Q.1 WHAT FOR BARRIERS ARE USED IN DCS & PLC SYSTEMS?

Ans. Barrier's are associated apparatus, this is normally

Used in safe area to hazardous area signal transmission
Interface Purpose, and protect both equipments each other
From fault conditions. As well It is minimizing the energy like a transducer of
transmitted signal to hazardous area, Which area is classified as minimum
energy electrical spark, can produce explosive with the atmosphere. Although it
should.
1,2 or 3 fault conditions can with stand, and made easy to maintain hazardous
area equipment.EX for hazardous area instrument get faulty, if want to replace
may need shout down that area operation, it’s too troublesome.
Q.2 WHAT IS THE DIFFERENT BETWEEN OPEN LOOP AND CLOSE
LOOP?
LET's elaborate in right way!
Ans.IN closed loop system, a feedback is provided so that output can be
compared with the reference value to give an error signal. by this one can
control the parameters of a system and output value can be optimized.
Whereas in OPEN LOOP, no feedback is provided. Optimization is not possible.
Q.3 RE: WHAT IS THE DIFFERENCE BETWEEN HMI AND SCADA?
Ans. HMI IS Human to (Hand to) Machine Interface i.e. a Display
Screen Like a computer monitors which HAS THE CONNECTIVITY
TO MACHINE CONTROLS THRU SPECIFIC SOFTWARE, It may have 3D
Switches parameter setting alarm indication etc etc
Where as SCADA (Supervisory Control And Data Acquisition) is a
System combined a software May be a PC with monitor or HMI by which one
can monitor the process and control it this
Has got lot of options in monitoring, recording of process data. So HMI is a part
of SCADA System.
Q.4 HOW TO TRIM THE PRESSURE TRANSMITTER?
Ans. ensure that you have the necessary document on your hand
Such as PTW.
Connect a HART Communicator, and then close the Tx isolation valve
And open the VENT isolation to atmosphere.
Apply LRV and check w/ HART Comm., if the LRV is out, perform
TRIM function using HART 375/475
Q.5 WHAT ARE THREE MAIN PROGRAMMING IN PLC
Ans. Ladder logic diagram
Statement list
Functional block diagram
Q.6 DIFFERENCE B/W GROUND AND EARTH
Ana. Ground or earth in a mains (AC power) electrical wiring
System is a conductor that provides a low impedance path to
The earth to prevent hazardous voltages from appearing on
Equipment (the terms "ground" (North American practice) And "earth" (most
other English-speaking countries) are
Used synonymously here). Under normal conditions, a
Grounding conductor does not carry current.
Neutral is a circuit conductor that carries current in
Normal operation, which is connected to ground (or earth).

-1-
Q.7 IF BOILER DRUM LEVEL TRANSMITTER IS NOT WORKING
PROPERLY
WHAT YOU WILL DO FOR RESOLVING THE PROBLEM IN PLANT
RUNNING CONDITION?
Ans. We will first force the drum level through DCS by taking it in manual mode.
Then we will check the transmitter, rectify the problem and again bring back the
transmitter to normal mode (auto mode)
Q.8 WHAT IS CASCADE CONTROLLER?
Ans. cascade Control is one controller's output goes to another
Controller’s set point.
Q.9 WHY 4-20 MA IN CONVECTION SYSTEM?
Ans. 4-20 MA signal differentiates live process 0% with 4mA
Signal with a wire break (0 ma), current is also used for
Transmission because even if your receiver or PLC/DCS card
Is far away current signal sent proportionately by the
Transmitter will be received as the same current at the
Receiver/PLC/DCS card, although it is converted as a voltage
Signal (1 to 5 VDC) by a 250ohm resistor, since
Micro-processor process signals in voltage levels.
Q.10 WHY HUNTING WILL OCCUR IN CONTROL VALVE?
Ans. Control valve is used in close loop control system. If it is hunting, then to
troubleshoot first put loop for few sec in
Manual mode, still if v/v is hunting then it is field
Problem i.e. v/v or I/P converter problem.
If it is not hunting in manual mode, then the problem can
Be either the loop process variable (PV) is hunting or if PV
Is ok, either the load/process is varied or loop needs
Tuning.
OR
1) I/P PROBLEM
2) INSTRUMENT AIR LEAK (Signal)
4) FLOW DISCHARGE FROM THE PUMP MAY FLUCTUATING
Q.12 WHERE & WHY WE ARE USING SURGE PROTECTION? Ans.SURGE
protection are mostly used on discharge line of Compressor cause it's very
heavy pressure it can cause Damage compressor & its condition can may be
create disaster Q.13: WHERE IS A LEVEL DISPLACER IS USED?
Ans. Displacer type level transmitter is used in interface level measurement
and closed tank level measurement. It is Working under weight loss, the
Archimedesprinciple. Q.14 RE: WHAT IS SEEBECK EFFECT?
Ans. When two dissimilar metal conductors are joined together to Form a loop,
at two different temperatures are imposed at two junctions, there is a current
flowing through the Loop. This effect is known as seeback effect.
Q.15: WHAT IS THE USE OF KEYPHASOR IN TURBINE.
Ans. Keyphasor always used to give pulse triggering in each and every rotation
of the shaft.
Q.16 WHAT IS THE DIFFERENCE BETWEEN ANALYTICAL INSTRUMENTS
AND OTHER INSTRUMENTS?
ANS Analytical instruments are those which are used to calculate the exact
proportion in which the various constituents are present in a substance. For
exp: a gas chromatograph can be used to calculate the exact quantities in
which oxygen, co2, nitrogen and other gases are present in air.
where as the other instruments are used to measure
the various physical quantities such as pressure,
Temperature, level, flow etc in a process.
Q.17 WHY WE USE NEGETIVE (-) VOLTAGE IN VIBRATION SYSTEM
Ans. Actually in proximity probes inside used PNP tanasistor.so
Transistor biasing supply need - dc voltage.
Q.18 WHAT IS MEAN BY HOT LOOP AND COLD LOOP TESTING, WHTS
DIFFERENT BETWEEN BOTH
Ans.Cold Loop checking: Checking of wires continuity of
Respective field instrument-Junction box-DCS/PLC
Marshalling panel terminal. Hot loop checking: Once you power up your field
instrument through DCS/PLC system, by stimulating process input from
respective field instrument and cross check its response at DCS/PLC sytsem
Q.19 WHAT IS DIFFERENCE BETWEEN PROFIBUS AND FIELD BUS?
Ans.Fieldbus (or field bus) is the name of a family of industrial computer
network protocols used for real-time distributed control, now standardized as
IEC 61158.
PROFIBUS (Process Field Bus) is a standard for field bus communication in
automation technology.
The Profibus in his Process version (Profibus PA) is two wires (Twisted pair) for
data and power.
Field bus foundation is only for process (Mainly for instruments), Profibus is for
process and automation (instruments, drives, I/O, motor controllers to PLC,
PLC to PLC etc.).

Q.20: WHAT IS MASS FLOW METER PRINCIPAL?

Ans.coriolossis effect is principle of
Mass flow meter.
Q.21 WHT IS DCS ARCHITECTURE? CAN U GIVE EXAMPLE?
Ans. 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
Q.22 WHAT IS LINERITY AND NON-LINEARITY?
Ans. linearity; means when input is changes at a same time
Output also changes. Is called linearity.
Non linearity: means input are varied some parameter but
Output is not varied with respected to input is called
Nonlinearity.
Q.23 WHY NEED 3 ELEMENT SYSTEM IN POWER PLANT? IF IT IS NOT
THERE THEN WHAT L HAPPEN?
Ans. As steam flow and feed water flow effects the level of
Boiler drum these two are taken as two elements in three
Element control system to achieve smooth control on drum
Level ideally these two are capable to maintain the drum
Level but the third element as drum level actual itself is
Taken to compensate various leakages etc. As we know the
Controller doesn't respond unless it senses some error
Between PV and SV and if drum level actual is taken alone to
Control the drum level, controller will respond only if
Level goes up or down to its set point and this will
Maintain always a pulsating drum level instead of a straight
Line. Steam flow and feed water flow consideration gives a
Feed forward effect to controller hence a smooth control on
Drum level can be achieved

Q24.WHAT IS DIFFRENCE BETWEEN CASCADE & THREE ELEMENT

SYSTEM.?
Ans. Cascade loop is the general terminology in control system.
It consist one master and slave controller. In that one
Controller output is given as set point to the other Controller. The secondary
controller output will go to final Control element.
Three element controls is technique which is used in boiler
Drum level control. In that, by measuring steam flow
(Demand) we are controlling the feed water flow to maintain the drum level. In
this technique we are using cascade loop.
Q25. WHAT IS THE DIFFERAENCE BETWEEN PLC AND DCS?
Ans. The basic diff is that DCS is a network based one, so that
It can used to any extend without complexity but plc will
Become very complex when I/O are large

Q26. WHAT IS SHRIKING AND SWELL EFFECT FOR A BOILER ?

Ans. The shrink/swell effect is caused by small pressure changes causing
bubbles in the tubes to reduce (shrink) or increase (swell) as a result of small
changes in pressure - so that the mixture of steam and water in the tubes
remains at the saturation temperature for the pressure at each location
Q27. WHAT IS THE DIFFERENCE BETWEEN HMI AND SCADA?
Ans. Actually HMI stands for human machine interface previously
It was called MMI (man machine interface) but MMI term was
Out due to its sexiest tone.
So HMI is monitoring station from where u can see the
Process, control the process by giving commands via Software compatible to it.

Whereas SCADA (supervisory control and data acquisition)

Composed of mainly two parts MTU and rtu.mtu (master
Terminal unit) _ to control several RTU’s (remote terminal
Unit) with wire or wireless technology.
SCADA is composed of many HMI's.
Q28. WHT IS LOOPS ? HOW MANY LOOPS ARE THERE?
Ans. 1.during commissioning, we do loop checks. It means from
Field instrument (pt, tt, ft, lt or switches) the signal is
Checked with the DCS.
For example consider a pt, we will simulate 4 to 20 ma in the
Instrument and the same value should be shown in the dcs also.

2. There are two loops

Open loop and closed loop
Closed loop for controllers to control the process. For
Example, antisurge control in gas compressor, three elements
Control in boiler
Q29. HOW TO FORCE THE BIT IN GE MARK V?
Ans. Use logic forcing page and type in the logic name.
Select the logic name and use the force/ unforced tab

Q30. WHAT IS DCS?

Ans. DCS is distributed control system which is geographically
Distributed and connected through a communication network.
The control stations and its sub stations can be located in
Different locations of the plant. It is capable of doing
Different functions since it also functionally distributed.

Hence, in a short, DCS is geographically and functionally

Distributed.
Q31. HOW TO USE ONE 4-20 mA SIGNAL FOR TWO INDICATER OR
CONTROLLER & GIVE NECESSARY PRECAUTION.
Ans. 24vdc output of transmitter will be connected in series
With two indicator, don't connect in parallel otherwise it
Will be damage.
Q32. WHAT IS INSTRUMENTATION AMPLIFIER?
Ans. A type of differential amplifier with high input impedance
And low output impedance. Mostly used in all transducers
Because of its common mode rejection ratio property so that
Noise can be eliminated from signal produced by primary sensing element.
Q33. DEFINE SIMULATION A AND WHAT IS THE NEED OF IT?
Ans. Simulation is tools for giving false appearance at input
For checking logic result.
By simulation we can check stroke (operation) of control
Valves, control test of motor (start/stop),
And major advantage is, during plant running, if any input
Not working properly, then by simulating we can rectify its
Problem in such way we can avoid the false tripping of plant
Q34. WHY THERMOCOUPLE CALLED THERMOCOUPLE?
Ans. Two dissimilar metal are couple together one end & other end
Is open & used for temperature measurement.
Q35. WHAT DO WE MEANT BY INSTRUMENT MAINTENANCE IN
SOFTWARE SIDE.
Ans. maintenance in software side is about the DCS backup of history data,
erdb file eye
Q36. WHAT IS THE STANDARD CONTROLL PRESSURE
Ans.3 to 15 psi.
Q37. HOW CAN CHECK THE LOOPCHECKING FOR VALVES?
Ans. Control valve loop check means we have to identify open
Loop or closed loop, if its closed loop we have to simulate
From primary instruments up to final control element we need
To check, if it’s in open loop we can stroke check from
Control desk.
Q38. WHICH INSTRUMENT USED TO CALIBRATE CONTROL VALVE?
Ans. We can use the 4-20ma source for calibration of the electro
Pneumatic valves.
Q39. WHAT IS THE BASIC PRINCIPLE OF VIBRATION MEASUREMENT BY
BENTLY NEVADA VIBRATION MEASUREMENT SYSTEM? AND WHY IT
GIVES THE -VE VOLTAGE OUTPUT?
Ans. First, the question of negative voltage. The short answer
Is that when Don Bentley worked on making solid-state
Versions of the eddy-current measurement system (it was
Actually originally designed in the 1930s by Ge engineers
Using vacuum tubes), he had a choice between using n-p-n
Transistors or p-n-p transistors. At the time, transistors
Were quite expensive, so he chose the least expensive of
The two: p-n-p (apparently, PNP transistors they were less
Expensive to manufacture 50 years ago than their NPN
Counterparts).
Because the circuits used PNP transistors, a negative bias
Voltage was required rather than a positive bias voltage.
Don chose -18v. This was later changed to -24v to allow
More linear range from the transducer.
At that time, the industrial instrumentation community had
Not yet standardized on +24 VDC and by the time they did,
There were so many Bentley Nevada eddy current vibration
Sensors installed that changing to +24v rather than -24v
Was not greeting with enthusiasm by users. Hence, it has
Remained -24v to this day.
This was not a deliberate effort to "be different" or "non-
Conformist" on the part of Bentley Nevada. It was quite
Literally based on which components were the least
Expensive when the technology was originally introduced 50-
Plus years ago.
Now, the question of how an eddy-current proximity probe
Works:
An eddy-current probe works by passing an alternating
Current through a coil of wire and measuring the coils
Impedance. This impedance changes when the probe is brought
Near an electrically conductive material and the impedance
Change is proportional to the physical gap between the coils
And the conductive target. The sensing electronics in turn
Convert this impedance change to a voltage, providing an
Electrical output directly proportional to physical gap.
The above is an excerpt from a recent article in our orbit
Technical journal. You can read the full-length article
Here:
Http://www.gepower.com/prod_serv/products/oc/en/orbit/downlo
Ads/1q09_prox_probes.pdf
Here are some other articles that may also prove helpful in
Understanding how proximity probes work in actual machinery
Vibration/position measurement applications:
Http://www.gepower.com/prod_serv/products/oc/en/orbit/downlo
Ads/1q01sabin3.pdf
Http://www.gepower.com/prod_serv/products/oc/en/orbit/downlo
Ads/1293jordan.pdf
Finally, i am including a link to a datasheet for our 8mm
Proximity probe system. Although it does not go into a lot
Of detail on principles of operation, you may find some
Useful information therein.
Should you have additional questions, please contact the
Undersigned.
Q40.WHAT IS TSI? HOW ITS WORK?
Ans. Yes TSI stands for turbine supervisory instrumentation.
But it’s not such a easy thing to understand. Turbine is the
Soul of any power plant. The job of every engineer in any
Thermal plant is to give maximum protection to the turbine.
For that this TSI concept is there.
In order to protect our turbine we use more than 100 sensors
All around the turbine body depending upon the size or the
Capacity of the turbine. These sensors include
Thermocouples, RTD, pressure gauge, pressure transmitter,
Temperature gauge, bi metal thermometer, temperature switch
, pressure switch. But most important thing that we do for
The protection for a turbine is we erect vibration sensor,
Speed sensor, differential expansion (de) sensor, and casing
Expansion detector or sensor (LVDT).
These entire instruments gets the field result and send it to
the TSI. The TSI evaluate all the input from all these
Sensor and control the governing valve and other related
Mechanism for a safe working of turbine.

