . Installation Consideration
Application of Turbine Meters : Custody transfer and in line blending. Turbine Meters are used where high
ability are required.Pulse output from the Turbine Meter may be scaled for direct totalization in engineering
are ideally suitable for batch Control application
What is the meaning of SAT and FAT ( Site Acceptance Test and Factory
Acceptance Test )
Factory Acceptance Test : FAT is to verify that the system and its components function properly that all manufacturing assembly software
generation and configuration have been done correctly and completely and that the system performance is in compliance with the agreed upon
procurement specification
Site Acceptance Test : SAT takes place after the complete installation and final configuration. This test should repeat FAT or an acceptable subset
of the test to verify that no damage occurred during shipment and installation.
Analogue IO cards
Normal analog I/p is in the range of 0 to 10V or 4-20ma signals.For that type of signals normal analog input cards are used. But RTD ouput are in
resistance variation and Thermocouples output are in the range of mv which require special conditioning before processing. For this type of
signals , we are using special type of analog input cards. Example for Honeywell DCS, For normal analog input using HLAI cards(High Level
Analog Input) and for RTD and T/C using LLAI cards(Low level Analog Input).
What is to be done, if a transmitter gives a maximum output , where the transmitter range (jumper) is already in maximum selection
Replace the capsule (sensor) for a higher range in the transmitter.
Separation between the ESD System and the F&G System; standard or just a good practice?
Separation of systems has nothing to do with the fact that one is fail safe and the other is non-fail safe. Nor does it have anything to do with alarm
segregation.
There is no standard which specifies the requirement for independent ESD and F&G systems. However, if you read between the lines you will
find that this is more often than not implied and common sense.
One of the important things to remember here is that if going for independent systems, you can take credit for these systems as independent layers
of protection. So for instance, if the pressure in a vessel goes about High and into the HiHi range you can consider the ESD HiHi trip as a layer of
protection. If this fails then a flange leak may lead to loss of containment which could be picked up by F&G detectors and prevent further
escalation of events.
If using an integrated system, you have to ensure that there are no common mode failures because of sharing the same PLC.
Generally it will be difficult to prove that no common mode failures can originate and this is why it is generally advisable to consider 2
independent systems up front, rather than changing things after orders have been placed.
If your F&G system is small, localized and has specific trip actions for electrical isolation then these may be treated as F&G executive actions
and you need not implement these in a separate ESD system.
The design also depends on the nature of process risk associated with your operations. If risks are low then there is no need to go for independent
systems.
Always analyze risk before making decisions, this will make the answer clear to you.
2.
Define all the process Variable and state their unit of measurement. ?
3.
4.
What are the different types of orifice plates and state their uses?
5.
6.
7.
8.
9.
What is the seal liquid used for filling impulse lines on crude and viscous liquid ?
10.
How do you carry out piping for a Different pressure flow transmitter on liquids, Gas and steam services Why ?
11.
12.
An operator tells you that flow indication is more, How would you start checking?
13.
14.
How would you do Glycol filling or fill seal liquids in seal pots 7 Draw and explain.
15.
How do you calculate new factor from new range using old factor and old range?
16.
How will you vent air in the D.P. cell? What if seal pots are used?
17.
18.
19.
20.
21.
What is Vacuum?
22.
23.
How will you calibrate an absolute pressure transmitter using vacuum manometer. Range 0-400mm abs?
24.
You are given a mercury manometer range 0 -760 mm ? A vacuum gauge reads 60 mm vacuum. The test manometer reads 50
vacuum ? Which of the two in correct.
25.
26.
27.
Draw and explain a pressure gauge ? What is the used of a Hair spring ?
28.
29.
Explain how you will measure level with a different pressure transmitter.
30.
31.
32.
How is D.P transmitter applied to a close tank & open tank with Dry leg?
33.
34.
35.
36.
37.
38.
39.
40.
What will happen if the displacer has fallen down while in line ?
41.
42.
43.
44.
