(Instreng - Com) All Interview Instrumentation Questions Answered by Carl Ellis

This document includes Carl Elliss responses to the questions posed on Allinterview.
coms
instrumentation forum.
Q.
No
Ra
nk
Question
Q#
warning lamp does not light, but it does light when the wire from the lamp going to
9880 the sending unit is grounded (the part that plugs into the sending unit) what does this
indicate)?
Answ If the lamp lights when the wire from lamp to the sending
unit is grounded, then the other side of the lamp has
er
power.
The circuit is designed for the lamp to light when
the sending unit provides a complete electrical circuit.
Post
ed
Date
0 2014
-0418
The lamp lighting proves that

- the bulb is good
- there is power at the lamp.
If the warning lamp does not light when it should, then the
sending unit is faulty.
Carl Ellis
Measure First
Q#
Could anybody tell how much amps will a single input to plc will consume?
6054
6
Answ The spec sheets on my desk have these specs:
er
for an AC voltage digital input:
2 mA nominal @ 230 VAC, 50 Hz
for a DC voltage digital input:
2.3 mA @ 12 VDC
6.9 mA @ 24 VDC nominal
for a dry contact digital input (internal 15Vdc source):
2.6 mA nominal
Interviewees should be able to convert from milliamps to amps.
Normally, power (watts) is 'consumed'.
Current (amps) is a 'draw' on the power supply.
Carl Ellis
Measure First
2014 Carl Ellis, Measure First
0 2014
-0406
Q#
how in the 2 - wire transmitter, 24v supply and the 4ma signal gets in the same path?
1008
74
Answ The 2 wire transmitter, DC power supply and the load (some
0 2014
receiver, an analog input on a
er
-01PLC/DCS/Controller/recorder/indicator) are wired in series.
06
The installer 'gets them in the same path', an electrical
series circuit.
The transmitter uses about 3.5-3.6 mA of current as power to
run its own electronics that excite and/or read the sensor,
interpret the sensor's signal and create a scaled output.
A 2 wire transmitter acts like a variable resistor, or
transistor, in that it regulates its internal resistance so
that the output is scaled 4.0-20.0 mA, proportional to the
process variable it is sensing, with the loop current the
ranging 4-20mA.
The power supply voltage must be high enough to drive 20mA
(21.xmA if upscale failsafe is used/selected) through the
load (the input's resistance, wire resistance, any stray
resistance (terminal block). 24Vdc power supplies are the
most widely used power supplies, but most 2 wire
transmitters can operate with power supplies up to about
32-36 volts DC.
Carl Ellis
Measure First
Q#
how to check the leak in thermowells
1045
60
Answ
From Wika's FAQ:
er
What tests and inspections are stipulated for thermowells?
In accordance with DIN 43772 Point 4.6, all tests and
certifications should be agreed between the manufacturer and
operator.
What tests are usual or possible for thermowells?
Common non-destructive tests are the pressure test and, for
welded thermowells, the liquid penetrant test. In addition,
to test the centrality of the bore, ultrasound or X-ray
testing is possible. To test the sealing, helium leak
testing is an option. The surface finish or surface
hardness may also be tested. A material test would be
Positive Material Identification (PMI test).
What does ZFP, NDE or NDT mean?
ZFP is the German abbreviation for "Zerstrungsfreie
0 2013
-1226
Prfungen" (non-destructive examinations). The abbreviations

NDE or NDT stand for "Non-Destructive Examination" or
"Non-Destructive Testing", respectively. This is used to
refer to non-destructive inspections or tests on components
in general.
What is a hydrostatic pressure test?
The hydrostatic pressure test is a pressure and strength
test of the components of a thermowell in accordance with
the AD2000 data sheet HP30. For the test, the thermowell is
clamped into a test fixture and loaded at room temperature
with a defined test pressure and duration (e.g. three
minutes). In general, one differentiates between external
and internal pressure testing. Typical test pressures are
1.5 times the nominal pressure of the flange with external
pressure, or 500 bar with internal pressure. The test is
performed with water with a chloride content < 15 ppm. After
passing the hydrostatic pressure test, the thermowell is
marked with a "P".
What is a helium leak test?
For leak testing in accordance with DIN EN 1779 (1999) / EN
13185, helium 4.6 is used as a test gas. The test is able to
detect minimal leakage rates and is considered the most
sensitive test method for leak testing. In general, one
should distinguish between an integral and local test
method. In the integral test, leak rates (e.g. 1x10-7 mbar *
l / s) can be determined, while the local testing enables
the location of the leak to be determined using a spray
probe. After passing a helium leak test, the thermowell is
labeled with a corresponding sticker.
What is a PMI test?
The PMI (positive material identification) test proves which
alloy constituents exist in the material. There are various
common test procedures. With optical emission spectrometry
(OES) in accordance with DIN 51008-1 and -2, an arc is
generated between the thermowell surface and the test
equipment, and the spectrum of this arc enables the alloys
elements to be identified both qualitatively and
quantitatively. A characteristic feature of this procedure
is the fire mark that is left on the workpiece. A test
procedure which doesnt damage the surface is X-ray
analysis; during the X-ray the atoms of the thermowell
material are energised until they radiate themselves. The
wavelength and intensity of the emitted radiation is again a
measure of the alloys constituent elements and their
concentrations. Following a successful PMI test / positive
material identification test, the thermowell is marked with
"PMI".
What is a dye penetrant test?
With the penetrant test in accordance with DIN EN 571-1,
fine surface cracks and porosities in weld seams can be made
visible. After cleaning the surface to be inspected, a
contrast agent (red or fluorescent) is sprayed on. Through
the capillary effect, this agent penetrates any surface