But before we install all these instrument it is most

Important that all these instrument should be thoroughly
Calibrated and their record b store prior being installed on
The field.
Q41.HOW MANY TYPES 0F THERMOCOUPLES?
Ans. These are the types of thermocouples.
1. K type. (chromyl/alumal) up to 1150c
2. J type. (iron/constantan) up to 1300c
3. R type. (platinum/13%platinium, aradium) up to 1700c
4. S type. (platinum/10%platinium, a radium) up to 1700c
5. B type.
6. E type.
Q.42. WHY WE USE 0.2 TO 1.0 KG/CM2 OUTPUT IN CONTROL VALVE?
Ans. As you know....0.2 to 1 kg/cm2 is equal to 3-15 psig..
Generally we are considering this range...reasons are following...
1) Suppose if you have set lower limit at 0 psig, then how you can differentiate
zero signal level and pipe breakage..!!!! You cannot distinguish two things...That
why we select some elevated range from 0 psig.
2) Our all instrument are producing linear response in the range of 3-15 psig.
3) Pneumatic supply to all instruments is 20 psig..So always there is bleeding of
air from instrument..for standardization purpose all are considering 3-15 psig..
Q.43 HOW TO CALCULATE WAKE FREQUENCY FOR
THERMOWELL???WITH OUT SOFTWARE.
Ans. Wake frequency
Fw = 2.64 x fluid velocity (feet/sec) / dia. Of well tip
(Inch).
Refer to asme ptc 19.3
Q.44 WHAT IS THE CONVERSION FACTOR FOR NM3 TO KG/HR IN AIR
FLOW
Ans.
1nm3 (normal m3) of air is a volume of 1m3 of air under
Normal conditions of pressure (1 atm = 101.330 kpa) and
Temperature (0 deg c = 273 k) (Europe);
Since air can be assumed to behave as an ideal gas under
Those conditions, its compressibility factor is 1; so in
The relation: pv=zmrt; z=1;r for air= 0.287 kpa.m3/(kg.k);
V=1m3; therefore 101.330*1=1*m*0.287*273; so m = 1.295 kg.
Conversion factor: 1 nm3/hr = 1.295 kg/hr
Q.45 WHAT IS DDC-MIS?
Ans. DDC MIS stands for digital distributed control monitoring and information
system. The name itself is self Explanatory. Generally used in power plants
controls and
Instrumentation.
Q.46 WHAT IS THE DIFFERENCE BETWEEN ANALYTICAL INSTRUMENTS
AND
OTHER INSTRUMENTS?
Ans. analytical instruments are those which are used to calculate
The exact proportion in which the various constituents are
Present in a substance. For e.g.: a gas chromatograph can be
Used to calculate the exact quantities in which oxygen,
Co2, nitrogen and other gases are present in air.
Whereas the other instruments are used to measure
The various physical quantities such as pressure,
Temperature, level, flow etc in a process.
Q.47 WHY FLOW TRANSMITTER SHOWING 2.2MA?
Ans. If there is zero error, the output will be minimum peak of
3.1 ma. If it like 2.2ma, the transmitter electronics may
Be problem. Interchange with good transmitter and check.
Q.48 RADIAL & AXIAL VIBRATION SENSOR OUTPUT VOLTAGE IS AC OR
DC VOLT?
Ans. Dc volt
Q.49 WHY CANT WE USE MV INSTEAD OF MA?
Ans. Distance is the main consideration, as distance increases
Voltage drop will be increased where current remains same
Q.50 PLEASE EXPLAIN ABOUT FAT? WHAT IS THE DIFFERENCE
BETWEEN
FAT AND SAT?
Ans. Fat = factory acceptation test
Sat = site acceptation test
When any company going to install new instrument control
System, they have to test how it’s working? In the fat shop
They will do configuration setting for all instrument loops.
According to configuration the system provider will do
Function test by simulating signals.
But during the sat they will check all function with real
Input signals.
Q51. WHAT ARE SINKING AND SOURCING IO CARDS.
Ans. If the power is coming through the I/P or o/p device to
The IO card then that I/O card is called sinking I/O card.
And if the power is transferred from IO card to the I/P and
O/p devices then the I/O card is called sourcing IO card
Q.52 HOW TO DEFINE THE SIZE OF CONTROL VALVE?\
Ans. "CV" for valve is known as: valve sizing coefficient or
Valve flow coefficient
#it refers to “how many gallons per minute can pass
Through a fully open valve under differential pressure of 1
Psi”
CV is a unit less value and by getting its value we can
Get the valve size in inch from tables.
CV is got from calculations using s/w provided by
Manufacturer as we have many parameters affect its value,
And CV value is critical as it affects valve size which
Leads us - if wrong - to oversized valve or undersized
Valve, which harm the process.
CV - as mentioned - is got from calculations using s/w,
But it has a basic formula for gas service and liquid
Service.
#for liquid service:
Q = CV (Dp/Roh)^.5, roh is specific gravity
#for gas service:
Q = 963 cv (dp(p1+p2)/roh*t)^.5, t is gas temperature in Rankin
Q.53, WHAT IS THE MAIN DIFFERENCES BETWEEN GE MARK IV AND
MARK V TURBINE CONTROL SYSTEM? 2. WHAT IS THE MAIN
DIFFERENCES BETWEEN GE MARK V AND MARK VI?
Ans. main difference in between m-iv & m-vi is called the sift
Technology then meaning of this technology is that if there
Is two different alarm in two different processer i.e. x & y
Or x & z the controller (m-iv) will give the trip command
To the turbine but in m-vi controller the same diagnostic
Must be in the both communicator then the controller gives
The trip command to the turbine.
Q.54 : WHAT IS THE DIFFIRENCE BETWEEN EARTH AND NEUTRAL,?
Ans. One more...neutral is not supposed to carry any current or
Voltage.Earth wire will carry current, voltage in case of short Circuit.
Q.55, HOW TO OVERHAUL CONTROL VALVES.WHAT ARE THE PROPER
PROCEDURES.
Ans. It is a very lengthy topic. I will try to explain some major point.
1. Mark the parts orientation before dismantling, such as mark at body, bonnet,
yoke, pressure chambers casing.
2. Note down the threads upper side and lower side of coupling.
3. Suppose, valve is air to open, open it with direct feeding signal to diaphragm
upto 5%.
4. Remove the coupling.
5. Release load pressure
6. Loose yoke nut and remove yoke from bonnet
7. Remove gland packing nuts, remove gland pusher
8. Dismantle bonnet nuts
9. Remove bonnet from body
10. Remove trim material
Q56.WHAT IS DIFF BETWEEN THE CENTRIFUGAL AND
RECIPROCATING?
Ans. In centrifugal, kinetic energy is converted to potential
Energy by rotary motion.
In reciprocating, energy is given to piston for axial
Movement in piston cylinder. Volume equal to piston movement
Is displaced in each stroke of piston
Q.57.WHAT IS PROTOCOL ?
Ans. It’s a set of rules and regulations for communication for both the DCS and
the PLC.
Q.58 WHAT IS THE FORMULA FOR CALCULATING MILLIAMPERE AT
DIFFERENT PRESSURE POINTS FOR EG 4-20 mA = 3-15 PSI BUT IF I
HAVE TO CHECK THE mA AT 4.6 mA?
.ans. As per as nick formula it is not fulfill another range like
As 0-100 for level, 0-14 for ph
Formula is
16*(unknown value-low end of rang)
Ma o/p = 4+ ---------------------------------
transmitter span
Suppose range is 3-15 psi according to question what is the
Psi for 4.6 ma
By the formula
4.6-4 =16*(unknown value-3psi)
----------------------
12 psi
0.6*12psi
--------- = (unknown value-3psi)
16
7.2 psi
------- = (unknown value-3psi)
16
0.45 psi = (unknown value-3psi)

0.45psi+3psi = unknown value psi

3.45 psi = unknown value psi answer

Q59. WHAT IS THE DIFFERENCE BETWEEN INTRINSIC INSTRUMENTS
AND ATEX INSTRUMENTS?
Ans. ATEX means atmosphere explosives. ATEX is European body for
Issuing certification to instruments for their use in Hazardous area/application.
ATEX has specific marking on
Instruments which mentions class, div, temp class, gas class.

Intrinsic safe means it is one type achieving safety for

Using instruments in hazardous application. Electronics in
Instruments is designed in a such way that energy generated
During spark inside is such low so that it will not ignite Explosive gas-air
mixture. All components are low power Feed.
Q.60 WHT IS DCS ARCHITECTURE ? CAN U GIVE EXAMPLE?
Ans. 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.
Q.61 WHAT IS BASIC WORKING PRINCIPLE OF GOVERNER IN POWER
PLANT?
Ans. Auto regulation of steam pressure/flow with respect to
Speed of the turbine.
Q.62 COULD ANYBODY PLS GIVE ANS OF BOILER 3 ELEMENT CONTROL
SYSTEM?
Ans. In boiler drum level control it uses the three elements
Principle wherein it consist of feed water flow, actual drum Level and steam
flow.
In the feed water line there are two flow control valves (37%and 100%). The
37% is being controlled by single element
(single controller). The sp of single controller is the
Actual pressure compensated drum level. If the steam flow
Is more than 30% of its designed max flow, drum level
Control will shift automatically to three elements control
Which is in cascaded mode (two controllers). The output of
Primary controller which is compensated by the steam flow
as feed forward control is being fed to the secondary Controller as set point for
the feed water flow. The output
Of secondary controller is sent to 100% FCV to manipulate
The feed water flow.
Therefore, 3 elements control is to attain that feed water
Flow will be equal to the steam flow
Q.63 WHAT IS SLPC & MLPC? HOW IT WORKS?
Ans. SLPC is single line process controller
MLPC is multi line process controller
Q.64 CAN YOU TELL ME HOW WE WILL SELECT RTD AND
THERMOCOUPLES FOR TEMPERATURE APPLICATIONS. I.E HOW WE
WILL CHOOSE ACCURATE ONE FOR A SPECEFIC OPERATION IF BOTH
HAVING SAME RANGES?
Ans. Both thermocouples and RTD have their specific advantages,
According to our need we have to choose for our purpose am
Explaining below:
1. Thermocouples can measure up to a temp. Of 1700 degree
Celsius, where as RTD’s are limited to 800 degree Celsius
2. Grounded thermocouples are inheriting tip sensitive, While RTD elements
are isolated from their sheaths. A
Grounded thermocouple will respond to a 63% step change in
Temperature nearly 3 times faster than a RTD counterpart.
3. Normally RTD’s are costlier i.e.2.5 or 3 times than
Thermocouples
4. As the case is taken on behalf of accuracy and linearity
RTD shows improve characteristics than thermocouple.
5. due to their linearity and virtually drift free output,
RTD’s are more stable than thermocouples.
Q.65 WHAT IS THE DIFFERENCE BETWEEN RTU & MTU IN SCADA
SYSTEM?
Ans. All the signals from remote field devices (RTU) is terminated to the master
terminal unit (MTU) via appropriate physical medium (wired or wireless). The
field signals such as pump or motor f/b , digital switches or even analog signals
(4-20 ma, 0-10 v etc)are terminated to basic level to RTU .there can be 'n' no.
Of RTU's placed in a system which carries all the field device status to the mtu.
ans2. RTU is remote terminal unit. RTU is the basic component of
SCADA that converts analog signals (either from some level
Sensor, temperature sensor) to digital signals that can be
Accepted at the plc end.
MTU is maximum transmission unit. It is the maximum size of
A data block that can be transmitted through any of
Transmission protocol e.g. Ip protocol.
Q.66 HOW CAN I ZERO CHECK OF WET LEG TYPE DP TX ?
Ans. First isolate hp side of transmitter. And open vent port of hp side, Lp side
fill service liquid up to Lp tapping and set the
Zero.
Q.67 WHAT ARE THE CHARECTERSTICS OF CONTROL VALVE.?
Ans. These are flow patterns.
A. Equal percentage
B. Linear
C. Quick opening

The plug and cage is made in such a way that you can get
Flow any one of above construction.
Suppose, valve cage, plugs are equal percentage, then at
Opening of valve of 30 percent, you may get flow of only 6
To 8%
If linear, then flow also 30%,
If quick opening, then flow almost double, about 60%,
It all depends upon process requirements.
Suppose for vent valve, usually quick opening type valves
Are used
Q68. HOW TO CALIBRATE A CAPILLARY TYPE LEVEL TRANSMITTER
FOR A CLOSED TANK IN FIELD? ALSO WHAT IS THE PROCEDURE FOR
COMMISSIONING A CAPILLARY LEVEL TRANSMITTER FOR A CLOSED
TANK?
Ans. There are two methods: 1. Workshop calibration, 2. Field
Calibration.
Suppose you installed transmitter at vessel and want to
Calibrate it. Follow following field procedure:
1. Close process side valves of both upper and lower
Flanges.
2. Lose upper remote seal from process flange, it should
Not get any pressure from process.
3. Remove lower side transmitter flange from process side
Flange. (it will be high side of transmitter)
4. Put your local made calibration flange at transmitter
Remote seal and apply pressure.
(this flange must be same level of vessel flange from where
You removed it)
Suppose transmitter range is 0 to 1000 mm of h2o.
5. Apply this supply to your connected flange and take
Readings at 0, 250, 500, 750, 1000 mm of h2o.
Q.69, WHAT IS BASIC OF INSTRUMENTATION?
Ans. instrumentation is the science and art of using instruments
In a control system for the purpose of monitoring and
Control of the process variables such as flow, temperature,
Level, pressure and so forth..
Q.70 : WHY WE USED CAGE IN CONTROL VALVE?
Ans. The walls of the cage contain openings that usually
Determine the flow characteristic of the control valve.
But add one thing more, Cage also controls cavitations and flashing, it routes
flow at different angles to avoid flashing and cavitations.
Q.71 GENERALLY TRANSMITTER POWER SUPPLY HAVING SOME
RANGE(12V TO 35V) BUT THE OUT PUT(4-20 MA) MUST SAME FOR
GIVEN INPUT.IF WE VARY THE POWER SUPPLY VOLTAGE THEN
OUTPUT MA ALSO TO BE CHANGE ACCORDING TO V=IR. IS THERE ANY
VOLTAGE REGULATOR IN THE TRANSMITTER ?
Ans. My point of view is

-->12V to 35V is given as Power supply, this is given

because to switch on the transmitter

-->4 to 20mA is produced depends upon the pressure and flow

applied on the transmitter and it is given to the
microprocessor and it convert it into mA

-->Then the 4 to 20mA is converted into 1 to 5V using 250

Ohm Resistance and is given to DCS.

-->The main thing for using mA is, there won't be any

wastage in Current, but if you use V,there will be voltage
drop due to cables.
Q.72 WHAT IS THE DIFFERENCE BETWEEN HMI,SCADA AND MMI,NOT
ABBREVATION?
Ans. HMI and MMI are same, Graphical units. You can say,
Hardware which can give view of system's process. One can
input data from it as well.
Now a days we can have PLC's which have graphical units but
usually process related decision making is not work of
GU, they are only done through if operator decides something.

In case of SCADA we can have all decision making and

Graphic display through it. Hence in that case you can
operate your plant through SCADA or can integrate number of
PLC and HMI in single SCADA to operate from main control
room as supervisory unit.
Q.73 DIFFERENCE BETWEEN TRANSDUCER AND CONVERTER IN
INSTRUMENTATION?
Ans. Well, transducer convert the physical parameter like
PRESSURE,LEVEL,TEMPERATURE & FLOW etc, to an electrical
signal that can be used for the purpose of monitoring or
control further signal conditioning is required.

converter in process drawing & P&ID drawing we refer to it

as I/P OR P/I converter current to pressure or pressure to Current. More or less
converter & transducer sound the same.
Q.74 WHAT IS HYSTERESIS MEAN IN INSTRUMENT?
Ans. The delay between the action and reaction of a measuring
instrument.
Q.75 HOW THE TRANSMITTER SEND MA?
Ans. A 2 wire transmitter never send mA. It acts as load to the
24VDC supply from Analog Input module. Assume Transmitter as
a rheostat with resistance change based on process
parameter changes.
Q.76 WHAT ARE THE INPUTS (DRAWINGS) WE NEED TO PREPARE LOOP
SCHEMATICS??
Ans. starting from your control desk terminal --- i/o details in
i/o cards of your DCS or PLC ---terminal block details of i/o
rack cabinet----any marshalling cabinets in between that
terminal details---any interface in power room ie.. like
motor control panels---- then field junction box terminal
details---- then final field devices like txr or valve or
motor terminal details. Then you can finish your loop
drawing joining control room /i/o cabinet/marshalling
cabinet/ power interface room if exists/field jn box/field
device terminal.
Q.77 WHY THE DERIVATIVE IN PID IS ALWAYS SET TO ZERO?
Ans. Derivative gain is used to take the preventive action in
control. i.e. it gives the corrective action for future
based on the nature of present error. And Derivative action
is used to fast the process.
Due to this property of Derivative gain, the process may
become fast and unstable. To avoid this, generally
Derivative gain is kept as minimum as possible i.e. zero.
Q.78 DESCRIBE YOURSELF?
Ans. My name is Vishal Patel. I am from surat.i am instrument technician.
I have 10 years experience in instrumentation field. I have well
Knowledge in calibration, troubleshooting and maintenance of various types of
SMART and NON SMART instruments. And I have
Very good knowledge of loop checking and commissioning had
Just complete.
Project of poly ethylene and normal alpha olefins plant in
Q chem. II Qatar with technimont Italy. also I had worked in Saudi
Arabia, Bahrain, Abu Dhabi.
In India I had worked in reliance, essar,ongc and gujarat electric
board.
I am familiar with DCS PLC and foundation field bus systems
Q.79 WHICH IS TYPE OF THERMOCOUPLE IS USED TO MEASURE
1000DEG?
Ans. If you are looking to measure temperature ranging from 1000
C to 1500 C, type R & S are more suitable..Type K are
suitable in the range of 600 C to 1200 C.
Q.80 WHAT CMMS STANDS FOR?
Ans. Computerized Maintenance Management System.

Q.81 WHAT IS CAVITATIONS?

Ans.Cavitation is defined as the phenomenon of formation of Vapor bubbles of
a flowing liquid in a region where the
Pressure of the liquid falls below its vapor pressure
Q.82 WHAT IS THE PRINCIPAL OF FLOW TRANSMETER, LEVEL TRANS
METER,PRESSER TRANSMETER?
ANS. Basically TRANSMITTER is a device which transmits the
Signal based on its input signal. There is a difference
Between the excitation signal and input signals. The
Excitation signal may be air signal(less than or equal to
15 PSI)known as pneumatic transmitter OR electrical signal
(+24V DC or 110 V AC) known as electronic transmitter. Then
the output signal will be 3 to 15 PSI for pneumatic
transmitter and 4 to 20 mA for electronic transmitter.
Then the input given to the transmitters may be of FLOW or
LEVEL or PRESSURE. Based on this input given to
transmitter, it produces a output according to process input.
STEP I: [LEVEL MEASUREMENT]
The level sensor may of any type (eg:air purging system)
which measures the leves with the appication of ~20 PSI
inlet pressure,because of back pressure the output air
pressure taken back and given to the transmitter,it
produces 4 to 20 mA or 3 to 15 PSI based on the natuire of
transmitter given to the control room.
STEP II: [PRESSURE MEASUREMENT]
The same procedure for each ,transmitter just measures the
process variables ans produces the output based on the
application of process inputs.
FINALLY TRANSMITTERS ARE SAME BUT THE INPUT,EXCITATION
AND OUTPUT SIGNALS MAY VARIED.
OR
transmitter is a signal conditioning element in the loop
itmeans it provides a signal which is standrad and suitable
for controller like DCS or PLC.For example megnetic flow tx
inputs induced mv signal from element(sensor) and gives 4-
20ma output depends upon the range of flow.No a days
transmiitter used are smart tranmitter wich is programed to
convert input signal to standard electrical signl.
Tansmitter type varies depending upon input signal from
sensor.
Q.83 HOW CONTROL VALVE WORKS? Ans.
control valve opens or closes fully or partially by
receiving the signal from controller that compare set
point to process variable whose value is provided by the
sensors.
Q.84 WHY TWO PROBES ARE USED IN TURBINE FLOW METERS?
Ans. Two probes are used to have a counter check on pulse
failure and to ensure pulse intregrity.Means if one probes
misses some pulses you can get an alarm or error message on
that.
Q.85 HOW TO MEASURE HIGH FREQUENCY USING THERMISTOR
Ans. thermistor is basically a temp measuring device.
At 25deg it is having a resistance value typically of 60k.
If we are placing thermistor in ac or in dc bridges then
The resonant frequency depends on the the value of
resistance. it is a useful measure for measuring high
frequency
Q.86 WHAT IS THE DIFFRENCE BETWEEN PLC&DCS?
Ans. simply plc is a controller we can control analog and digital
i/o s but i/0 limit is there in plcs.dcs is nothing but
networking of plcs.EX
plc1+plc2+smart instruments+mc baesd instruments all are
controlled by dcs at a time .ic has redundancy also
Q.87 WHAT ARE THE PROGRAMMING LANGUAGES USED IN DCS?
Ans. ladder logic, statement list, functional block,and atill
more two is there ...
Q.88 WHAT IS THE EQUATION FOR GAS FLOWMETERING? WHIC
INCLUDES GAS FLOW, PRESSURE, AND TEMPERATURE?
Ans. PV=nRT
Q.89 WHICH TYPE SIGNAL IN & OUT IN DCS?
Ans. In DCS 4 TYPES OF SIGNAL IS USED

1) AI - ANALOG INPUT THIS FEED BACK SIGNAL FORM (4 - 20 mA)

2) AO - ANALOG OUTPUT COMMAND GIVEN FROM DCS (4 - 20 mA)
3) DI - DIGITAL INPUT (FEED BACK 0 OR 1, HIGH OR LOW)
4) DO - DIGITAL OUTPUT (PICK UP THE RELAY 0 OR 1, HIGH OR
LOW COMMAND GIVEN FROM DCS)
Q.90 WHAT IS DIFF BETWEEN THE MOTOR AND PUMP?
Ans. Motor : Driver (Provides source of mechanical motion to
driven)
Pump : Driven (Receives the source from driver to pump out
the substance) OR
Motor is a electrical device which converts electrical
energy into mechanical energy and pump is mechanical device
which converts mechanical energy into work to be done.
Pump is driven by motor only.
Q.91 WHAT IS DIFFRENCE BETWEEN TRANSDUCER AND
TRANSMITTER?
Ans. Transducer:It is a device which converts one form energy
(physical quantity) to another form of energy(normally
electrical quantity).
Transmitter:It is a device which converts the sensor output
into a form suitable for transmission over a large distance.
Q.92 HOW TO CHECK THERMOCOUPLE ,ITS WORKING OR NOT?
Ans. check physicall condition.
Then check the resistance of therocouple.
if it is open theremocouple is dead.
if it showing some ohms nearer to Zero. Then it is ok.
Then heat the thermocouple check the mv & verify with the
standard chart.
Q.93 WHAT IS THE EXPANSION OF RADAR? HOW IT WORKS?
Ans. RADAR means RAdio Detection And Ranging. The RADAR sysytem
has a receiver emits either radio or microwaves that are
refelected by the target and detected by the receiver which
will be placed in the same location as transmitter.Distance
is measured by the time it takes the pulse to travel to and
from the target.Knowing the frequency the wave length is
determined by dividing the frequency in MHz into give the
wave length in meters. Radar is used in marine industries
and military application.
Q.94 WHAT IS THE DIFFERENCE BETWEEN RADAR AND ULTRASONIC
LEVEL TRANSMITTER? WHICH METHOD IS BEST AND MORE
ACCURATE?
Ans. Radar is based on Microwave and detects the change in
dielectric constant where as Ultrasonic is based on Sound
Wave at high frequency (Ultrasonic Wave) and detects change
in density of medium. Based on performance and accuracy
Radar is a better solution than Ultrasonic. However for
lower range liquid application ultrasonic is a cost
effective solution.
Q.95 WHAT DO YOU MEAN BY LOOP IN C?
Ans. declaration is performed until the condition gets satisfied.
Q.96 WHAT IS THE DIFFERENCE BETWEEN E/P POSITIONER AND I/P
POSITIONER IN A CONTROL VALVE? IN WHICH APPLICATIONS THE
RESPECTIVE POSITIONERS ARE USED IN?
Ans. I/p convertors converts a current input signal for eg. 4-20
ma to pneumatic siganl which controls the opening and
closing of a control valve and e/p have simmiliar
operations as those of i/p but it can be either a voltage
input based or current input based.
Q.97 WHAT IS ORIFICE?AND HOW WE ARE USING IT IN
INSTRUMENTATION?
Ans. orifice is nothing but a plate having hole at the centre
.when it is placed across a flow line a differential
pressure is created across the orifice due the diff. in the
dia of orifice and pipe line.this diff pressure is directly
proportional to the flow of the liquid.this differential
pressure is given to the differential pressure transmitter.
Q.98 WHY WE USE 4-20 MA TO DO CALIBRATION OF THE
INSTRUMENTS.WHY WE CANT USE 0-20 MA?
Ans. 1) This is called the live zero or elevated zero concept.
It makes us differentiate between the signal failure and
the zero reading of the transmitter. Let's say, LRV=0 mA
and the instrument cable is cut. How can somebody ascertain
that this is process zero(LRV) and not the cable fault.
whereas if LRV = 4mA and the cable is cut, the current
through the loop would be 0mA and one can find out that
this is the cable fault.