How will you check zero of a level D.P. transmitter while is line?
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
What type of sensing element would you use to measure very low temperature ?
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
What is Cv of a valve ?
78.
79.
What types of bonnets would you use of high temp. and very low temp. ?
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
An operator tells you that a control valve in a stuck ? How will you start checking ?
96.
97.
98.
differentiator ?
99.
100.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Foundation Fieldbus
An open, bus-powered, digital, multi-drop communication technology for intelligent field devices and automation systems.
enables digital replacement of 4-20 mA
enables unification of field with business / control
enables some basic and even advanced process control in the field
How is Fieldbus Different from 4-20
Fieldbus devices are connected in parallel on the bus, which carries digital data from/to all the devices on the bus
Fieldbus devices provide almost unlimited information to all other devices on the network
Data has cyclical redundancy checking (CRC) to ensure receiving devices use only good data
A multidrop fieldbus does not have the shortcoming of point-to-point wiring
FOUNDATION Fieldbus Differentiators
Supports Intrinsic Safety and Existing Wiring
Uses IEC/ISA fieldbus standard.
Secure Process Data Messages
Time-critical process data first priority
Alarms and events second priority
Background MMI messages, downloads, etc., in free bandwidth
Function Blocks
Standard Set (AI, AO, DI, DO, PID, ML, SS, ...)
Modeled after DCS points
Supports distribution of control to field devices
Device Description Language (DDL)
Defines parameters and function blocks in a device
Provides interoperability between devices
Supported by major global controls suppliers
Less wiring and commissioning time
Access to diagnostics for better asset management
what is cascade loop and how it work and why it used instead of PID single loop? In cascade, Which loop is faster and slower? Please explain
with loop drawing and example...
A.1) In cascade loop the parameter to be controlled is in series with another parameter which is to be measured for normal operating conditions
i.e 2 manipulated variables are in series
it is used in fractional distillation system , boiler operation in power plants etc In pid
only one variable is measured and controlled at a time .it is used for temperature , pressure , flow control system
A.2) cascade loop is the combination of two pid control.where 1st controller output ie mv is the input of 2nd controller.1st contrroler more fater
than second controoler.
it's used in boiler three element.it's control feed water flow,drum level and steam flow.
The 250 ohm resiatance is necessary to support the communication between transmitter and HART because it equalizes
1. loop resistance
2. barrier resistance
3.wire resistance
4. receivers resistance
What is Dry Leg Calibration and Wet Leg Calibration?
Dry leg calibration and Wet Leg Calibration are used for closed and pressurized vessels level measurement.
Difference:
Wet leg calibration is used for vapourised liquid (which will be condensated by atmosphere) level.In LP side
Tapping ,liquid filled .
Dry leg calibration for the liquid under pressurised condition which will not be condensated.
The main reason to have a bevel in the orifice is to avoid turbulence thereby providing more accuracy to the measurement. Restriction Orifice
plates are not beveled since their intent is to reduce the pressure only.
What is difference between fault tolerant and redundant system?
In a fault tolerant system, there may not be a back-up component to take over in the event of a component failure. Redundant systems will have
back-up components that take over in the primary component fails.
For instance, a DCS system may have redundant processors that take over control if the primary processor fails for some reason. Typically, these
systems have redundant power supplies as well. You may also see redundant field devices on critical systems. Boiler drums will usually have
several level transmitters set up so that any one failure would not impact the operation of the boiler.
In a fault tolerant system, you may not have any back-up components. The system is designed to continue operations in the event of a failure of
one or more components. In thinking about this topic, a newer model automobile engine came to my mind. The emissions controls on these newer
engines use inputs from several sensors to control the engine and limit emissions. Typically, these systems would run on what is called a closed
loop control, where the sensor inputs are used by the computer to control parameters to the engine. If one of the components fails in the emissions
control system, the engine will continue to run, but not as efficiently. The emissions control system will go into open loop mode where a set of
fixed parameters is used to let the engine continue to operate at some reduced efficiency level.