Instrumentation and P&ID question:

1. Why to use P&ID?

To describe all plant and equipment. This indicates the flows in a plant and the sensors or other
devices in question. It gives names and parameters to each sensor and other equipment.

It is a pictorial image of the processing facilities:

1. Key piping and instrument details

2. Control and shutdown schemes
3. Safety and regulatory requirements
4. Basic start up and operational information

2. What are the items that will listed in a P&ID?

1. Instrumentation and designations
2. Mechanical equipment with names and numbers
3. All valves and their identifications
4. Process piping, sizes and identification
5. Miscellanea – vents, drains, special fittings, sampling lines, reducers, increasers and
swaggers
6. Permanent start-up and flush lines
7. Flow directions
8. Interconnections references
9. Control inputs and outputs, interlocks
10. Interfaces for class changes
11. Computer control system
12. Identification of components and subsystems

3. What are the different flow meters?

• Differential pressure(DP) flow meter

• Velocity Flowmeter
• Positive displacement flowmeter:
• Mass flowmeter

4. What are the different types of temperature measuring instruments?

• Thermometer
• Thermister
• RTD
• Pyrometer
• Thermometers
 5. What is Flow compensation?
In steam or gas flow measurement, the density of the steam or gas changes as pressure and
temperature change. This change in density can affect the accuracy of the measured flow rate if
it is uncompensated. Temperature, pressure compensated flow control is a mathematically
adjusted flow control with one or more additional variables.

6. Why 4-20mA signal 12 is preferred over a 0-10v?

If the instrument is faulty, it can be detected easily. If the output is 0 ma, it will be hard to
determine whether it is a defective signal or a good signal.

20 ma is used as maximum because the human heart can withstand up to 30 ma of current

only. For safety reason 20 ma chosen as the maximum value.

7. How DP transmitters are connected to closed tanks?

The bottom of the tank is attached to the transmitter’s high-pressure side in a closed tank. The
top of the tank is fixed to the transmitter’s low-pressure leg. The pressure of the vessel can be
measured in this way.

8. How does the DP flow transmitter system vary on gas and liquid pipeline?
To stop gas condensation in the signal line and HP & LP chamber, DP is mounted above the
orifice plate for the gas line.

To stop gas trapping in the signal line and the HP & LP section, DP is mounted below the orifice
plate for the liquid side.

9. Why is the Orifice tab provided?

1. Indication of the orifice plate in a line

2. The orifice diameter is marked on it.
3. The material of the orifice plate.
4. The tag number of the orifice plate.
5. To mark the inlet of an orifice.

10. Why thermowells are used?

Thermowells are equipment that protects temperature-measuring devices from exposing the
device to the measuring substance.

Wells are used to protecting against corrosion damage erosion and processes of high pressure.
A thermowell can also be used to protect a sensor during handling and routine operations from
physical damage.
 11. What is RTD?
RTDs (Resistance Temperature Detector) are temperature detectors that change their
resistance as temperature rises. RTDs are used for continuous measurement of temperature,
indicating a positive coefficient of temperature.

12. What is the main difference between RTD and Thermistor?

RTD has a positive coefficient of temperature and Thermistor has a negative coefficient of
temperature:

13. How to identify between RTD & Thermocouple?

Connect the transmitter to a multimeter in resistance mode. If you read in ohms, otherwise it’s
RTD, it’s a thermocouple.

13. What is the control valve?

The control valve is a final control element that controls the user to regulate or restrict the fluid
flow through a flow channel. It allows direct flow rate control and consequent regulation of
process quantities such as pressure, temperature, and volume of liquid.

14. What are different types of control valve you know?

15. What is the use of valve positioner?

The valve positioner’s aim is to improve the valve action’s accuracy. Positioners are used to
completely perform the function of the final control variable in the control loop.

16. What are the uses of valve positioner?

• Quick action
• Valve hysteresis
• Viscous liquids
• Split range.
• Line pressure changes on valve
• Bench set not standard
• Reverse valve operations

17. What is the solenoid valve?

A solenoid is a valve that is electrically operated. This consists of a solenoid coil passing in a
magnetic plunger. This plunger is attached to the pump, opening or closing the valve. Two
styles of solenoid valves are present:

• Normally opened
• Normally closed
 18. What is I to P converter?
The pneumatic signals of the instrumentation are sustained at a maximum of 3-15psi. The air
compressor system delivers air at a much higher pressure which is then decreased employing
restrictions and further control of 3-15psi. The I/P converter is used to provide this restriction
and control.

19. What are the different types of Bourdon tubes?

• C type
• Spiral type
• Helix

20. State the principle of LVDT

The LVDT’s secondary winding differential output voltage is proportional to the displacement felt
by the mass induced by the Core acceleration; the differential output voltage becomes an
acceleration metric.