2) its the lowest linear possible range with minimum power

consumption.
Q.99 WHY WE USE 250 OHM RESISTOR IN SERIES WITH HART
PROTOCOL COMMUNICATION?
Ans. Becoz DCS is given the signal in terms of voltage(1 TO 5 V).
And V=IR,
Now Whwn I=4ma
V Should be 1 V
putting in V=IR we get r=250 ohms.
Same in case when I=20 ma
and V=5V WE GET r=250 ohms. OR
Ohms law (V = IR) dictates that a resistor must be present
with current to receive a voltage. Most field devices
transmit HART as +/- 0.5mA imposed on the 4-20mA current
loop. The 4-20mA is the centerline of the 1mA signal. The
resistance in the loop converts the current to a voltage
which is used as a digital voltage signal. The carrier
detect is 100mV nominally. If there is no voltage, there is
no carrier, and therefore no communications.

Frequency Shift Key modulation is used to transmit the

digital HART data via the current loop. FSK allows two
separate frequencies to represent digital data. 2,200 Hz for
binary 0 and 1,200 Hz for binary 1
Q.100 WHERE IS A LEVEL DISPLACER IS USED?
Ans. Displacer type level transmitter is used in interface level
Measurement and closed tank level measurement. It is
Working under weight loss, the Archimedes principle.
Q.101 WHAT IS DEAD WEIGHT TESTER AND WHERE IT IS USED?.
Ans. Dead weight tester used for pressure gauge, pressure
Transmitter, pressure switch calibration in high range.
(Kg\cm2or bar). it is used for industrial purpose in
Instrumentation department.
Q.102 WHAT IS THE DIFFERENCE BETWEEN SCADA AND DCS?
Ans. DCS- means Distributed Control systemm.This is mainly
Process oriented system. If we ask the feedback from the
System, it will give from the I/O field. This is a independent
Control system.

SCADA-means supervisory control and data acquisition

System. This is basically a data gathering system and given
The control based on that datas. This system will depends
PLC or DCS for its control.
Q.103 WHAT IS MEANT BY CALIBRATION?
Ans. in calibration primary standard is compared with another
Working standard
Q.104 WHY WE ARE USING MARSHALLING PANEL? WHAT IS THE
ROLE?
Ans. Marshalling panels are used as interface between field
Junction box & DCS control panel..

It also isolates the DCS panel from field control panel..

Q.105 WHAT IS THE BASIC WORKING PRINCIPLE OF I/P AND
POSITIONER IN ANY CONTROL VALVE?
Ans. I/P is basically working on the flapper and nozzle
Principle. And the positioners is working on the Forced
Balance principle.
Q.106 WHAT IS MEAN BY LOOP CHECKING?
Ans. Loop checking means, First we want to check the continuity
Of cable. Then whether 24 V DC or 4 - 20 MA DC is coming
From DCS or JB want to check. That is called loop Checking.
Q.107 EXAMPLE OF DRY CONTACTS & WET CONTACTS?
Ans. Dry contact: it is nothing but without the load voltage
Contact in the loop.
Wet contact: it is nothing but with load voltage contact in
The loop.
Q.108 CAN U GUYS TELL ME WHY WE ARE USING SHEILD IN JUNCTION
BOS WIRING?
Ans. Shield wire is to eliminate the noise pickup in the signal
Wire due to magnetic interference from the near by
Source
Panel or JB side shield to be earthed but Instrument side
No need to do earth (cut the shield and tape).
Q.108 PLEASE EXPLAIN ABOUT FAT? WHAT IS THE DIFFERENCE
BETWEEN FAT AND SAT?
Ans. FAT = Factory acceptation test
SAT = Site acceptation test

When any company going to install new instrument control

System, they have to test how it’s working? In the FAT shop
They will do configuration setting for all instrument loops.
According to configuration the system provider will do
Function test by simulating signals.
but during the SAT they will check all function with real
Input signals.
Q.109 WHAT IS BASIC WORKING PRINCIPLE OF GOVERNER IN POWER
PLANT?
Ans. Auto regulation of steam pressure/flow with respect to
Speed of the turbine.
Q.110 WHAT MASTER PLC DOES?
Ans. Master PLC will control whole the system and send or receive
the information & command from the connected slave id's.
Q.111 WHAT IS "SMART" IN SMART TRANSMITTER?
Ans. Single module auto ranging
Transmitter
Q.112 WHAT IS DIFFERENCE BETWEEN ACCELEROMETER VIBRATION
SENSOR AND PROXIMITY VIBRATION SENSOR?
Ans. Accelerometers are a piezo-electronic (crystal) device. A
Pre- loaded crystal is charged with current and as the
Crystal is compressed or de-compressed by vibration an
Output proportional to g's (gravity) is provided. A "g" is
Equal to 9.80 meters/second2 or one (1) standard earth
Gravity.
Accelerometers are normally used for high-frequency bearing
Cap vibration readings (Case/Bearing Cap Absolute on
Machines using rolling element bearings. Usually the output is integrated
electronically to velocity (in/sec or mm/sec). Other applications include
monitoring Gears and
High Frequency Applications.
Eddy or Proximity Probes are a displacement device that
Measure the relative motion between the probe mounting
Location and the target (shaft). Output is directly
Proportional to displacement and is usually measured in
Mills (.001") or millimeters (mm).
Eddy Probes are used on machines with Journal (Sleeve) type bearings. Where
the measurement of motion between the, Bearing and Shaft is critical.
Q.113 HOW TO CALIBRATE PH METER?
Ans. you can calibrate in three phase 4/7/9 ph buffer solution, normally we are
calibrating with 4 & 9 ph buffer that mean 4ph--4ma/9ph—20
Q.114 WHAT IS THE DIFFERENCE BETWEEN SENSOR AND
TRANDUCERS?
Ans. 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.
Q.115 WHAT IS THE WAY OF MEASURING AIR FLOW IN AIR
DUCT?EXPLAIM INSTRUMENTS USED AND DP CREATION IN LINE?
Ans. There are different formulas for calculating air flow in, duct according to
the duct type, mean a rounded duct or square duct, etc... Using anemometer in
FPM (feet per min.) or CFM (cubic feet per min.)
Q.116 what is the safety integrity levels (SIL)?
Ans. Safety Integrity Level (SIL) is defined as a relative level of risk-reduction
provided by a safety function, or to specify a target level of risk reduction. In
simple terms, SIL is a measurement of performance required for a Safety
Instrumented Function (SIF).
Q.117 WHAT THE DIFFERANT BETWEEN WET LEG / DRY LEG?
Ans. They are differential pressure transmitter "installation
Technique" used in "level measurement"

When installing differential pressure transmitter we attach 2

Impulse lines with high & low transmitter sides, the 1
Attached to low side is empty impulse line so it is "dry
Leg" or it's filled with a sealing liquid with density
Greater than the process liquid so it is "wet leg".

We use "dry leg" for closed pressurized tank.

We use "wet leg" for closed pressurized tank also but if we have the probability
of process liquid condensable vapor which will give a faulty measurement.
If we have an open tank, the Tx low side is atmospheric.
Q.118 WHAT IS THE DIFFERENCE BETWEEN DRY CONTACT AND WET
CONTACT?
Ans. Dry contact is volt free contact. for e.g- relay contacts .Wet Contact is
voltage at the relay contacts.
Q.119 WHAT IS MEANT BY FAIL SAFE CONDITION IN PLC?
Ans. Fail Safe condition means when ever if input main supply fail to plc
processor then on regaining power it takes all its original data from its previous
conditions.
Q.120 HOW DOES WE DO BENCH CALIBRATION OF A DIFFERENTIAL
TRANSMITTER.
Ans. DP transmitter is having range of few w/c. take example of you want to
calibrate 0-50 in h2o dp transmitter. Connect power supply and millimeter to
connection point. Connect small hand pump to high side of DP transmitter.
Keep low side of DP open to atmosphere. First check 4ma when both
connections are open to atmosphere. Then connect hand pump to high side
and give 12.5, 25.0, 37.5 & 50 in h20 and check 8, 12,16,&20 ma o/p.
Q.121 HOW WILL YOU MEASURE SURFACE TEMPERATURE OF SUN?
Ans. by using optical pyrometer
Q.122 WHAT IS DIFFERENCE BETWEEN TWO WIRE &THREE WIRE PT
100?
Ans. Two wire RTD used for short distance like compressor, pump and three
wire RTD used for long distance from field to control room. So outside
atmospheric temp.present so we need compensation resistance. Third wire
used for compensation of lead wire resistance.
Q.123 WHAT IS THE DIFFERENCE BETWEEN CNC AND PLC?
Ans. Plc Means Programmable logic control.
CNC Means computerized numerical control.
CNC used for controlling the movement by numerical value.
Nowadays it widely used in automatic machines like which is to program & do
any operation.
Q.124 WHAT IS NEGATIVE RANGE IN TRANSMETER?
Ans. Negative range of a transmitter is nothing but the range
Required to measure the vacuum of any equipment. If the
Pressure inside a tank or equipment drops below zero and
goes to negative side then it is measured by the
Transmitter. Maximum of 14.7 psi vacuum can be measured at
Ideal conditions. For example a transmitter range is
Calibrated as -600 to +600 mm of water means the
Transmitter will measure negative pressure inside a pipe or column or tank and
give output as 4 MA and at pressure of 600mm(positive )it give 20 MA output.
Q.126 WHY HUNTING WILL OCCOUR IN CONTROL VALVE?
Ans. Control valve is used in close loop control system. If it is hunting , then to
troubleshoot first put loop for few sec in manual mode, still if v/v is hunting then
it is field problem i.e. v/v or I/P converter problem.
If it is not hunting in manual mode, then the problem can
Be either the loop process variable (PV) is hunting or if PV is ok, either the
load/process is varied or loop needs
Tuning.
Q.127 WHAT IS PIEZO ELECTRIC TRANSDUCER? IT’S PRINCIPLE?
Ans. Piezo electric crystal exhibits
Whenever there is dimensional change occurring, voltage is induced inside and
vice versa active tds

Q.128 WHAT IS BOILING POINT AND EFFECT OF HEIGHT ON IT?

Ans. The boiling point decreases with increase in altitude. Boiling point of a
liquid is defined as the temperature at which the vapour pressure of the liquid
equals the outside pressure. At this point the liquid vapourises. Since
atmospheric pressure decreases with increase in altitude, the temperature at
which the vapour pressure of the liquid becomes equal to the outside pressure
decreases.
Q.129 EXPLAIN THE WORKING OF AN ELECTRONIC LEVEL TROLL.
Ans The variation in level of 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. The resulting torque tube movement varies the angular
motion of the rotor in RVDT providing a rotor change proportional to the rotor
displacement, which is converted and amplified to a D.C. current. Q.130
Explain Bernoulli’s theorem. State its application. Ans.
Bernoulli’s theorem states that the ‘total energy of a liquid flowing from one
point to another remains constant’. It is applicable for non-compressible liquids.
For different types of liquid flow Bernoulli’s equation changes. There is direct
proportion between speed of fluid and its dynamic pressure and its kinetic
energy. It can be used in various real life situations like measuring pressure on
aircraft wing and calibrating the airspeed indicator. It can also be used to low
pressure in the venturi tubes present in carburetor.
Q.131 What are the automatic controller MODES?
Ans. Following are the mode of control. Ratio Control, PID Control, PI Control,
ON/OFF Control, Cascade Control, Override Control, Feedback Control, Feed
Froward Control. These control are can be set in to MAN and AUTO Mode, If
this in MANUAL the mode of control is disable, If this is in AUTO the mode of
control is enable.
Q.132 Why thermo wells are used? What materials are used in thermo
wells?
Ans. In numerous applications, it is neither desirable nor practical to expose a
temperature sensor directly to a material. Wells are therefore used to protect
against damage corresion, arosion, aborsion and high pressure processes. A
thermo well is also useful in protecting a sensor from physical damage during
handling and normal operations. Materials used in thermo wells: Stainless steel,
Inconel, Monel, Alloy Steel, Hastelloy…
Q.133 Explain working principle of lvdt?
Ans. When an AC excitation signal is applied to the Primary Coil (P), voltages
are induced in the two Secondary Coils (S). The MAGNETIC CORE inside the
COIL WINDING ASSEMBLY provides the magnetic flux path linking the Primary
and secondary Coils.Since the two voltages are of opposite polarity, the
Secondary Coils are connected series opposing in the center, or Null Position.
The output voltages are equal and opposite in polarity and, therefore, the output
voltage is zero. The Null Position of an LVDT is extremely stable and
repeatable. When the MAGNETIC CORE is displaced rom the Null Position, an
electromagnetic imbalance occurs. This imbalance generates a differential AC
output voltage across the Secondary Coils which is linearly proportional to the
direction and magnitude of the displacement. As shown in the figure, when the
MAGNETIC CORE is moved from the Null Position, the induced voltage in the
Secondary Coil, toward which the Core is moved, increases while the induced
voltage in the opposite Secondary Coil decreases. LVDTs possess the inherent
ruggedness and durability of a transformer and truly provide infinite resolution in
all types of environments. As a result of the superior reliability and accuracy of
LVDTs, they are the ideal choice for linear motion control.
Q.134 Explain the working of Rota meter.
Ans. 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
rota meter consists of a vertical tapered tube through which the metered fluid
flows in upward direction. As the flow varies the ‘float’ rises or falls to vary the
area of the passages that the differential across it balances the gravitational
force on the ‘float’. The differential pressure is maintained constant. The
position of the ‘float’ is the measure of the rate of flow.
Q.135 Define all the process variable and state their unit of measurement?
Ans. Flow: Any fluids or liquids flowing from one place to another place is called
flow and it is defined as volume per unit of time at specified temperature
and pressure conditions, is generally measured by positive-displacement or rate
meters.
Units: Kg / hr, litter / min, gallon / min,
Pressure: Force acting per unit Area. P = F/A
Units: Bar, Pascal. (gases)
Level: The height of the water column, liquid and powder etc., at the desired
measurement of height between minimum level points to maximum level point
is called level. The measurement principle is, head pressure method.
Units: Meters, mm, cm, percentage.
Temperature: It is the degree of hotness or coldness of a body is call
temperature.
Units: Degree Centigrade, Degree Fahrenheit, Degree Kelvin, Degree Rankin.
Quality: It deals with analysis. (PH, Conductivity, Viscosity)Q.136 Explain the
working of Rota meter. Ans: 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 rota
meter consists of a vertical tapered tube through which the metered fluid flows
in upward direction. As the flow varies the ‘float’ rises or falls to vary the area of
the passages that the differential across it balances the gravitational force on
the ‘float’. The differential pressure is maintained constant. The position of the
‘float’ is the measure of the rate of flow.
Q.137 What is the working principle of the magnetic meter?
Ans. 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 consist of straight cylindrical
electrically insulated tube with a pair of electrodes nearly flush with the tube
walls and located at opposite end of a tube diameter. This device is limited to
electrically conducting liquids. The magnetic meter is particularly suited to
measurement of slurries and dirty fluids.
Q.138
❑ Which filling fluid is used in impulse line at the service of crude oil?
(Water, Thinner, Glycol, Diesel)

❑ Which action of controller eliminates offset error?

(KP, KI, KD)

❑ Which type of flow element will use at the service containing tinny particles?
(Venturi, Flow Nozzle, Turbine Flow meter, Orifice)

❑ The reading of measuring instrument is different from the actual process variable,
what type of error it will be?
(Zero Error, Hystersis Error, Span Error, Instrument Error)

❑ Optical Fibre describes as?

(Explosion Proof, High Accuracy, Immunity to radio interface, all of them)

❑ What is the color of –ve Lead of K- Type Thermocouples in British System?

Blue

❑ A Bubbler method have a purge point located at the bottom of the tank. If it is
open then what is the relation between pressure in purge tube and bottom of
tank?
Purge tube have pressure less than bottom of tank.

❑ If we increase the pneumatic signal and valve stem lifts up and travels toward
close position, then valve behavior will be?
Air to Close / Reverse acting

❑ Increasing the atmospheric pressure, boiling will be

Increases

❑ Which quantities are enough to take every physical measurement?

Mass, Length and Time
❑ If the hot Junction value lower than the Cold Junction value then the output will
be?
Negative (O/P = HJ – CJ)

❑ Maximum pressure to which a switch or a transmitter or a valve my be exposed

to without suffering any damage is called Proof Pressure.

❑ Passive type speed probe provides sinusoidal frequency.

❑ The output provided by a speed probe is in terms of voltage and frequency.

❑ At higher RPM, speed produces more frequency.

❑ In Vibration we measure
(Average gap from probe tip to target surface, Amplitude and frequency of
vibration, Both)

❑ Flame signal strength from ultra violet scanner increases when flame becomes
more blue.

❑ For control valve seat leakage testing standard test pressure is 45 to 60 psid.

❑ In N Type Thermocouple which of the leg is positive?

(Nickle, Chromium, Silicon)

EXPLAINATIONS

❑ Antisurge Loop of Compressor and explanation with calculation

❑ Basic structure of Mark-V and description of each controller

❑ Description of “Interface Level Measurement”

❑ Bently Nevada Monitor calibration procedure with the help of TK-3.

❑ Block Diagram of interlocking between DCS and PLC.

❑ Explaination of Displace Level Measurement with Calculation

❑ Direct and Reverse actions of Control Valve

❑ what is the supply voltage and frequency of the LVDTs of GCV and SRV?
❑ BMS share the operation during normal operations, Yes Or No?

❑ What is the difference B/W PLC-5/20 and PLC-5/40?

❑ How many networks involves in Mark V?

DENET (Data Exchange Network), IONET (IO Network), Stage Link, BUNET (BOI
Network)

❑ If one speed pickup has failed in gas turbine, Turbine could be start OR not?
Yes, because of TMR

❑ Briefly description of all cores of Mark V?

❑ At startup of gas turbine, where we need AC power supply?

❑ Describe the signals of <P> core?

❑ Boiler start up sequence?

❑ Boiler’s permissive?

❑ Three-element loop?

❑ CTU’s functions in DCS?

Termination and Conditioning of Analog and Digital Inputs & Outputs.
Converts Field Signal to 1 ~ 5 VDC as required by Slave Modules.

❑ What is proximeter, their excitation frequency for probe?

It is a Oscillator and Demodulator. Excitation Frequency for Probe is 1.5
MHz.

❑ Lay out of Bently Nevada cabnite, and description of system monitor?

Power Input Module ---- System Monitor ----- Vibration / Thrust /
Temperature Monitor etc (any combination)
System Monitor Provides Key Phasor output (KΦ inputs at Power Input
Module) at front panel to external devices, Lower and Rising Keys for
adjustment of Alert and Danger Set points, Alarm Reset Key, Indication for
Supplies Ok and Trip Multiply

❑ How much Key phaser could be install at one system monitor?

Four in 3300 System. One in 7200 System.
❑ A process has change from smooth to deviate condition, You have assigned at
this Job, How U will start your job, Stepping?

❑ If <C> core has failed and we wants to start turbine with BOI. Can we get startup
OR not?
Yes, because BOI will connect via BUNET

❑ If we have 14 inch length of Displacer, what is the maximum travel at 100% of

level?

❑ Write down the three calibration methods of Displacer type LT?

❑ The name of signal originated by the Mark V to servo is?

❑ How many cores are in Mark V?

Eleven (<R>, <S>, <T>, <C>, <CD>, <QD1>, <QD2>, <P>, <PD>, <D>, <CD>)

❑ What are the main functions of <PD> core?

Power Distribution Core provides DC Power for Cores and Cards, AC
Power for Ignition Transformer, Auxiliary components for “Special”
contact outputs.

❑ Pressure conversions?

❑ Temperature conversions?

❑ Function of Key-phasor?

❑ An alarm originated by the Mark V system. How U will trace back at droops?

❑ In the Controller tuning activity, which action of the controller will be first tuned,
Proportional, Reset OR rate?

❑ A cascade controller need to tune, and tuning activity will be done at master,
what will be the mode of slave, Auto OR Manual?

❑ What are the names of “Trim Parts”?

❑ If NPM and NIS cards has failed in DCS Bailey INFI-90, Plant will goes to trip OR
remain in Operation?
Plant will remain be in operation but no monitoring will be in this case as
PCU is isolated from Infinet.
❑ Two standard signals in mA? (4-20 mA and 0-20 mA).

❑ Which type of Actuator has more Power? (1: Diaphragm type, 2: Piston type, 3:
Motor operated type)?

❑ What is the difference between RS-232C and RS-485?

❑ What is the back plane process when you click any link in the web browser, how
you access the information?

❑ Explain the digital mode of smart series transmitters, How these will configure?

❑ Does any smart transmitter can work as a node on loop, in digital configuration?

❑ In digital mode of operation, all transmitters will connected in series at a single

cable, this is huge risk that breakup of cable from any where can cause failure
of all chain of transmitters, How you eliminates this risk?

❑ What are protocols?

❑ Explain OSI models layer by layer?

❑ Draw a line which having water service, pickup the tap connection for pressure
measurement, and why we get tap from pointed location?

❑ If we adjust the Pressure transmitter, 10 meter below the water line, what will be
the compensation pressure?

❑ Draw a line which having Gas service, pickup the tap connection for pressure
measurement, and why we get tap from pointed location?

❑ Draw a line which having water service, pickup the tap connection for flow
measurement?

❑ If we adjust the flow transmitter, 10 meter below the water line, what will be the
compensation pressure, if we are using Orifice as a DP creator device?

❑ If we have received complain and now you have required to isolate the
transmitter, how you perform this task?
❑ Why it is necessary to follow the Isolation procedure, if we bypass these
procedures, what will happen?

❑ How we linearize the output of flow transmitter?

❑ Why we apply square root in flow calculation?

To linearize the output of flow transmitter

❑ What is Bernoulli’s effect?

❑ If you have received complain from operation department regarding the Flow
transmitter, what will be your steps to diagnose the problem?

❑ What is the working principle of vibration probe of Bentley Nevada?

❑ Why we use two vibrations probes at radial directions instead of one?

❑ What is the angle between both of them and explain?

❑ Both probes are functioning individually or making average for collective output?

❑ What are the usual set points for alarm and trip in FJFC for radial position?

❑ What is the term TMR in gas turbine?

Triple Modular Redundancy

❑ What is NOX?

❑ Why we use reduction process of NOX, what will be the effect, if we loose it?

❑ What is the working principle of seismic probe?

❑ What are the tripping and alarming criteria on gas turbine regarding Bentley and
seismic probes?
❑ What is the mounting location of seismic probes on turbine?

❑ What is the usual set point of seismic probe for tripping on turbine?

❑ With the help of seismic probes, we are taking vibration of, Casing or Rotor?

❑ Draw the main control loops of boiler?

❑ Explain the Attemprator loop?

❑ Board man reported that flow of de-super heater are gone increased than normal
values, How you diagnose this problem, define your steps?

❑ Explanation of pressure control strategy at final steam header location?

❑ What will happen, if steam drum level decreases and increases?

❑ Decrease of drum level can cause to melt or damage the tubes of boiler, Explain
How?

❑ What principled analyzer is being used to determine the percentage of oxygen in

exhaust flue gases of boiler?

❑ What are ON/OFF specs sheets?

❑ HSE and PTW stands for?

Health Safety and Environment :: Permit To Work

❑ OSHA stands for?

Occupational Safety and Health Association

❑ Draw the Infi loop from field to system and vise versa?

❑ If an error occurs between MFP and INFINET link, what will be its effect on field
control?
Monitoring will lose while no effect on field controlling.

❑ What are the designing logics designated for Hima and Allen Bradley PLCs?
❑ Draw Infi loops (temperature & pressure complete loops).
❑ What is I/O expender bus, control way physically?

❑ Describe each module of Infi loop.

❑ Difference between FBS & ASI.

❑ Temperature compensation at C70.

❑ Can we install direct termination at slave card?

No, not possible

❑ Why we use C70.

❑ Exception reporting.

❑ What is OIS for?

❑ Thrust adjustment.

❑ If vibration occurs, what steps will you take?

❑ Voltage against per mill.

❑ How many mills per volt?

❑ How many relays use in Bentley? one or more for each monitor?

❑ Bypass activity for alert or danger.

❑ How to change set point?

❑ Lay out of vibration panel.

❑ How many checks against high vibration?

❑ Trip relays (danger and alert relay) are common or different?

❑ Scale of monitor.

❑ What are the voltages to be adjust?

❑ Complete startup of GT. (cross-questioning).

❑ At what speed excitation occurred?

❑ What happened at 95% speed?

❑ At which speed DG disengaged?

❑ LVDT supply voltage + out put voltage.

❑ Why we use two LVDT?

❑ Fuel supply drawing (p&id)

❑ What is SRV?

❑ Igniter supply voltage + scanner supply

❑ Scanner principle

❑ How many combustion chambers?

❑ Jaw clutch principle (disengage)

❑ What is hydraulic pressure?

❑ Exhaust speed

❑ MARK V component layout and description of each component.

❑ What signals are in <P> core?

❑ How many protective processors?

❑ Communication protocols + their speed

❑ Components of PLC (AB)

❑ What is hardware configuration?

❑ Dry leg /wet leg principal, use, and their calculation

❑ Why we use capacity bottle instead of TEC?

❑ Gland packing

❑ Why we use positioner (advantages)?

Overcoming Hysteresis Losses

❑ If a value is stacked at 30% signal from I/p is 50% what will be the output of
positioner?

❑ Flow calculation against delta pressure and mA against each present of flow after
square root
P = 25% 50% 75% 100%
Flow = 50 75 82.83 100
MA = 8 12 16 20

• Measured P
▪ Q= ----------------- * Max Flow
• Max. P

▪ Measured value / Total value * 16 + 4 = mA

❑ What are the common errors of PI?

❑ What are the common errors of Ti`s?

❑ What is suitable methods to check Ti`s in area?

❑ What is suppression & elevation?

❑ Calculation of given level with wet leg

❑ What is difference of displacer and float?

Float moves upward with an increase in level and it will always at the top
of liquid surface. While Displacer losses its weight with liquid level
according to Archimedes law.

❑ Calculation of level with displacer

❑ What is mA against given % P?

❑ Function of Mag flow.

❑ Can we use thermocouple at CTU against Tts input at same CTU?

❑ Thermocouple function? Calculation of mV and temperature?

❑ Function of RTDs

❑ Bubbler method?

❑ What are Cv & Kv?

Cv & Kv are Flow coefficients. (Cv in Matric System, Kv in British system).
It is defined as the numbers of gallons per minute of water at room
temperature which will pass through a given flow restriction with a pressure
drop of 1 psi.

❑ If 2-inch valve one is single plug and other is double seated, in which there will
be maximum flow?
❑ Type of valves according to actuator.

❑ Type of valves according to body.

❑ What are trim parts?

❑ What is cage? Function and types of cage?

❑ What are main functions of positioner?

❑ What is PID?

❑ Function of proportional.

❑ Why and where we use piston operated valves?

❑ Why we use double seated valves and where it used?

❑ What are equal percentage, quick opening and linear?

These are Flow Characteristics of Valves (% Flow against % Stem Travel)

❑ What define equal percentage, quick opening and linear?

❑ Why 4 to 20 mA are used?

To differentiate between Zero and No signal (Live Zero Concept).

❑ How pH analyzer is works? It’s electrode construction?

 Questions & Answers on Turbines
What is a stage in a steam turbine?
In an impulse turbine, the stage is a set of moving blades behind the nozzle. In
a reaction turbine, each row of blades is called a "stage." A single Curtis stage
may consist of two or more rows of moving blades.

What is a diaphragm?
Partitions between pressure stages in a turbine's casing are called diaphragms.
They hold the vane-shaped nozzles and seals between the stages. Usually
labyrinth-type seals are used. One-half of the diaphragm is fitted into the top of
the casing, the other half into the bottom.

What is a radial-flow turbine?

In a radial-flow turbine, steam flows outward from the shaft to the casing. The
unit is usually a reaction unit, having both fixed and moving blades. They are
used for special jobs and are more common to European manufacturers, such
as Sta-Laval (now ABB).

What are four types of turbine seals?

1. Carbon rings fitted in segments around the shaft and held together by garter or
retainer springs.
2. Labyrinth mated with shaft serration’s or shaft seal strips.
3. Water seals where a shaft runner acts as a pump to create a ring of water around
the shaft. Use only treated water to avoid shaft pitting.
4. Stuffing box using woven or soft packing rings that are compressed with a gland to
prevent leakage along the shaft.

In which turbine is tip leakage a problem?

Tip leakage is a problem in reaction turbines. Here, each vane forms a nozzle;
steam must flow through the moving nozzle to the fixed nozzle. Steam escaping
across the tips of the blades represents a loss of work. Therefore, tip seals are
used prevent this.

What are two types of clearance in a turbine?

Radial - clearance at the tips of the rotor and casing.
Axial - the fore-and-aft clearance, at the sides of the rotor and the casing.

What are four types of thrust hearings?

Babbitt-faced collar bearings.
Tilting pivotal pads.
Tapered land bearings.
Rolling-contact (roller or ball) bearings.

What is the function of a thrust bearing?

Thrust bearings keep the rotor in its correct axial position.

What is a balance piston?

Reaction turbines have axial thrust because pressure on the entering side is
greater than pressure on the leaving side of each stage. To counteract this
force, steam is admitted to a dummy (balance) piston chamber at the low-
pressure end of the rotor. Some designers also use a balance piston on
impulse turbines that have a high thrust. Instead of piston, seal strips are also
used to duplicate a piston's counter force.

Why should a steam or moisture separator be installed in the steam line

next to a steam turbine?
All multistage turbines, low-pressure turbines, and turbines operating at high
pressure with saturated steam should have a moisture separator in order to
prevent rapid blade wear from water erosion.

What are some conditions that may prevent a turbine from developing full
power?
The machine is overloaded.
The initial steam pressure and temperature are not up to design conditions.
The exhaust pressure is too high.
The governor is set too low.
The steam strainer is clogged.
Turbine nozzles are clogged with deposits.
Internal wear on nozzles and blades.

Why is it necessary to open casing drains and drains on the steam line
going to the turbine when a turbine is to be started?
To avoid slugging nozzles and blades inside the turbine with condensate on
start-up; this can break these components from impact. The blades were
designed to handle steam, not water.

What is steam rate as applied to turbo-generators?

The steam rate is the pounds of steam that must be supplied per kilowatt-hour
of generator output at the steam turbine inlet.

What are the two basic types of steam turbines?

Impulse type.
Reaction type.

What is the operating principle of an impulse turbine?

The basic idea of an impulse turbine is that a jet of steam from a fixed nozzle
pushes against the rotor blades and impels them forward. The velocity of the
steam is about twice as fast as the velocity of the blades. Only turbines utilizing
fixed nozzles are classified as impulse turbines.

What is the operating principle of a reaction turbine?

A reaction turbine utilizes a jet of steam that flows from a nozzle on the rotor.
Actually, the steam is directed into the moving blades by fixed blades designed
to expand the steam. The result is a small increase in velocity over that of the
moving blades. These blades form a wall of moving nozzles that further expand
the steam. The steam flow is partially reversed by the moving blades, producing
a reaction on the blades. Since the pressure drop is small across each row of
nozzles (blades), the speed is comparatively low. Therefore, more rows of
moving blades are needed than in an impulse turbine.
What are topping and superposed turbines?
Topping and superposed turbines arc high-pressure, non-condensing units that
can be added to an older, moderate-pressure plant. Topping turbines receive
high-pressure steam from new high-pressure boilers. The exhaust steam of the
new turbine has the same pressure as the old boilers and is used to supply the
old turbines.

What is an extraction turbine?

In an extraction turbine, steam is withdrawn from one or more stages, at one or
more pressures, for heating, plant process, or feedwater heater needs. They
are often called "bleeder turbines."
What is a combination thrust and radial bearing?
This unit has the ends of the babbitt bearing extended radially over the end of
the shell. Collars on the rotor face these thrust pads, and the journal is
supported in the bearing between the thrust collars.

What is a tapered-land thrust bearing?

The babbitt face of a tapered-land thrust bearing has a series of fixed pads
divided by radial slots. The leading edge of each sector is tapered, allowing an
oil wedge to build up and carry the thrust between the collar and pad.

What is important to remember about radial bearings?

A turbine rotor is supported by two radial bearings, one on each end of the
steam cylinder. These bearings must be accurately aligned to maintain the
close clearance between the shaft and the shaft seals, and between the rotor
and the casing. If excessive bearing wear lowers the he rotor, great harm can
be done to the turbine.

How many governors are needed for safe turbine operation? Why?
Two independent governors are needed for safe turbine operation. One is an
overspeed or emergency trip that shuts off the steam at 10 percent above
running speed (maximum speed). The second, or main governor, usually
controls speed at a constant rate; however, many applications have variable
speed control.

How is a flyball governor used with a hydraulic control?

As the turbine speeds up, the weights are moved outward by centrifugal force,
causing linkage to open a pilot valve that admits and releases oil on either side
of a piston or on one side of a spring-loaded piston. The movement of the
piston controls the steam valves.

What is a multi-port governor valve? Why is it used?

In large turbines, a valve controls steam flow to groups of nozzles. The number
of open valves controls the number of nozzles in use according to the load. A
bar-lift or cam arrangement operated by the governor opens and closes these
valves in sequence. Such a device is a multi-port valve. Using nozzles at full
steam pressure is more efficient than throttling the steam.

What is meant by critical speed?

It is the speed at which the machine vibrates most violently. It is due to many
causes, such as imbalance or harmonic vibrations set up by the entire machine.
To minimize damage, the turbine should be hurried through the known critical
speed as rapidly as possible. (Caution, be sure the vibration is caused by
critical speed and not by some other trouble).

How is oil pressure maintained when starting or stopping a medium-sized

turbine?
An auxiliary pump is provided to maintain oil pressure. Some auxiliary pumps
are turned by a hand crank; others are motor-driven. This pump is used when
the integral pump is running too slowly to provide pressure, as when starting or
securing a medium-sized turbine.

Besides lubrication, which are two functions of lubricating oil in some

turbines?
In large units, lube oil cools the bearings by carrying off heat to the oil coolers.
Lube oil in some turbines also acts as a hydraulic fluid to operate the governor
speed-control system.

What is meant by the water rite of a turbine?

What is the difference between partial and full arc admission?

In multi-valve turbine inlets, partial arc ad mission allows the steam to enter per
valve opening in a sequential manner, so as load is increased, more valves
open to admit steam. This can cause uneven heating on the high-pressure
annulus as the valves are individually opened with load increase. In full-arc
admission, all regulating valves open but only at a percentage of their full
opening. With load increase, they all open more fully. This provides more
uniform heating around the high-pressure part of the turbine. Most modern
controls start with full-arc and switch to partial arc to reduce throttling losses
through the valves.

At what points does corrosion fatigue does show up?

It attacks trailing edges, near the base of the foil and also the blade-root
serration’s.

Besides lubrication, what are two functions of lubricating oil in some

turbines?
In larger units, lube oil cools the bearings by carrying off heat to the oil coolers.
Lube oil in some turbines also acts as a hydraulic fluid to operate the governor
speed-control system.
But despite these preventive measures, damage due to moisture
impingement has been found, in certain cases, in the shield and beyond.
Why?
Shields are designed and fabricated on the basis of predicted range of
steam/water quantities impacting the blades at specific angles.
Now if the operating conditions deviate significantly from design parameters
then the erosion damage will occur. And in some cases it may go beyond
nominal erosion wear and warrant repair.
Also the corrosion of casing can occur due to blockage/clogging of water drains
or extraction thereby forcing the water back into the casing. If this condensate
water is carried over to steam path and impacts the blade, thermal-fatigue
failure can occur within a short period.

By monitoring the exhaust steam temperature, how can the blade

deposition be predicted?
Immediately after the 1st commissioning, the different values of exhaust
temperature for different steam flow rates are precisely determined and plotted
against steam flow. This will produce the first actual graph. This is for a clean
turbine.
Similar graphs are to be drawn at later periods for comparing with the initial
graph.
A rise in exhaust steam temperature under the same conditions refers to
deposit formation.
An increase of exhaust steam temperature by more than 10% in the range of 70
to l00% steam flow, indicates inadmissible blade depositions. Shutdown is to be
taken and blades are to be washed off deposits.