21. What is a hazardous area location?

The hazardous areas is a probability analysis and a risk assessment of a manufacturing area or
process that processes a potentially flammable atmosphere that focuses solely on minimizing or
eliminating electrical energy as a source of potential ignition.

22. In Area Classification what are the difference between Class 1 Zone 0, Class 1 Zone 1 &
Class 1 Zone 2 Location?

Class 1 Zone 0

In which ignitable concentrations of flammable gases or vapors are present Continuously and in
which ignitable concentrations of flammable gases or vapors are present for long periods of
time.

Class 1 Zone 1

In which ignitable concentrations of flammable gases or vapors are likely to exist under normal
operating conditions or vapors may exist frequently because of repair or maintenance
operations or because of leakage and in which equipment is operated or processes are carried
on, of such a nature that equipment breakdown or faulty operations could result in the release of
ignitable concentrations of flammable gases or vapors and also cause simultaneous failure of
electrical equipment in a mode to cause the electrical equipment to become a source of ignition.

Class 1 Zone 2

in which ignitable concentrations of flammable gases or vapors are not likely to occur in normal
operation and if they do occur they will exist only for a short period or in which volatile
flammable liquids, flammable gases, or flammable vapors are handled, processed, or used, but
in which the liquids, gases, or vapors normally are confined within closed containers of closed
systems from which they can escape, only as a result of accidental rupture or breakdown of the
container system and in which ignitable concentrations of flammable gases or vapors normally
are prevented by positive mechanical ventilation, but which may become hazardous as a result
of failure or abnormal operation of the ventilation equipment.

Cable schedule interview questions:

1. What is the difference between IS and non IS cables?

Non IS cables are used in non-hazardous areas where protection needs no special
consideration.

Cables that are safe in faulty situations, protected from external electrical or magnetic field
damage and used in intrinsic circuits are referred to as intrinsically safe cables or IS cables

2. What is Cable Shielding ?

Control and instrumentation cables may feature a type of electromagnetic shielding material,
which is wrapped around the cable underneath the outer jacket.

3. How do we determine the rating of a cable?

The continuous current rating of a cable is determined by the ability of the cable to dissipate the
heat generated by the current passing through its conductor.

It depends on a number of parameters, but the most important are the:

 Conductors’ DC resistance;
 Thermal resistance of the insulating sheathing materials; and
 Ambient conditions of the environment where the cable is installed (for example the
surrounding air temperature).

4. Differences between solid and stranded conductors?

Solid conductors are constructed of one, single piece of metal. It is tougher than a stranded
conductor, but rigid and less flexible than a stranded conductor.

Stranded conductors are made of multiple small strands, which group together to make up a
single conductor. It is more flexible than a solid conductor, but less durable.

5. What is the purpose of the screens in instrumentation cables?

The presence of large machines, welders and other processes in industrial environments create
a lot of electrical interference (noise).

6. What is the difference between the Power & Control Cables?

Power Cables – No. of Cores 2,3, 3 1/2 & 4 Core

Control Cables – Upto 63 Cores or above Standards Applicable for both – IS-694 & IS-1554 .
 7. What is the difference between Unsheathed & Sheathed Single Core Cable as per
IS-694?
Unsheathed – Only Core Insulation will be done and there will be no Sheathing.

Sheathed – Sheathing will be done on Core Insulation.

8. What is the difference between Control & Instrumentation Cable?

Control Cables – They are generally Core Constructed.

Instrumentation Cables – They are generally Pair Constructed with Shielding.

9. What is the difference between Thermocouple & Instrumentation Cable?

Conductor Material is different for both.

10. What is the difference between Armoured & Unarmoured Cable?

a. Armour.

b. Inner Sheath will be provided for Armoured Cable before Armouring.

11. What is a Co-Axial Cable?

This type of cable is used for Very High Frequency (V.H.F.) Applications.

12. Number of Strands for Cables ?

a. Solid Conductor – One

b. Multistrand – either 3 or 7

c. Flexible – No of Strands above 7 – Dia of Strands upto 0.3 mm .

13. What is the difference between RTD / Instrumentation Cable?

RTD Cables will be Triad Constructed.
Instrumentation Cables are Pair constructed.

14. What are the normal sizes of Control Cables?

1.5 & 2.5 Sq.mm

15. What will be the normal Conductor sizes for instrumentation / RTD Cables?
0.5, 0.75, 1.0, 1.5 & 2.5 Sq.mm

16. Thermocouple Cable Conductor normal sizes ?

a. Single pair – 16 AWG (1.295 mm dia)

b. Multi pair – 20 AWG (0.813 mm dia)