Do the radial axial-bore cracks occur in the LP rotor/shaft alone?

These are also known to occur in the HP as well as HP rotors.

Do you stop cooling-water flow through a steam condenser as soon as

the turbine is slopped?
You should keep the cooling water circulating for about 15 mill or more so that
the condenser has a chance to cool down gradually and evenly. Be sure to
have cooling water flowing through the condenser before starting up in order to
prevent live steam from entering the condenser unless it is cooled. Overheating
can cause severe leaks and other headaches.

Do you think that turbine blade failure is the only cause of unreliability of
steam turbines? Does upgrading of turbine means replacement of blades
and/or improvement of blade design?
Like the blades, the steam-turbine rotors are highly stressed components. They
are subject to cracking by a variety of failure mechanisms. Rotor failures do
occur. And when they occur the result is catastrophic with the complete
destruction of the unit and the total loss of generating capacity.
Therefore, special attention should be given to rotor upgrading and repairing
techniques.
FACTORS BLADE FAILURES
Unknown 26%
Stress-Corrosion Cracking 22%
High-Cycle Fatigue 20%
Corrosion-Fatigue Cracking 7%
Temperature Creep Rupture 6%
Low-Cycle Fatigue 5%
Corrosion 4%
Other causes 10%
TOTAL 100%
Besides, many damage mechanisms operate in combination of
poor steam/water chemistry,
certain blade design factors that vary from one turbine manufacture to other,
system operating parameters,

How can damaged tenons be repaired?

By adopting modern welding techniques, tenons can be rebuilt This in some
cases results in extended blade life.

How can problems of "excessive vibration or noise" due to piping strain

be avoided on steam turbines?
The inlet as well as exhaust steam lines should be firmly supported to avoid
strains from being imposed on the turbine.
Adequate allowance should be made for expansion of steam pipes due to heat.

How can steam turbines be classified?

By the action of steam:
Impulse.
Reaction.
Impulse and reaction combined.

The number of step reductions involved:

Single stage.
Multi-stage.
Whether there is one or more revolving vanes separated by stationary reversing
vanes.
The direction of steam flow:
Axial.
Radial.
Mixed.
Tangential.
Helical.
Reentry.

The inlet steam pressure:

High pressure.
Medium pressure.
Low pressure.

The final pressure:

Condensing.
Non-condensing.

The source of steam:

Extraction.
Accumulator.

How can the deposits be removed?

Water soluble deposits may be washed off with condensate or wet steam.
Water insoluble deposits are removed mechanically after dismantling the
turbine.
Experience shows that water soluble deposits are embedded in layers of water-
insoluble deposits. And when the washing process is carried out, water soluble
parts of the deposit dissolve away leaving a loose, friable skeleton of water-
insoluble deposits which then break loose and wash away.

How can the detection of deposits in a turbine be made during operation?

Pressure monitoring.
Internal efficiency monitoring.
Monitoring exhaust steam temperature.
Monitoring specific steam consumption.

How can the disadvantages of the impulse turbine question 7 be

overcome?
Velocity compounding
Pressure compounding
Pressure-Velocity compounding.

How can the fatigue damage on high-pressure blades be corrected?

Fatigue-damage on high-pressure blades arises due to vibration induced by
partial-arc admission. This can be corrected by switching over to full arc
admission technique.

How can the misalignment be rectified?

The bolts holding the flanges together are to be tightened. The coupling is to be
checked for squareness between the bore and the face. At the same time axial
clearance is to be checked. Using gauge block and feeler gauges, the gap
between coupling faces 1800 apart is to be measured. After rotating the
coupling-half 1800, the gap at the same points is to be measured. After this, the
other coupling is to be rotated 1800 and the gap at the same points is to be re-
measured. These measures should come within a few thousands of an inch.
Dividing the coupling faces into four intervals, the distance between the
coupling faces at this intervals is to be measured with the aid of a gauge block
and feeler gauges. These gap measurements should come within 0.005 inch for
proper angular shaft alignment. After proper alignment at room temperature, the
two halves of the coupling are to be connected.

How can the problem of excessive speed variation due to throttle

assembly friction be overcome?
The throttle should be dismantled. Moving parts should be checked for free and
smooth movement. Using very fine-grained emery paper, the throttle valve
seats and valve steam should be polished.
How can the speed variation be reduced by making a governor droop
adjustment?
If the internal droop setting is increased, the speed variation will reduce.

How do the problems of vibration and fatigue arise with steam turbine
blades?
These arise due to flow irregularities introduced because of manufacturing
defects, e.g. lack of control over tolerances.
System operating parameter, e.g. low flow may excite various modes of
vibration in the blades.

How does deposit formation on turbine blades affect turbine efficiency?

About 500 g of deposits distributed more or less evenly all over the blading
section can bring down turbine efficiency by 1%.

How does improper governor lubrication arise and

In the event of low governor oil level or if the oil is dirty or foamy, it will cause
improper governor lubrication.

What is the remedy to it?

The dirty or foamy lube oil should be drained off, governor should be flushed
and refilled with a fresh charge of proper oil.
In the event of low level, the level should be built up by make- up lube oil.

How does pressure monitoring ensure detection of turbine deposits?

Pressure of steam expanding in the turbine is measured at characteristic points,
i.e., at the wheel chamber, points of pass-out, inlet/outlet of HP, IP and LP
stages of the turbine.
The turbine manufacturer provides the pressure characteristics in the form of
graphs.
At 1st commissioning, the user supplements these theoretical curves with those
derived from actual measurements. These are actual pressure characteristics
for a clean turbine. Now these pressure characteristics are compared with those
obtained during operation in the later period.
Under identical conditions, an increase in pressure shows the formation of
deposits.
For a steam throughput in the range 70-100%, an increase in wheel chamber
pressure of more than 10% indicates severe blade depositions.

How does solid-particle erosion occur?

Solid-particle erosion, i.e. SPE occurs in the high-pressure blades. And it takes
place when hard particles of iron exfoliated by steam from superheater tubes,
reheater tubes, steam headers and steam leads strike on the surface of turbine
blades.

How does the damage to turbine-blades tell upon the efficiency of the
unit?
The damage to blade profiles changes the geometry of steam flow path and
thereby reducing the efficiency of the unit.

How does the dirty safety trip valve trip the safety trip at normal speed?
Dirt may find its way to the safety trip valve and get deposited around the spring
end cap end. This will block the clearance between the safety trip valve and the
spring end cap. As a result the steam pressure in the spring cap gets lowered
allowing the valve to close.

What is the remedy to it?

The spring end cap as well as safety trip valve should be cleaned.
 How does the foreign-particle damage of turbine blades arise?
It occurs due to impact on blades by foreign particles (debris) left in the system
following outages and become steam-borne later.

How does the internal efficiency monitoring lead to the detection of

turbine deposits?
Process heat drop.
Adiabatic heat drop.
The process heat drop and adiabatic heat drop are obtained from a Mollier-
Chart for the corresponding values of steam parameters - pressure and
temperature - at initial and final conditions.

How does this modification reduce the vibration fatigue damage?

Joining the blade segments together at the shroud band increases the length of
the arc-to a maximum of 360° that alters the natural frequency of the blade
grouping from the operating vibration mode.
This design has gained considerable success in commercial service.

How is a flyball governor used with a hydraulic control?

As the turbine speeds up, the weights are moved outward by centrifugal force,
causing linkage to open a pilot valve that admits and releases oil on either side
of a piston or on one side of a spring-loaded piston. The movement of the
piston controls the steam valves.

How is oil pressure maintained when starting or stopping a medium-sized

turbine?
An auxiliary pump is provided to maintain oil pressure. Some auxiliary pumps
are turned by a hand crank; others are motor-driven. This pump is used when
the integral pump is running too slowly to provide pressure, as when starting or
securing a medium-sized turbine.

How is pressure compounding accomplished?

This is accomplished by an arrangement with alternate rows of nozzles and
moving blades.
Steam enters the 1st row of nozzles where it suffers a partial drop of pressure
and in lieu of that its velocity gets increased. The high velocity steam passes on
to the 1st row of moving blades where its velocity is reduced.
1. The steam then passes into the 2nd row of nozzles where its pressure is again
partially reduced and velocity is again increased. This high velocity steam
passes from the nozzles to the 2nd row of blades where its velocity is again
reduced.
2. Thus pressure drop takes place in successive stages. Since a partial pressure
drop takes place in each stage, the steam velocities will not be so high with the
effect that the turbine will run slower.
How is pressure-velocity compounding accomplished?
Answers:
0. It is a combination of pressure compounding and velocity compounding.
1. Steam is expanded partially in a row of nozzles whereupon its velocity gets
increased. This high velocity steam then enters a few rows of velocity
compounding whereupon its velocity gets successively reduced. (Fig. 5)
2. The velocity of the steam is again increased in the subsequent row of nozzles
and then again it is allowed to pass onto another set of velocity compounding
that brings about a stage-wise reduction of velocity of the steam.
3. This system is continued.
How is the washing of turbine blades carried out with the condensate?
Answers:
0. The washing is carried out with the condensate at 100°C.
1. The turbine is cooled or heated up to 100°C and filled with the condensate via a
turbine drain.
2. The rotor is turned or barred by hand and the condensate is drained after 2 to 4
hours.
3. It is then again filled with the condensate at 100°C (but up to the rotor center-
level), the rotor is rotated and the condensate is drained after sometime. This
process is repeated several times.
How is turbine blade washing with wet steam carried out?
Answers:
0. Wet steam produced usually by injecting cold condensate into the superheated
steam, is introduced to the turbine which is kept on running at about 20% of
nominal speed.
1. For backpressure turbine the exhaust steam is let out into the open air through
a gate valve. For a condensing turbine, the vacuum pump is kept out of service
while cooling water is running, with the effect that the entering cooling steam is
condensed. The condensate is drained off.
2. The washing steam condition is gradually adjusted to a final wetness of 0.9 to
0.95.
Note, it is important:
3. not to change washing steam temperature by 10°C/min,
4. to keep all turbine cylinder drains open.
How is velocity compounding accomplished?
Answers:
0. This is accomplished by an arrangement with alternate rows of fixed blades and
moving blades. The mounted on the casing while the moving blades are keyed
in series on a common shaft. The function of the fixed blades is to correct the
direction of entry of steam to the next row of moving blades.
1. The high velocity steam leaving the nozzles passes on to the 1st row of moving
blades where it suffers a partial velocity drop.
2. Its direction is then corrected by the next row of fixed blades and then it enters
the 2nd row of moving blades. Here the steam velocity is again partially
reduced. Since only part of the velocity of the steam is used up in each row of
the moving blades, a slower turbine results. This is how velocity compounding
works.
How many governors are needed for safe turbine operation? Why?
Answer:
Two independent governors are needed for safe turbine operation:
0. One is an overspeed or emergency trip that shuts off the steam at 10 percent
above running speed (maximum speed).
1. The second, or main governor, usually controls speed at a constant rate;
however, many applications have variable speed control.
How many types of particle-impact damage occur in turbine blades?
Answers:
0. Erosion/corrosion.
1. Foreign-particle impacts.
2. Solid-particle erosion.
3. Water damage.
How to prevent turbine deposition?
Answers:
By upgrading the quality of steam. That is by ensuring proper:
0. Boiler feedwater quality.
1. Steam boiler model.
2. Boiler design.
3. Boiler operation.
How will you detect that misalignment is the probable cause of excessive
vibration?
Answers:
0. Coupling to the driven machine is to be disconnected.
1. The turbine is to be run alone.
2. If the turbine runs smoothly, either misalignment, worn coupling or the driven
equipment is the cause of the trouble.
How would you slop a leaky tube in a condenser that was contaminating
the feed-water?
Answer:
To stop a leaky tube from contaminating the feedwater, shut down, remove the
water-box covers, and fill the steam space with water. By observing the tube
ends you can find the leaky tube. An alternate method is to put a few pounds of
air pressure in the steam space, flood the water boxes to the top inspection
plate, and observe any air bubbles. Once you have found the leaky tube, drive
a tapered bronze plug (coated with white lead) into each end of the tube to cut it
out of service. This allows you to use the condenser since the tubes need not
be renewed until about 10 percent of the tubes are plugged.
How would you stop air from leaking into a condenser?
Answer:
First, find the leak by passing a flame over the suspected part while the
condenser is under vacuum. Leaks in the flange joints or porous castings can
be stopped with asphalt paint or shellac. Tallow or heavy grease will stop leaks
around the valve stems. Small leaks around the porous castings, flange nuts, or
valve stems can always be found by the flame test. So, you might have to put
the condenser under a few pounds of air pressure and apply soapsuds to the
suspected trouble parts.
In how many patterns are tie wires used?
Answers:
0. In one design, tie wire is passed through the blade vane.
1. In another design, an integral stub is jointed by welding/brazing.
In some weld-repair cases, it has been found that the Stellite survived
while the filler material eroded away. Why?
Answers:
 If Inconel is used as the filler material, it has the inferior resistance to erosion in
comparison to the Stellite insert. So filler material erodes away underneath.
In steam turbines, is there any alternative to the shrunk-on-disc design?
Answers:
Two designs are available at present:
0. Welded rotor in which each individual disc is welded, instead of shrunk, onto the
main shaft.
1. Monobloc rotor in which the entire shaft and blade assembly is manufactured
from a single forging.
In which case does upgrading imply life extension of steam turbines?
Answer:
For a capital-short electric utility plant, upgrading comes to mean extending the
life of that plant scheduled for retirement.
In which cases does erosion corrosion damage appear?
Answer:
It is commonly encountered in nuclear steam turbines and old fossil-fuel-fired
units that employ lower steam temperatures and pressures.
In which cases does moisture-impingement and washing erosion occur?
Answers:
0. These are encountered in the wet sections of the steam turbine.
1. For nuclear power plants, these wet sections can involve parts of high-pressure
cylinder.
In which cases does upgrading mean up-rating the turbine capacity?
Answer:
For an electric utility system facing uncertain load growth, upgrading is chiefly
up-rating. It is an inexpensive way to add capacity in small increments.
In which part of the steam turbine does corrosion fatigue occur?
Answer:
In the wet stages of the LP cylinder.
In which part of the steam turbine does stress corrosion cracking (SCC)
occur?
Answer:
In the wet stages of the low-pressure turbine.
In which section of the steam-turbine rotors is the problem of rotor failure
mostly prevalent?
Answers:
Rotor failures occur mostly on the large low-pressure rotors.
Basic causes of the problems are:
0. Normal wear.
1. Fatigue failure due to high stress.
2. Design deficiency.
3. Aggressive operating environment
In which turbine is this pressure compounding used?
Answer:
In the Rateau turbine.
In which turbine is tip leakage a problem?
Answer:
Tip leakage is a problem in reaction turbines. Here, each vane forms a nozzle;
steam must how through the moving nozzle to the fixed nozzle. Steam escaping
 across the tips of the blades represents a loss of work. Therefore, tip seals are
used to prevent this.
In which turbine is velocity compounding utilized?
Answer:
In the Curtis turbine.
In which turbines, is this pressure-velocity compounding principle
employed?
Answer:
In the Curtis turbine.
In which zone of steam turbines has temperature-creep rupture been
observed?
Answer:
Damage due to creep is encountered in high temperature (exceeding 455°C)
zones. That is, it has been found to occur in the control stages of the high-
pressure and intermediate-pressure turbines where steam temperature
sometimes exceed 540°C. In the reheat stage, it has been observed that creep
has caused complete lifting of the blade shroud bands.
Is there any adverse effect off full-arc admission operation?
Answer:
At low loads, this results in a heat-rate penalty, due to throttling over the
admission valves.
Is there any alternative to the shrunk-on-disc design?
Answers:
Two designs are available at present:
0. Welded rotor in which each individual discs are welded, instead of shrunk, onto
the main shaft.
1. Monobloc rotor in which the entire shaft and blade assembly is manufactured
from a single forging.
Is there any factor other than corrodents and erodents that contributes to
turbine blade failure?
Answers:
0. Turbine blade damage and failures can be effected by vibration and fatigue.
a. These arise due to flow irregularities introduced because of manufacturing
defects, e.g. lack of control over tolerances.
b. System operating parameter, e.g. low flow may excite various modes of
vibration in the blades.
1. Is there any other type of racking occurring in HP/IP rotors and causing
rotor failures?
Answers:
1. Blade-groove-wall cracking.
2. Rotor-surface cracking.
2. Of all the factors that contribute to the unreliability of steam turbines,
which one is the most prominent?
Answer:
It is the problem of turbine blade failures that chiefly contribute to the
unreliability of steam turbines.
3. Rim cracking continues to be a problem of shrunk-on-disc type rotors in
utility steam turbines. Where does it occur?
Answer:
 Cracking has been located at the outer corners of tile grooves where the blade
root attaches to the rotor.
4. So can you recommend this technique as a permanent measure?
Answer:
No, this can be recommended in extreme cases or at best temporarily.
5. So what should be the more sound approach?
Answers:
1. The more reasonable and better approach is to replace the damaged blades
with new ones that are stiffened by:
a. Serrating the interface surface of individual blades so they interlock, or
b. Welding the blades together.
c. In some cases, a single monolithic block is machined out to manufacture the
blades in a group.
d. In some other cases, blades themselves are directly welded into the rotor.
1. Steam blowing from a turbine gland is wasteful. Why else should it be
avoided?
Answer:
It should be avoided because the steam usually blows into the bearing,
destroying the lube oil in the main bearing. Steam blowing from a turbine gland
also creates condensate, causing undue moisture in plant equipment.
2. The consequences of turbine depositions have three effects?
Answers:
1. Economic Effect:
a. Reduction in turbine output
b. Decrease in efficiency requiring higher steam consumption.
1. Effect of Overloading and Decreasing Reliability in Operation:
a. Pressure characteristic in the turbine gets disturbed with the effect that thrust
and overloading of thrust bearing increase.
b. Blades are subjected to higher bending stresses.
c. Natural vibrations of the blading are affected.
d. Vibration due to uneven deposition on turbine blading.
e. Valve jamming due to deposits on valve stems.
1. Corrosion Effect:
a. Fatigue corrosion.
b. Pitting corrosion.
c. Stress corrosion.
1. Usually it has been found that SCC attack takes place particularly at
keyways of shrunk-on-disc rotors of low-pressure turbines. Why are
keyways prone to SCC attack?
Answers:
1. Keyways shrunk-fit each disc onto tile rotor shaft. They improve the rigidity of
the connection between the disc and the central shaft However, key ways are
subjected to abnormal centrifugal forces due to high overspeed, that reduce the
amount of shrink. Tangential stresses tend to gravitate at the keyway
connection and steam tends to condense.
2. It is a one-piece-construction, and thus has inherent rigidity.
3. Advanced steel making techniques enable building of monobloc rotors almost
free from non-metallic inclusions and gas bubbles. Even large monobloc rotors
of clean steel are being manufactured today.
4. It exhibits lower inherent stresses.
5. The chance of disc loosening during operation is eliminated.
6. Highly stressed keyway is eliminated.
2. What are four types of thrust bearings?
Answers:
1. babbitt-faced collar bearings
2. tilting pivotal pads
3. tapered land bearings
4. rolling-contact (roller or ball) bearings
3. What are four types of turbine seals?
Answer:
1. Carbon rings fitted in segments around the shaft and held together by garter or
retainer springs.
2. Labyrinths mated with shaft serrations or shaft seal strips.
3. Water seals where a shaft runner acts as a pump to create a ring of water
around the shaft. Use only treated water to avoid shaft pitting.
4. Stuffing box using woven or soft packing rings that are compressed with a gland
to prevent leakage along the shaft.
4. What are some common troubles in surface-condenser operation?
Answer:
The greatest headache to the operator is loss of vacuum caused by air leaking
into the surface condenser through the joints or packing glands. Another trouble
spot is cooling water leaking into the steam space through the ends of the tubes
or through tiny holes in the tubes. The tubes may also become plugged with
mud, shells, debris, slime, or algae, thus cutting down on the cooling-water
supply, or the tubes may get coated with lube oil from the reciprocating
machinery. Corrosion and dezincification of the tube metal are common
surface-condenser troubles. Corrosion may be uniform, or it may occur in small
holes or pits. Dezincification changes the nature of the metal and causes it to
become brittle and weak.
5. What are the advantages of steam turbines over reciprocating steam
engines?
Answers:
1. Steam turbine has higher thermal efficiency than reciprocating steam engines.
2. The brake horsepower of steam turbines can range from a few HP to several
hundred thousand HP in single units. Hence they are quite suitable for large
thermal power stations.
3. Unlike reciprocating engines, the turbines do not need any flywheel, as the
power delivered by the turbine is uniform.
4. Steam turbines are perfectly balanced and hence present minimum vibrational
problem.
5. High rpm l8000 - 24000 can be developed in steam turbines but such a high
speed generation is not possible in the case of reciprocating steam engines.
6. Some amount of input energy of steam is lost as the reciprocating motion of the
piston is converted to circular motion.
7. Unlike reciprocating steam engines, no internal lubrication is required for steam
turbines due to the absence of rubbing parts.
8. Steam turbines, if well designed and properly maintained, are more reliable and
durable prime movers than steam engines.
6. What are the advantages of velocity compounding?
Answers:
1. The velocity compounding system is easy to operate and operation is more
reliable.
2. Only two or three stages are required. Therefore, first cost is less.
3. Since the total pressure drop takes place only in nozzles and not in the blades,
the turbine casing need not be heavily built. Hence the economy in material and
money.
4. Less floor space is required.
7. What are the advantages of welded rotors?
Answers:
1. Welded rotor is a composed body built up by welding the individual segments.
So the limitations on forgings capacity do not apply.
2. Welding discs together results in a lower stress level. Therefore, more ductile
materials can be chosen to resist SCC attack.
3. There are no keyways. So regions of high stress concentrations are eliminated.
8. What are the basic causes of the problem of rotor failure?
Answers:
1. Normal wear.
2. Fatigue failure due to high stress.
3. Design deficiency.
4. Aggressive operating environment
9. What are the causes of radial axial-bore cracks on HP/IP rotors/shafts?
Answers:
1. The predominant cause is creep, which may act with or without low cycle
fatigue.
2. Also the cracks result due to poor creep ductility due to faulty heat treatment
process.
10. What are the differences between impulse and reaction turbines?
Answers:
1. The impulse turbine is characterized by the fact that it requires nozzles and that
the pressure drop of steam takes place in the nozzles.
2. The reaction turbine, unlike the impulse turbines has no nozzles, as such. It
consists of a row of blades mounted on a drum. The drum blades are separated
by rows of fixed blades mounted in the turbine casing. These fixed blades serve
as nozzles as well as the means of correcting the direction of steam onto the
moving blades.
3. In the case of reaction turbines, the pressure drop of steam takes place over
the blades. This pressure drop produces a reaction and hence cause the
motion of the rotor.
11. What are the disadvantages of velocity compounding?
Answers:
1. Steam velocity is too high and that is responsible for appreciable friction losses.
2. Blade efficiency decreases with the increase of the number of stages.
3. With the increase of the number of rows, the power developed in successive
rows of blade decreases. For as much as, the same space and material are
required for each stage, it means, therefore, that all stages are not economically
efficient.
12. What are the factors that contribute to bearing failure in a steam turbine?
Answers:
1. Improper lubrication.
Only the recommended lubricant should be used.
2. Inadequate water-cooling.
a. The jacket temperature should be maintained in the range of 37-60°C
b. The flow of cooling water should be adjusted accordingly.
1. Misalignment.
It is desirable that ball bearings should fit on the turbine shaft with a light press
fit. If the fitting is too tight, it will cause cramping. On the other hand, if the fitting
is too loose it will cause the inner race to turn on the shaft. Both conditions are
undesirable. They result in wear, excessive vibration and overheating. And
bearing failure becomes the ultimate result.
2. Bearing fit.
3. Excessive thrust.
4. Unbalance.
5. Rusting of bearing.
1. What are the losses in steam turbines?
Answers:
1. Residual Velocity Loss - This is equal to the absolute velocity of the steam at
the blade exit.
2. Loss due to Friction - Friction loss occurs in the nozzles, turbine blades and
between the steam and rotating discs. This loss is about 10%.
3. Leakage Loss.
4. Loss due to Mechanical Friction - Accounts for the loss due to friction
between the shaft and bearing.
5. Radiation Loss - Though this loss is negligible, as turbine casings are
insulated, it occurs due to heat leakage from turbine to ambient air which is at a
much lower temperature than the turbine.
6. Loss due to Moisture - In the lower stages of the turbine, the steam may
become wet as the velocity of water particles is lower than that of steam. So a
part of the kinetic energy of steam is lost to drag the water particles along with
it.
2. What are the main causes of turbine vibration?
Answer:
1. unbalanced parts
2. poor alignment of parts
3. loose parts
4. rubbing parts
5. lubrication troubles
6. steam troubles
7. foundation troubles
8. cracked or excessively worn parts
3. What are the points of SCC attack?
Answers:
1. SCC attack predominates where corrodents deposit and build up i.e. in those
blading areas where flowing steam cannot provide a washing effect.
2. What are these points in particular?
a. Tie wires.
b. Tie wire holes.
c. Brazings.
d. Blade covers.
e. Tenon holes.
1. At what points does corrosion fatigue does show up?
2. It attacks trailing edges, near the base of the foil and also the blade-root
serration’s.
3. What are the possible causes for the turbine not running at rated speed?
Answers:
1. The possible causes are:
a. too many hand valves closed,
b. oil relay governor set too low,
c. inlet steam pressure too low or exhaust pressure too high,
d. load higher than turbine rating,
e. throttle valve not opening fully,
f. safety trip valve not opening properly,
g. nozzles plugged,
h. steam strainer choked.
1. What are the possible causes of a governor not operating?
Answers:
1. Restriction of throttle valve reflex.
2. Failure of governor control on start-up.
If it is found that after start-up, the speed increases continuously and the
governor is not closing the throttle valve, it may be that the governor pump has
been installed in the wrong direction.
2. What are the possible causes of excessive vibration or noise in a steam
turbine?
Answers:
1. Misalignment.
2. Worn bearings.
3. Worn coupling to driven machine.
4. Unbalanced coupling to driven machine.
5. Unbalanced wheel.
6. Piping strain.
7. Bent shaft.
3. What are the possible causes of the speed of the turbine rotor increasing
excessively as the load is decreased?
Answers:
1. Throttle valve not closing fully.
2. Wearing of throttle valve seats.
4. What are the stresses to which a steam turbine rotor is subjected during its
service life?
Answers:
1. Mechanical stress - The factors that contribute to mechanical stress in the
shaft are the centrifugal forces and torque’s generated due to revolving motion
of the shaft as well as bending arising during steady-state operation.
2. Thermal stress - Transient operating phases i.e. startup and shutdown the
genesis of thermal stress induced to the turbine shaft.
3. Electrically induced stress - They originate due to short circuits and faulty
synchronization.
5. What are these points in particular?
Answers:
1. Tie wires.
2. Tie wire holes.
3. Brazings.
4. Blade covers.
5. Tenon holes.
6. What are three types of condensers?
Answer:
1. surface (shell-and-tube)
2. jet
3. barometric.
7. What are topping and superposed turbines?
Answer:
Topping and superposed turbines are high-pressure, non-condensing units that
can be added to an older, moderate-pressure plant. Topping turbines receive
high-pressure steam from new high-pressure boilers. The exhaust steam of the
new turbine is at the same pressure as the old boilers and is used to supply the
old turbines.
8. What are two types of clearance in a turbine?
Answers:
1. radial - the clearance at the tips of the rotor and casing
2. axial - the fore-and-aft clearance, at the sides of the rotor and the casing
9. What design modification is adopted to reduce susceptibility of last low-
pressure stages to fatigue failure?
Answer:
One modification is to join the blade segments together at the shroud band.
10. What does "upgrading" generally means in the context of steam turbines?
Answer:
Upgrading is a most widely used tern. It encompasses a variety of meanings
verses life extension, modernization and up-rating of steam turbines.
11. What does the term "ramp rat" mean?
Answer:
Ramp rate is used in bringing a turbine up to operating temperature and is the
degrees Fahrenheit rise per hour that metal surfaces are exposed to when
bringing a machine to rated conditions. Manufactures specify ramp rates for
their machines in order to avoid thermal stresses. Thermocouples are used in
measuring metal temperatures.
12. What factors are responsible for turbine-blade failures?
Answers:
1. In the high pressure cylinder, the turbine blades are mostly affected by:
a. solid-particle erosion (SPE),
b. high cycle fatigue,
1. Whereas in the last few stages of the low-pressure cylinder, the blade damage
is mainly afflicted by:
a. erosion,
b. corrosion,
c. stress/fatigue damage mechanism.
d. According to EPRI (Electric Power Research Institute, USA) data stress-
corrosion cracking and fatigue are the chief exponents for turbine-blade failures
in utility industries.
1. What factors cause excessive steam leakage under carbon rings?
Answers:
1. Dirt under rings. - steam borne scale or dirt foul up the rings if steam is leaking
under the carbon rings.
2. Shaft scored.
3. Worn or broken carbon rings.
These should be replaced with a new set of carbon rings. The complete ring is
to be replaced.
2. What factors contribute to excessive speed variation of the turbine?
Answers:
1. Improper governor droop adjustment.
2. Improper governor lubrication.
3. Throttle assembly friction.
4. Friction in stuffing box.
5. High inlet steam pressure and light load.
6. Rapidly varying load.
3. What is a balance piston?
Answer:
Reaction turbines have axial thrust because pressure on the entering side is
greater than pressure on the leaving side of each stage. To counteract this
force, steam is admitted to a dummy (balance) piston chamber at the low-
pressure end of the rotor. Some designers also use a balance piston on
impulse turbines that have a high thrust. Instead of pistons, seal strips are also
used to duplicate a piston's counter force.
4. What is a combination thrust and radial bearing?
Answer:
This unit has the ends of the babbitt bearing extended radially over the end of
the shell. Collars on the rotor face these thrust pads, and the journal is
supported in the bearing between the thrust collars.
5. What is a diaphragm (turbine)?
Answer:
Partitions between pressure stages in a turbine's casing are called diaphragms.
They hold the vane-shaped nozzles and seals between the stages. Usually
labyrinth-type seals are used. One-half of the diaphragms are fitted into the top
of the casing, the other half into the bottom.
6. What is a multiport governor valve? Why is it used?
Answer:
In large turbines, a valve controls steam flow to groups of nozzles. The number
of open valves controls the number of nozzles in use according to the load. A
bar-lift or cam arrangement operated by the governor, opens and close the
valves in sequence. Such a device is a multiport valve. Using nozzles at full
steam pressure is more efficient than throttling the steam.
7. What is a radial-flow turbine?
Answer:
In a radial-flow turbine, steam flows outward from the shaft to the casing. The
unit is usually a reaction unit, having both fixed and moving blades. They are
used for special jobs and are more common to European manufacturers.
8. What is a shrunk-on-disc rotor?
Answer:
These are built by heat expanding the discs, so that upon cooling they shrink on
the main rotor forging.
9. What is a stage in a steam turbine?
Answer:
 In an impulse turbine, the stage is a set of moving blades behind the nozzle. In
a reaction turbine, each row of blades is called a "stage." A single Curtis stage
may consist of two or more rows of moving blades.
10. What is a tapered-land thrust bearing?
Answer:
The babbitt face of a tapered-land thrust bearing has a series of fixed pads
divided by radial slots. The leading edge of each sector is tapered, allowing an
oil wedge to build up and carry the thrust between the collar and pad.
11. What is an air ejector?
Answer:
An air ejector is a steam siphon that removes non-condensable gases from the
condenser.
12. What is an extraction turbine?
Answer:
In an extraction turbine, steam is withdrawn from one or more stages, at one or
more pressures, for heating, plant process, or feedwater heater needs. They
are often called "bleeder turbines."
13. What is combined-cycle cogeneration?
Answer:
A combined cycle using a gas turbine or diesel, usually driving a generator in
which the exhaust gases are directed to a waste heat-recovery boiler or heat-
recovery steam generator (HRSG). The steam from the HRSG is then directed
to a steam turbo-generator for additional electric power production. The use of
the exhaust heat from a gas turbine improves the overall thermal efficiency. In
cogeneration, electric power is produced, but part of the steam from the HRSG
or from extraction from the steam turbine is used for process heat, hence the
term cogeneration-the simultaneous production of electric power and process
heat steam.
14. What is done when cracks due to SCC or corrosion-fatigue are found?
Answer:
The damaged blade is usually replaced, as repairing is difficult.
15. What is gland-sealing steam?
Answer:
Low-pressure steam is led to a sealing gland. The steam seals the gland, which
may be a carbon ring or of the labyrinth type, against air at the vacuum end of
the shaft.
16. What is important to remember about radial bearings?
Answer:
A turbine rotor is supported by two radial bearings, one on each end of the
steam cylinder. These bearings must be accurately aligned to maintain the
close clearances between the shaft and the shaft seals, and between the rotor
and the casing. lf excessive bearing wear lowers the rotor, great harm can be
done to the turbine.
17. What is meant by critical speed?
Answer:
It is the speed at, which the machine vibrates most violently. It is due to many
causes, such as imbalance or harmonic vibrations set up by the entire machine.
To minimize damage, the turbine should be hurried through the known critical
speed as rapidly as possible.
 Caution: Be sure the vibration is caused by critical speed and not by some
other trouble.
18. What is meant by the water rate of a turbine?
Answer:
It is the amount of water (steam) used by the turbine in pounds per horsepower
per hour or kilowatts per hour.
19. What is the cause of axial-bore cracks?
Answer:
Inadequate toughness of rotor steel and transient thermal stresses.
20. What is the cause of circumferential cracking?
Answer:
High cycle fatigue with or without corrosion.
21. What is the cause of turbine deposits?
Answers:
The turbine deposits are steam-born foreign matters settled on turbine blades.
Substances dissolved in the BFW transfer partly from the water to steam,
during the process of evaporation. They get dissolved in the steam and are
carried into the steam turbine.
22. What is the definition of a steam turbine?
Answers:
A steam turbine is a prime mover that derives its energy of rotation due to
conversion of the heat energy of steam into kinetic energy as it expands
through a series of nozzles mounted on the casing or produced by the fixed
blades.
1. Neilson defines it: The turbine is a machine in which a rotary motion is
obtained by the gradual change of the momentum of the fluid.
2. Graham's definition: The turbine is a prime mover in which a rotary motion is
obtained by the centrifugal force brought into action by changing the direction of
a jet of a fluid (steam) escaping from the nozzle at high velocity.
23. What is the difference between partial and full arc admission?
Answer:
In multi-valve turbine inlets, partial arc admission allows the steam to enter per
valve opening in a sequential manner, so as load is increased, more valves
open to admit steam. This can cause uneven heating on the high-pressure
annulus as the valves are individually opened with load increase. In full-arc
admission, all regulating valves open but only at a percentage of their full
opening. With load increase, they all open more fully. This provides more
uniform heating around the high-pressure part of the turbine. Most modern
controls start with full-arc and switch to partial arc to reduce throttling losses
through the valves.
24. What is the essential distinguishing feature between a steam turbine and
reciprocating steam engine?
Answers:
1. In a steam turbine, the heat energy of steam is converted into kinetic energy by
allowing it to expand through a series of nozzles and this kinetic energy of
steam is then imparted to the turbine blades mounted on a shaft free to rotate to
drive this prime mover.
2. In a reciprocating steam engine, the pressure energy of steam is directly utilized
to overcome the external resistance. Here, the utilization of the KE of input
steam is negligibly small.
25. What is the function of a gland drain?
Answer:
The function of a gland drain is to draw off water from sealing-gland cavities
created by the condensation of the sealing steam. Drains are led to either the
condenser air-ejector tube nest or the feedwater heaters. Often, gland drains
are led to a low-pressure stage of the turbine to extract more work from the
gland-sealing steam.
26. What is the function of a thrust bearing?
Answer:
Thrust bearings keep the rotor in its correct axial position.
27. What is the harm if the rotor is oversped?
Answer:
Overspeed rotor grows radially causing heavy rub in the casing and the seal
system. As a result, considerable amount of shroud-band and tenon-rivet head
damage occurs.
28. What is the nature of circumferential cracking in shrunk-on-disc rotors in
steam turbines?
Answer:
Regions of high stress concentration give birth to this type of cracking. It begins
in corrosion pits and propagates towards the bore by high-cycle fatigue. It may
culminate in a catastrophe, if it penetrates the bore (happily this usually does
not occur).
29. What is the nature of rotor surface cracks in steam turbines?
Answer:
They are shallow in depth and have been located in heat grooves and other
small radii at labyrinth-seal areas along the rotor.
30. What is the operating principle of a reaction turbine?
Answer:
A reaction turbine utilizes a jet of steam that flows from a nozzle on the rotor.
Actually, the steam is directed into the moving blades by fixed blades designed
to expand the steam. The result is a small increase in velocity over that of the
moving blades. These blades form a wall of moving nozzles that further expand
the steam. The steam flow is partially reversed by the moving blades, producing
a reaction on the blades. Since the pressure drop is small across each row of
nozzles (blades), the speed is comparatively low. Therefore, more rows of
moving blades are needed than in an impulse turbine.
31. What is the possible cause of slow start up of a steam turbine?
Answer:
This may be due to high starting torque required by the driven equipment.
32. What is the potential problem of shrunk-on-disc type rotor?
Answers:
1. It is the failure due to circumferential cracks, which are not limited to old rotors
of early models (1960), but they also take place on present-day rotors.
2. As a result corrodent impurities like chlorides concentrate at key ways. This
factor coupled with high stress concentration lead to SCC attack on keyway
areas.
33. What is the principle of a steam turbine?
Answers:
1. If high-velocity steam is allowed to blow on to a curved blade, the steam will
suffer a change in direction as it passes across the blade, and leaves it as
shown.
2. As a result of its change in direction across the blade, the steam will impart a
force to the blade. This force will act in the direction shown.
3. Now if the blade were free in the direction of force as depicted. if, therefore, a
number of blades were fixed on the circumference of a disc which is free to
rotate on a shaft, then steam blown across the blades in the way described,
would cause the disc to rotate. This is the working principle of a steam turbine.
34. What is the purpose of a turning gear?
Answer:
Heat must be prevented from warping the rotors of large turbines or high-
temperature turbines of 400°C or more. When the turbine is being shut down, a
motor-driven turning gear is engaged to the turbine to rotate the spindle and
allow uniform cooling.
35. What is the remedy for a bent steam turbine shaft causing excessive
vibration?
Answers:
1. The run-out of the shaft near the center as well as the shaft extension should be
checked.
2. If the run-out is excessive, the shaft is to be replaced.
36. What is the remedy for rotor-surface cracking?
Answer:
Current rotor/shaft should be machined off (skin-peeling).
37. What is the remedy of the damage to blade profiles?
Answers:
1. Upgrading the turbine and depending on the extent of damage, upgrading may
involve:
a. weld repair of affected zones of the blade,
b. replacement of damaged blades by new ones and of new design,
c. replacement of base material,
d. application of protective coatings to guard against corrosion and erosion
damage.
1. What are the remedies to this failure?
Answers:
2. For existing rotor, weld repair may be a choice; otherwise retire it.
3. For new rotors, materials with improved pitting resistance should be used.
1. What is the safe maximum tripping speed of a turbine operating at 2500
rpm?
Answer:
The rule is to trip at 10 percent overspeed. Therefore, 2500 x 1.10 = 2750 rpm.
2. What is the solution to the problem of SCC/corrosion fatigue of steam
turbine blades?
Answer:
It involves changing the blade material as well as minimizing the presence of
corrodents in steam to a permissible level.
3. What is to be done for erosion-induced damage on high-and low-pressure
stage blading?
Answers:
1. In such cases welding repair can be a good solution and this can be carried out
during a normal maintenance outage without removing the blade. Using
oxyacetylene torch, Stellite is generally deposited onto the damaged site.
Following this, the weld is subjected to stress-relieving and re-profiling.
2. In case of erosion penetrating the erosion shield and extending to the base
material, a filler material of consistent or identical composition of blade material
is used.
3. In some cases use is made of Inconel alloy to build up the metal base.
Therefore, using welding or brazing technique, a new shield can be attached to
the blade. If brazing technique is followed, the rebuilt section is stress-relieved
prior to the attachment of shield to it. If, on the other hand, the shield is attached
by welding, then they are stress-relieved together.
4. What is to be done in case of cracks originating at the lacing-wire holes?
Answers:
1. These are to be weld-repaired. However the following factors must be
considered:
a. The length of the crack that appears on the pressure and/or suction face.
b. Whether the cracks propagate towards inlet end, discharge end and or both.
1. What maybe the possible causes for the safety trip to trip at normal speed?
Answers:
1. Excessive vibration.
2. Leakage in the pilot valve.
3. Deposition of dirt in the safety trip valve.
2. What maybe the possible causes for the safety trip tripping during load
variation?
Answers:
1. Light load and high inlet steam pressure.
2. Safety trip set very close to the operating speed of turbine.
3. What other parts of the steam turbine blades suffer from damage?
Answers:
1. Blade roots.
2. Shroud band.
4. What provisions in the layout of a combined-cycle should be considered?
Answer:
It is important to consider the use of a bypass stack that will permit operating
the gas turbo-generator in case of a forced outage on the HRSG or steam
turbo-generator. However, in certain states, such as California, also to be
considered are NO limits that require steam injection and loading to limit the
exhaust temperature coming out of the simple-cycle gas turbine so that they do
not exceed jurisdictional limits.
5. What remedial measures you can suggest to cope with radial axial-bore
cracks?
Answer:
For new rotors, modified heat treatment process is recommended while for
existing rotors de-rating the turbine or replacement of the rotor may be a
solution.
6. What should be done if excessive vibration is due to an unbalanced turbine
wheel?
Answers:
1. The turbine wheel is to be checked if it became unbalanced due to
overspeeding.
2. The turbine wheel must be re-balanced or replaced.
3. What should be the remedial action?
Answers:
4. For new rotors, control cleanliness of the steel.
5. i.e. inclusion and segregates free and more homogeneous steel shaft is
required.
6. For current rotors, replace the rotor, grind and overbore.
7. What should be the remedial actions for blade-groove-wall cracking?
Answers:
1. Modified heat treatment of new rotors is a sound and lasting remedy.
2. For current rotors, cracks should be machined off and lighter blades should be
installed. Better, retire the cracked shaft.
8. What should you do if you lost vacuum while operating a condensing
turbine plant?
Answer:
If vacuum is lost shut down immediately. The condenser cannot stand steam
pressure; the condenser tubes may leak from excessive temperature.
Excessive pressure will also damage the shell, the exhaust, and the low-
pressure parts of the turbine.
9. What steps are taken to minimize damage from moisture on steam turbine
blades?
Answers:
The following measures are employed at the design stage:
1. Stellite inserts.
2. Hardening of the base metal.
3. Moisture-removal devices to combat impingement corrosion due to moisture.
10. What steps are taken to minimize damage from moisture?
Answers:
1. Stellite inserts.
2. Hardening of the base metal.
3. Moisture-removal devices to combat impingement corrosion due to moisture.
11. What steps/modifications should be implemented to curtail the damage
from moisture impingement on steam turbine blades?
Answers:
1. The drainage system should be redesigned. Larger drains are to be provided.
2. More effective water-catchers are to be in-stalled.
3. Radial seals are to be eliminated to remove water before it can chance upon
the blades.
4. Nozzle trailing edges are to be thinned to promote the formation of smaller and
less harmful droplets.
12. What steps/modifications should be implemented to curtail the damage
from moisture impingement?
Answers:
1. The drainage system should be redesigned. Larger drains are to be provided.
2. More effective water-catchers are to be in-stalled.
3. Radial seals are to be eliminated to remove water before it can chance upon
the blades.
4. Nozzle trailing edges are to be thinned to promote the formation of smaller and
less harmful droplets.
13. What type of deposits are formed on steam turbine blading?
Answers:
1. Water-soluble deposits.
a. NaCl, Na2SO4, NaOH and Na3PO4
1. Water-insoluble deposits.
a. SiO2 (mainly).
1. What types of cracking occur in the LP rotor shaft?
Answers:
1. Radial axial-bore cracks.
2. Circumferential cracks.
2. When "stall flutter" occurs?
Answers:
This problem is encountered when operating limits are exceeded i.e., when
turbine exhaust pressure exceeds the value what the manufacturer has
recommended. Stall flutter induces stress in the blades
3. When does SPE damage usually occur on steam turbine blades?
Answer:
It occurs usually during startup or abrupt load change.
4. When does SPE damage usually occur?
Answer:
It occurs usually during startup or abrupt load change.
5. When does upgrading mean modernization of utility industry?
Answer:
Upgrading is really modernization to all those units other than those facing
uncertain load growth and low-capital utility system. It involves replacement of
damaged parts/components by state-of-the-art components without scrapping
the entire machine.
6. Where are velocity compounded steam turbines mostly employed?
Answers:
1. They are chiefly used as the prime mover for:
a. Centrifugal pumps.
b. Centrifugal compressors.
c. Low capacity turbo-generators.
d. Feed pumps of high capacity power plants.
1. Where do water-soluble deposits prevail?
Answer:
In the high-and intermediate-pressure sections of steam turbines.
2. Where is pitting corrosion mostly prevalent?
Answer:
Upstream of LP stages as well as wet stages of LP cylinder.
3. Where would you look for a fault if the air ejector did not raise enough
vacuum?
Answer:
In this case, the trouble is usually in the nozzle. You will probably find
that:
1. the nozzle is eroded
2. the strainer protecting the nozzle is clogged
3. the steam pressure to the nozzle is too low
4. Which factors affect the extent of an upgrading program?
Answers:
1. Age of the unit.
2. How it has been operated.
Note: Turbines less than quarter of a century old can simply be upgraded
to their original design conditions.
5. Why are free-standing blades in the last low-pressure stage favored more,
in some cases, than those that are coupled and shrouded together?
Answers:
1. These free-standing blades are known to provide good and adequate protection
against stresses and aggressive environment.
2. They eliminate all areas viz. shroud/tenon interface and tie-wire/hole area
where corrodents can collect
6. Why are simple impulse turbines not so common?
Answers:
1. Since the whole pressure drop from boiler to condenser pressure takes place in
a single row of nozzles, the velocity of the steam entering the turbine is very
high. If some of this velocity is used up in a single row of turbine blading, as in
the de Laval turbine, the speed of the rotation of the wheel will be too high to be
blades are be useful for practical purposes, as there is the danger of structural
failures due to excessive centrifugal stresses.
2. Steam exits from the turbine with a sufficiently high velocity, meaning a
considerable loss of kinetic energy.
7. Why are some groups of steam turbine blades, particularly the first or
control stages more prone to fatigue failures than others?
Answer:
Blades in the first or control stages are under partial-arc admission that forces
the blades to move into and out of the steam flow causing alternating high-and
low-impact forces. This periodic change of impact forces imparts fatigue stress
that makes such groups of blades susceptible to fatigue failure.
8. Why could a turbine wheel become unbalanced?
Answer:
If the turbine is kept idle for a long spell without complete drainage of exhaust
casing, the solid matter can deposit in the lower half of the wheel causing
unbalance.
9. Why do blade roots suffer from damage?
Answers:
1. Fatigue is the common cause to the effect of blade root damage. Also a generic
type of fault often assists this factor in design or manufacturer.
2. Moreover, the root-fillet radii are subjected to a high degree of stress
concentration with the effect that they crack relatively easily.
10. Why do electrically induced stresses occur in steam turbine rotors occur?
Answer:
They originate due to short circuits and faulty synchronization.
11. Why do shroud bands suffer from damage?
Answer:
Steam borne solid particles and moisture strike the shroud band continually and
in that process they remove material from rivet heads until the rivet becomes
too weak to exercise its clamping effect whereupon it fails to hold the band in
place.
12. Why do thermal stress occur in the steam turbine rotors?
Answer:
Transient operating phases i.e. startup and shutdown the genesis of thermal
stress induced to the turbine shaft.
13. Why do these two types of cracking take place?
Answers:
1. The cause to the effect of blade-groove-wall cracking is creep with or without
low cycle fatigue.
2. Faulty heat treatment procedure results in poor creep ductility that may also
contribute to this type of faults.
3. Whereas thermal fatigue have been identified as the single cause to rotor-
surface cracking.
14. Why does mechanical stress occur in turbine rotors?
Answer:
The factors that contribute to mechanical stress in the shaft are the centrifugal
forces and torque’s generated due to revolving motion of the shaft as well as
bending arising during steady-state operation.
15. Why does SCC occur at the intermediate pressure stage in the steam
turbine?
Answer:
Steam turbines of nuclear power plants usually operate on wetter steam, than
those of thermal power plants. So even at the intermediate pressure stage,
steam becomes wet and it precipitates the impurities i.e. corrodents dissolved in
it These corrodents deposit and build up on rotor shaft causing stress-
corrosion-cracking.
16. Why is it poor practice to allow turbine oil to become too cool?
Answer:
If the turbine oil is allowed to become too cool, condensation of atmospheric
moisture takes place in the oil and starts rust on the polished surfaces of the
journals and bearings. Condensed moisture may also interfere with lubrication.
17. Why is there a relief valve on a turbine casing?
Answer:
The turbine casing is fitted with spring-loaded relief valves to prevent damage
by excessive steam pressure at the low-pressure end if the exhaust valve is
closed accidentally. Some casings on smaller turbines are fitted with a sentinel
valve, which serves only to warn the operator of overpressure on the exhaust
end. A spring-loaded relief valve is needed to relieve high pressure.
18. Why must condensate be subjected to salinity tests where brackish
cooling water is used?
Answer:
Condensate may leak from the cooling-water side to the steam side of the
condenser and contaminate the feedwater, thus causing scale to form in the
boilers. Or brackish cooling water may leak into the steam space from cracked
or porous lubes or from around the joints at the end of the tube ends, etc. By
taking salinity readings of the condensate, leaks may be found before they can
do any harm.
19. Why must steam turbines be warmed up gradually?
Answer:
Although it is probable that a turbine can, if its shaft is straight, be started from a
cold condition without warming up, such operation does not contribute to

L
 continued successful operation of the unit. The temperature strains set up in the
casings and rotors by such rapid heating have a harmful effect. The turbine, in
larger units especially, should be warmed slowly by recommended warm-up
ramp rates because of close clearances.
EQUIVALENT LADDER / LOGIC DIAGRAM
WET LEG PRINCIPLE FOR LEVEL MEASUREMENT

Zero Level Max. DP

H–L
0 – max = -x

Full Level Zero DP

H–L
Max – max = 0

Range = - x to 0
Q: If wet leg empty, while tank is full, what will happen?
Reading on display will be double of the upper range.
DP
H–L EQ EQ
Max - (-Max)
2 Max

MANIFOLDS EQ
H L
Rosemount H L Bailey

Vent
BUBBLER METHOD
• Can mount at any position (i.e. at H level or below H level.
• Air supply should be greater than the max. pressure of the Tank.
• Rotameters are used because of high accuracy for adjusting exact flow.
• Purging required if greater than 100% reading
• For un-pressurized tanks, L side will be open to atmosphere while for
pressurized tank L side is also connected to air supply via rotameter.
• At 50% level, 5 psi(as per example) back pressure to diaphragm cell of
Transmitter.

WET LEG

• Calibration w.r.t. low side.

• H2O filling is to avoid damage to capsule assembly from Steam.
• Transmitter will be mount below H side of Tank
• 4mA = 0% = Max DP
• 20mA = 100% = Min DP
• Capacity bottle of wet leg should be filled manually.
• Wet leg is mostly use for Level Measurement. Very uncommon for pressure or
flow.
• Wet leg can be identified by a capacity bottle at one side (While for Steam
(Pressure or Flow), two capacity bottles at both sides. If purged it, it will take
some time to making condensate in it.
WET LEG CALCULATIONS
DEAD BAND
Difference between set and Reset of a switch ↑3.7 ↓3.2

HYSTERISIS ERROR
At a point value is different in increasing and decreasing
→ 10.00 kg Gauge = 9.8
← 10.00 kg Gauge = 10.2
ABBREVIATIONS
HV Shutdown Valves
EV Solenoid Valve
XV On/Off Valves
XSH / XZH Torque Switches
FY I/P
ZT Position Transmitters
AT / AE Analyzers
BE /BSL Flame Scanners / Ignitors
HU Emergency Stop
WT / WZ Weighing Transmitters
DX Knockers
CALIBRATION BY PURGE POINT
Connect calibrator to H side for applying pressure
Open L side to atmosphere
BAILEY COMMUNICATOR
Protocols
FSK (Frequency Shift Keying)
HART (Highway Addressable Remote Transducer)

PTS Platinum series

EQS Equilibrium Series

Output Type
Linear
Square Root
3/2 Flow Mode
5/2 Mode
FUNC GENERATOR
Vol / Sphere
Vol / Cyliner
Objective type Questions
1‐Which Type of work permit is used for Grinding in the field?.
Ans‐ Hot work permit
2‐If a transmitter shows reading above normal what you will do?
Ans‐Get permit, Isolate the transmitter, purge and check Zero if problem then
calibrate.
3‐ What types of Ultrasonic Flow Measurement exist in industries?
Ans‐Transient & Doppler Effect Type.
4‐Describe the function of Accumulator into the Pump?
Ans‐ Reduce the pulsating in the suction fluid of a pump.
5‐Describe the following safety code of instrument>
Ex d II C T6
Ans‐
Ex=Explosion Protection
d= Types of protection d,Dust proof
II= indicates grouping Group I=Under ground work Group II=Surface work
C=Gas sub division Group c= Hydrogen
T6=Temperature class T6=85 degree
6‐ What means by IP65?
Ans‐ IP=Ingress protection
65=Degree of protection 6=Complete protected against dust
5=Protected against Jet of water from all direction of instrument
7‐If signal fails and valve goes to close?
Ans‐FTC(fail safe to close)
8‐If signal increase and valve goes to close position
Ans‐Direct acting
9‐Which mechanical device is used in pressure gauges to reduce pulsating>
Ans‐Snubber
10‐In steam service,pressure gauge is used with?
Ans‐Siphon
11‐Main purpose of cage is?
Ans‐Reduce noise
12‐If controller signal is 50%, and valve opening is 75%, valve characteristics is
Ans‐Quick Opening
13‐If Equal percentage valve is used and valve opening is 62% what is the controller
O/P
Ans‐75%
14‐Valve seat leakage class VI is
Ans‐Tight shut off
15‐If error in the controller is +2%, error in the transmitter is ‐1%, the total error is
Ans‐+1%
16‐Describe anti‐surge loop?
Ans‐To minimize/reduce or illuminate the surging effect in the compressor
17‐what effects a surging can produce in the compressor?
Ans‐a‐Bow of compressor Shaft b‐Stress on sealing’s c‐Damage internal parts .
18‐What mean by 2 out of 3 voting logic in the controller system?
Ans‐System trip when any 2 inputs variable goes to Bad state
19‐If the Feedback link disengages from the valve, what happened with valve?
Ans‐Valve goes to fail safe position either close/open
20‐If valve is opened with a momentum jerk, causes due to?
Ans‐Glands are over tight/Air supply UN sufficient
21‐What type of Serial links are used in control system normally?
Ans‐RS‐232/485
22‐Triconex used processing techniques of?
Ans‐TMR (Triple Modular Redundant)
24‐PlC has cycling speed than DCS?
Ans‐High
25‐One of the most popular method of Flow measurement is?
Ans‐DP type
26‐What LEL stands for?
Ans‐Low Explosive Limit
27‐What LTV stand for?
Ans‐Low Thresh hold Value
28‐To do job in the field, must be primary requirement is?
Ans‐PPEs(Personal Protective equipments)
29‐In Triconex system, RED LED indicates?
Ans‐Normal operation
30‐Software used in Triconex is called?
Ans‐TRI‐Station
31‐In 3500 vibration monitoring system, firmware used is called?
Ans‐RCS(Rack Configuration system)
32‐3500 monitoring system total PLC is called?
Ans‐System 1
33‐Active type speed probe needs?
Ans‐Energization power supply
34‐For minimum speed measurement, a suitable probe is?
Ans‐Active type
35‐The minimum conductance which can be measure/sensed by Mag flow meter?
Ans‐0.5micro Siemens
36‐In mountains area which type of Transmission is suitable?
Ans‐Line of Sight transmission
37‐The wave receiving by Radar Type transmitter is called?
Ans‐Echo
38‐The radar transmitter measures?
Ans‐The time factor of Echo
39‐In open Underground tank, level is measured by?
Ans‐Bubbler type transmitter
40‐Hart stands for?
Ans‐High Way Addressable Remote Transducer
41‐If a cable has 0.5 ohm/m resistance, how much a transmitter get resistance if the
cable length is 100 m?
Ans‐50 ohm
42‐Key phaser is basically used for?
Ans‐phase amplitude of shaft
43‐MSDS stands for?
Ans‐Material safety data sheet
44‐Rectifiers are used to convert?
Ans‐Ac/DC voltage
45‐In Triconex, communication to the other system which card is used?
Ans‐SMM (safety manager module)
46‐On line cards are replaced in Triconex due to?
Ans‐TMR techniques
47‐EMS standard is based of
Ans‐1400‐200(Environmental management system
48‐If a transmitter is installed 10 m below its tapping point how much pressure
exerted if fluid is water?
Ans‐4.3mH2O
49‐In 3‐Element loops what is the master variable?
Ans‐Level
50‐3‐element is used to illuminate the effect of?
Ans‐Swelling/Shrinking
51‐In‐3 element loop if we want to calibrate the transmitter we should keep controller
on?
Ans‐ Single loop
55‐In Gas turbine IGV stands for?
Ans‐Inlet gide Vanes
56‐IGV is used to control
Ans‐Speed of turbine
57‐In ISO mod of gas turbine operation?
Ans‐Load remains constant
58‐In Droop mode of GT,which remains constant?
Ans‐Speed constant.
59‐In boiler which Gas is used for Purging?
Ans‐Nitrogen
60‐What is NFPA Stands for?
Ans‐National Fire Protection Association
61‐In NFPA Diamond Blue Color shows?
Ans‐Health Hazard
62‐Which type of Fire extinguisher is used in Electric type fire?
Ans‐Co2
63‐K type thermocouple temperature range is?
Ans‐0‐‐‐1600Deg
64‐If DP is 25% what is volumetric flow rate?
Ans‐50%
65‐To convert DP transmitter O/P to a linear range is used?
Ans‐Square Root Extractor
66‐Explain the procedure of a PT calibration
Ans‐Do your Self.
67‐If a metallic object comes near to the probe the return energy?
Ans‐Reduce

68‐ To extinguish fire with water Process is called?

Ans‐Quenching method
69‐To purge an ammonia fluid transmitter ensure on high priority?
Ans‐Wind Direction
70‐Decode the following vibration probe No
330101‐00‐24‐02‐01
Ans‐330101=8mm UNF probe 00=unthreaded length 0 24=2.4inch probe length
02=Miniature male Coaxial connector 01=Agency approval 01(CSA)
71‐What is meant by REBAM vibration probe?
Ans‐Rolling Element Bearing Activity Monitoring
72‐Enlist the probe Tip materials?
Ans‐Teflon,PPS,Ceramic
73‐If we used 330101‐00‐050‐00‐05 what is probe length?
Ans‐50cm
74‐NSV type probe stands for?
Ans‐Narrow side view
75‐In DCS system a single task is performed by?
Ans‐Multiple Controllers
76‐If signal goes to increase, valve stem goes down and valve plug will open, what is
valve action?
Ans‐Air to close
76‐If signal decrease, valve stem goes down, valve plug goes to close?
Ans‐Air to Open
77‐In orifice Plate reduces stream size?
Ans‐Abruptly
78‐An orifice that is semicircular in shape rather than round, is called?
Ans‐Segmental‐bore orifice
79‐A manometer is relatively free from error because it has no?
Ans‐Moving parts
80‐The maximum recommended distance between an orifice and a manometer is?
Ans‐50 Ft
Subjective Questions
1‐How to check electrical health of Vibration probe?
2‐How you realize/select which vibration probe is able to use?
3‐Draw the schematic/functional block diagram of Triconex showing comprehensive
card detail?
4‐Define Surging/Anti surging System of a compressor?
5‐Explain with the sketch of Anti surging loop of Compressor?
6‐Which transmitter is used for direct level control Measurement?
7‐Describe 3500Vibration Monitoring system?
8‐What is meant by FSK‐Hart protocol?
9‐How does a positioned work?
10‐If a valve is hunting, what you will do?
11‐How to calibrate a temperature transmitter & how a Cold junction Compensation
will be carried out?
technical/operational organization?
12‐How Proximitor works?
13‐Describe/Draw Mark V/VI functional detail?
14‐Do you like to perform work as a Team Work or preferred to do work as a Single?
15‐What safety precautions you will adopt to work on Steam service control valve?
 16‐What is Preventive Maintenance Program (PMP) and how it is Effective in a
17‐What is procedure to work in your present organization?
18‐Why it needs to do Preventive maintenance (PM)?
19‐What is ERP program?
20‐If Company select you what is your notice period?
Multiple Questionnaires
21‐ Which one of the following combination of measured variable and its unit is
wrong?
Pressure‐Bar
Flow‐ Kg/hr
Temperature‐Kpa
Level‐%
22‐Which of the following combination is wrong for thermal elements
K‐Type Iron ‐Constant
J Type Iron ‐Constant
T Type Copper ‐Constant
E Type Chromel –Constant

23 If polarity of thermocouple is reversed,

The temperature indication will not be affected
The indicated temperature will be more
The indicated temperature will be less
The temperature indication will increase slowly and saturate at maximum scale
range

24‐which of the following meters does not use an obstruction in the line
Magnetic flow meter
Head meter
Turbine flow meter
Open channel meter

25 The Corlious effect associated with

Magnetic flow meter
Mass flow meter
Orifice flow meter Venture flow meter
26 choose the correct definition of mass flow
Mass flow =Volumetric Flow/Density of Medium
Mass flow =Volumetric Flow X Density of Medium
Mass flow =Volumetric Flow X Cross sectional area of Pipe
Mass flow =Volumetric Flow
27 which of the following principle is used in ultrasonic flow mete
Doppler Method
Transit time method
Faraday ,S law of electromagnetic induction
Both a & b
28 A pressure transmitter can also be used as
I/P convertor
P/I Convertor
Position Transmitter
None of the above
29 A DP type flow transmitter has been calibrated at 200”of WG for 2000 KG/hr range. It is
required to change the range to 4000 kg/hr.What will be the new DP Setting?
400” WG
200” WG
800” WG
600” WG
30 A tank of 20m height is filled with 10 meters of Water and 10 meters of Oil. Density
of Oil is 0.9. The resultant head pressure at the bottom wall of the tank is

a) 15 m
b) 14.5 m
c) 19 m
d) 10m
e) 19.1m
f) 15.2m
31 An air failure: Close: globe valve fails to close completely on Air failure.
What will be the probable cause?
The spring is weak/Broken
The diaphragm is punctured
Instrument Air supply pressure is not enough as per bench set requirement.
Instrument Air supply is very high as bench set requirement
32 Which of the following leakage class of control valve are the lowest shut‐off characteristics?
Class I
Class II
Class III
Class VI
Class IV
compressor anti surge control system
 33 The following characteristics of Control valve: Equal increment of travel yield equal
increments of flow constant pressure drop” refers to
Quick Opening
Parabolic
Equal percentage
Linear
Fast opening
None of them

34 what will happen if the feedback link of the control valve has failed during operation
valve will be locked
Will be hunting
Will seems no problem in operation
Positioned output will go to maximum on one direction depend upon positioned action
35 when proportional band is 100%,the gain of the automatic controller will be
5
0.5
50
1
36 If PID controller has no action of integral, what will be happen
The controller will tends to vibrate

The controller has steady offset from set point

Controller will be more noise sensitive
Action will be slow of controller
37 Which control philosophy works to measure the disturbance and correct
them before they cause upset to the controlled variable?
Feed forward control loop
Feed back control loop
Open loop
Cascade loop
38 the calibration errors noticed on various components of a pressure loop are
pressure Transmitter=1%” Controller Error=2%” Control valve=‐2%.What will the total
resultant error?
3%
9%
5%
2.3%
39 In safe area classification :an area where explosive gas‐air mixture is
continuously present: is called
Zone 1
Zone 0
Zone 3
Zone 2
 40 An instrument with following certification: EX d e m IIC T4” can be installed in which
zone?
Zone 0
Zone 1
Both b & c above
41 Which of the following frequencies contributes harmonics in a power line operating at 50 Hz
frequency
100. 150,200, 250‐‐‐‐‐‐
51, 52, 53, 54‐‐‐‐‐‐‐‐
60, 120, 180, 240‐‐‐‐
None of the above
42 To avoid Ground loop current in a two wire system which of the following practice is
recommended?
Ground the shield wire at one end( either at marshaling cabinet or transmitter end)
Ground the shield wire at both ends( transmitter & marshaling end)
Connect the negative power line to the shield
None b& c
43 which is the purpose of key phasor in compressor
To monitor axial displacement of the compressor shaft
For speed control of the compressor
To monitor speed of the machine and used in condition monitoring analysis
To measure the vibration of the compressor shaft
44 A BNC 3120 proximitor,driving BNC 300‐00‐00‐08‐18‐02 probe will require how
much feet of extension cable
18 feet
20 feet
17 feet
8 feet
45 In a TMR Triconex system with hot spare DO card installed, which of the following steps is
not recommended?
Removal of non‐active DO card
Removal of active DO card
On line down loading of changes
Forcing of an input
46 what is “Sequence of events” functionality in a DCS/PLS
It is program for sequence control of process
It is batch control process program
It is recording of all digital events with time resolution same as the plc scan time program
All the above
47 Using of the following modules.Tri station can be connected to Tricon Module?
SMM
EICM
NCM
Both b &C
48 Error detection that is typically used on Ethernet and most local area networks is
Checksum
CRC(Cyclic reduncy code)
Parity check
None of the above
49 To connect field transmitter, which frequency is used for wireless instruments?
2.4 GHz
2.0 GHz
2.4 MHz
Both a & c
50 What is meant by 2 out of 3 voting in instrument trip system?
Any 2 instrument give trip value, system goes to trip
Any 3 values jointly give trip, system will initiate trip
Any single trip value will trip system
Both a& b
Both b & c
51 In PLC feature that indicates which alarm has operated first is called as
SOE
Trip history
Both b & C
First out
52 To do job in a confined space vessel, one need to
Work permit
Entry permit & Work permit
JSA,vessel entry and Work permit
Both B & C
53 What steps should be taken to calibrate DP flow transmitter in Steam application
while plant is in running format
Work Permit, LP valve isolation, Equalize 3 way manifold, LP valve isolation.
Depressurize the impulse line, start calibration
Work Permit, LP valve isolation, Equalize 3 way manifold, LP valve isolation.
Depressurize impulse line, start calibration
Work permit, equalize 3 way manifold,LP valve isolation,LP valve isolation,
depressurize impulse line, start calibration
Hp valve isolation, Equalize 3 way manifold,LP vale isolation, Depressurize impulse line,
Work permit, Start calibration
54 The most important goal of :Continuity check” before powering up of field
instrument to ensure
Transmitter power is available
Transmitter is wired to the proper controller loop
Correct transmitter is installed
None of the above
55 which one of the following standards refer to Environmental management system
ISO 9002
ISO 14001
ISO 9001
OHSAS 18001
56 A P & ID need to be updated when:
A preventive maintenance activity is performed on a process equipment
A corrective maintenance activity is performed on instrument
A new process equipment is installed and commissioned
Both a & b
57 To minimize electrical interference when AC power and DC wiring meet in a control
panel, It is good to,
Use a different size wire
90 Degree Cross the both wire
Run the wire parallel to each other
Twisting AC wire across the DC wire
58 A DP type transmitter is mounted 3 Feet below the Zero level in a tank, for correct
value of the transmitter, its output must be;
Zero elevated
Calibrated for Span
Calibrated for true zero
Suppressed Zero concept
59 What is the resistance of 1000 ft of copper wire( Specific resistance=10.37)
given a cross‐sectional area of 10370Cmill and a wire temperature is 20 degree
1 ohm
2 Ohm
10 ohm
100 Ohm
60 what is the Standard Color code for K type thermocouple in the USA standard

a) White (+), Red (‐)

Purple(+), Red(‐)
Yellow(+), Red(‐)
Blue(+), Red(‐)

62. Which of the following is not true of thermocouples?

a. They do not use a reference junction.
b. They generate a small voltage.
c. They are composed of dissimilar metals.
d). They can be calibrated.
63. To calibrate a pressure transmitter, with a range of 0 psi to 600 psi, to .02% of
Reading accuracy, which of the following test equipment would be best suited for the
calibration?
a. Precision dial gage.
b. Precision dead weight tester.
c. High pressure mercury manometer.
d. Precision air piston
64. There is a problem with our HART475 it is not communicating with smart devices
error becomes "NO DEVICE FOUND"we have insert 250ohm resistance as per
requirement but invain plz tell me the solution
65. On liquid service if PT Head is 18 meters. How much pressure will be exerted on it.
If Transmitter is not in service?
66. If an Instrument has 550 ohm internal resistance and the cable used for that
instrument is 0.5 ohm
per meter resistance. If the voltage is 12volt.How much length cable can be used?
66. how the flow rate is measured from a pipe with the help of pressure?
67. What is transducer?
68. what would be the minimum flow rate that we can measure on rotameter..?
69. what is temperature compensation?
70. Can we install leveltrol in steam drum for measurement the level of steam drum? if
not then why?
71. What is the principle of ultrasonic flow meter and radar type flow meter?
72. What is modbus & what signals are taken through it
73. How to check earthing,what is minum ohms for proper earthing?
74. Explain about signal isolator?
75. What is mean by trim?
76. for crude oil application in floating roof tank, how to calibrate a DP Transmitter?
How is the floating roof weight considered?
77. Working principle capacitance type level transmitter?
78. What is procedure to change mmwc into tph?
79. How can I make calculation for Install level transmitter (DP) for open tank and cloes
tank?
80. How to calibration a control valve?
81. What is Dry Leg calibration and where is it used?
82. How to measure flow with DP?
83. What is coriolis principle for mass flow meter?
84. How to trim the pressure transmitter?
85. How to calibrate bubbler type level transmitter of Rosemount make and how to set
air flow
according to the range... Give one calibration procedure with one example?
86. Describe flow nozzle principle?
87. What are the characteristics of control valve?
88. What is the reason for flow fluctuations happen on differential flow transmitter
during in service?
89. How to calibrate the interface leveltrol?
90. What do u mean by 2/3 solenoid valves?
91. Explain about SOURCING & SINKING concepts in PLC to field sensor wiring?
92. What is sil (safety integrity level?
93. Where & why we are using SURGE PROTECTION?
94. Why using 4‐20ma not using 0‐20or why not using 1‐ 20ma?
 95. Define the terms Accuracy, precision, Spam, process tolerance while doing
calibration of an instrument? Explain with an example?
96. How do you calibrate the vacuum transmitter if it shows more reading?
97. How to calculate the total flow in square root?
98. What is the right procedure for adjusting the gap voltage of Bentley Nevada
vibration sensor?
99. Whether radar level transmitter is applicable for the open tank?
100. What is load line in control valve?
101. What is Field bus?
102. How to overhaul control valves. What are the proper procedures?
103. How to find out turn down ratio of Pressure transmitter?
104. Why we set ‐10 volt in vibration sensor output,

QAPCO TEST

1- How many moles contains 6 gram of carbon?

• 6 moles
• 12 moles
• 1/2 moles
• 3 moles
Mole= Weight in gm/Mol. wt
2- Complete and balance the equations?
• C2H6 + O2 =
• CH4 + O2 =
• NaOH + CO2 =
• H2 + S =
• C2H6 +O2 =
3- Why flooding occurs in a fractionation column?
• Sudden low Pressure
• Sudden high Pressure
• High liquid load
• Velocity increase of vapors
• Velocity decrease of vapors
4- What is the Latent heat?
• Change the phase
• Change the temperature
• Melt the solids
• Freeze the liquids
5- How you define boiling point?
• When liquid pressure equals to atmospheric pressure
• When Vapor pressure equals to atmospheric pressure
• When any liquid boils
• When any liquid change his phase
6- What is the color of mandatory sign of site?
 • Red
• Green
• Yellow
• Blue
7- Write the name of green house gas?
• Keton
• Portals
• CO2
• H2

8- What is the partial pressure?

• Pressure of the all gases
• Individual gas pressure
9- Which one is the quality policy sentence?
• Process is the main aim
• Quality of products is the target
• Specifications are not important
• Consumer's satisfaction is our goal
10- Why the cavitation occurs?
• Low NPSH
• High suction pressure
• Low discharge pressure
• High discharge pressure
11- Why surging occurs in a centrifugal compressor?
• High suction pressure
• Low discharge pressure
• Low suction flow
• High suction flow
• High discharge pressure
12- How we remove conductivity to make demin water?
• Remove ions
• Remove Ca, Mg
• Remove dust
• Remove salt
13- What is the effect of H2S gas on human body?
• Irritant and Toxic
• Very pleasant
• Bleeding start
• Cough start
14- Why IBD performed in a steam drum?
• To remove the TDS
• To control the level
• Because boss says
• To remove the slug
15- Where is the sensitive tray in the column?
• Where hydrocarbon enters
• Where temp is measure
 • Where higher/ heavy hydrocarbon boils
• Where stripping steam given
16- How you start the screw compressor?
• Open suction valve
• Open discharge valve
• Open suction and discharge valve
• Close suction and discharge valve

17- Why weeping occurs in a distillation column?

• Sudden low Pressure
• Sudden high Pressure
• High liquid load
• Velocity increase of vapors
• Velocity decrease of vapors
18- What does catalyst in reaction?
• Increase rate of reaction
• Decrease the rate of reaction
• Does not act any part in reaction
• Consume during reaction
19- Why maintain high PH in a boiler?
• Because acid prepares in boiler
• To steam flow easily
• To control TDS
• Because boss says
20- Which steam is called saturated steam?
• HP
• LP
• MP
• None of above
21- If you want to work on erected scaffolding what will you do?
• Check Safety tag
• See Height
• Nothing
• Check PTW
22- Where sieve trays use normally in column?
• In stripping section
• In top section
• In middle section
23- Why excess air confirmed in a fired heater?
• To ensure complete combustion
• To control draft
• To control firing
• No reason
24- At what temperature C2H4 liquefy?
25- Which department checks Scaffolding?
• Safety department
 • Process department
• Maintenance department
• None of above
26- Which give chemical information?
• MSDS
• PTW
• DMDS
• MEA
27- Which type of reaction is polymer reaction?
• Exothermic reaction
• No heat release
• Both endothermic exothermic
• Endothermic
28- How we control centrifugal pump flow?
• With discharge control valve
• With suction valve
• With both discharge and suction
• None of them
29- How we control PD pump flow?
• With stroke length
• With variable rpm
• Both of above
• None of above
30- Why we do fast purging in boiler?
• To remove water
• To remove slug
• To remove level
• To remove dust
31- Why CBD is opened in continuous operation of boiler?
• To steam purity
• To control level
• To remove slug
• To remove precipitates
32- How you purge out any vessel in industry?
• With N2
• With O2
• With air
• With fuel gas
33- If you find a fire what will you do first?
• Inform to control room
• Inform to unit head
• Leave the plant
• Try to extinguish the fire
34- Why boilers PH control more than 7?
• To control corrosion
• To control steam easy flow
• Because boss says
 • None of above
35- Liquid emission from plant?
• COD
• SO2
• CO
• CO2
36- How we increase or decrease PD compressor Capacity?
• Recycle Valve
• Suction valve
• Discharge valve
• RPM control
37- Why polymer became solids?
• Long chain molecule
• High molecular wt
• Fast reaction out of control
• All of above
38- Why reflux is used in a column?
• To increase purity
• To control product flow
• Because more liquid is prepared
• None of above
39- To enter a fork lifter in operation area?
• Its speed should be 40Km/hr
• Having a fire extinguisher
• PTW required
• Having no load
40- Partial pressure of a gas is equal?
• Individual pressure of gas
• Total pressure of gases
• None of above
• All of above
41 - Loading and unloading arm of ethylene before use required?
• Maintenance
• Pressure testing
• Cooling
• Heating
42- If a toxic gas released what will you do first?
• Leave the Plant
• Inform to control room
• Use BA to stop leakage
• Take no action
43- A vessel contains 1kg/cm2g air, increase pressure with N2 up to 6 kg/cm2g what will
be the O2 percentage in it?
• 5.5%
• 3.5%
• 3%
• 2.5%