defects there might be. After re-cleaning the surface, a
developer (white) is then sprayed on, which extracts the
contrast agent (from any hairline cracks, etc.) and through
color contrast, enables an easy evaluation of the defects.
After passing a liquid penetration test, the thermowell is
marked with "PT".
What is a X-ray testing?
Through an X-ray test to EN 1435 or ASME Section V, Article 2, Edition
2010, for example, full penetration welds on thermowells can be
investigated with respect to irregularities (cracks, voids, insufficient
bonding). Here,depending on the dimensions of the thermowell, up to five
X-ray images may be necessary to determine irregularities with sizes <
0.5 mm in the full-penetration weld. An X-ray examination can also be
used to record the bore centrality in solid body material thermowells.
For this purpose, two images of the thermowell tip at 90 to each other
are required.
What is an ultrasonic test?
Through an ultrasonic test to DIN EN ISO 17640, for example,full
penetration welds on thermowells can be investigated with respect to
irregularities (cracks, voids, insufficient bonding). To do this, the
reflections of a radiated ultrasonic signal from the interfaces of
irregularities are measured. To determine the position of the
irregularities, the ultrasound machine is set in advance with the aid of
a reference body. The ultrasonic method can also be used to measure the
wall thickness of a solid body material thermowell, in order to determine
the bore centrality.
Carl Ellis
Measure First
Q#
how to use K thermocouple instead E- type without compesation cable
1121
84
Answ Any thermocouple measuement requires 2 temperature measurements
- hot junction measurement
er
- cold junction measurement
A cold junction is created at the point where non-compensation wire is

connected to the thermocouple wire.
A measurement without compensation wire AND without a corresponding cold
junction measurement is not valid.
The only way to take a K type thermocouple measurement (or any type
thermocouple measurement) without compensating cable is to use a
temperature transmitter configured for the type of thermocouple because
the transmitter will perform the cold junction measurement at its wiring
terminals.
Carl Ellis
Measure First
0 2014
-0304
Q#
how can we measure the pressure in underground cooling water pipeline by using
1125 pressure transmitter?what about the tapping position?
76
Answ If the transmitter is not directly mounted on the
underground pipe, which is not unusual unless there is
er
vault access, then an impulse tube/pipe has to come up out
of the ground. The pressure measurement will be in error,
low, by the difference in elevation between the pipe's
elevation and the pressure transmitter's elevation.
0 2013
-1020
Suppose the pipe is 2.1m below the grade level and the
pressure transmitter is 1.6m above grade. The elevation
difference is 3.7m.
The measurement is 3.7m or 0.362 bar low.
It is not unusual to have water supplied at pressure
between at 4-8 bar. At 4 bar pressure, an error of 0.36m
water column is a 9% error, a vary large value for an
insturment capable of 0.25% or better accuracy.
The commissioning of the unit should include the
appropriate zero correction to compensate for such a large
error.
Carl Ellis, Measure First
Q#
Dear friends, I have a question: We work on a project which has some boilers to
1158 provide steam for desalination unit. The boiler area is safe and the only hazard source
79
is the fuel lines of boilers. I want to know according to NFPA standard which type of
instrument should be selected on the fuel line: Eex Type or Non-Eex type? Thanks in
advance
Answ I totally disagree. Because NFPA 86 (2007) specifically
0 2013
states
that
there
is
no
need
to
impose
requirements
for
er
-12wiring methods appropriate for a hazardous (classified
03
area).
------- NFPA 86 (2007) -----------A.4.1.3.3 Unless otherwise required by the local
environment, ovens and furnaces and the surrounding area
are not classified as a hazardous (classified) location.
The primary source of ignition associated with an oven
installation is the oven heating system or equipment or
materials heated. The presence of these ignition sources
precludes the need for imposing requirements for wiring
methods appropriate for a hazardous (classified) location.
Refer to Section 3.3 of NFPA497, Recommended Practice for
the Classification of Flammable Liquids, Gases, or Vapors
and of Hazardous (Classified) Locations for Electrical
Installations in Chemical Process Areas, and Section 3.3
------------ end --------------The 'gas train' or 'fuel train' is a pipe carrying fuel.
It is assumed that the fuel stays in the pipe until it gets
to the burner or is bypassed to an equally secure pilot
fuel line.
Control components in the pipeline typically need agency

approvals for conformance to failsafe conditions, but not
for explosion protection.
Carl Ellis
Measure First
Q#
How flow control valve is working with pnuematic positioner and I/P convreter from
1202 command is given from remote
66
Answ A controller (the remote device) generates an electronic
0 2014
4-20mA
output
signal
which
tells
the
valve
what
its
position
er
-07should be.
05
The 4-20mA signal is an input to an I/P
(current-to-pneumatic) transducer, which creates a pneumatic
output signal proportional to the 4-20mA electronic signal
from the controller, probably a 3-15psi pneumatic signal.
The pneumatic control signal is an input to the pneumatic
positioner, which mechanically senses the valve's position.
The positioner drives the actuator with as much supply air
pressure as is necessary to drive the valve to position
demanded by the control signal.
Carl Ellis
Measure First
Q#
What are the most frequent problem faces with Vortex flow meter?
1220
28
Answ Installation error - there is insufficient upstream and
downstream straight run piping for flow conditioning.
er
Failure to understand that all vortex do low flow cutoff at
approximately 10% of flow because there are not enough
vortices formed to produce an accurate flow rate
measurement. Low velocity flow rate in a steam header can
indicate zero flow even when the boiler is operating with
reasonable loads.
0 2014
-0218
Corrosive fluid destroys the thin sensor membranes.

Carl Ellis
Measure First
Q#
What is output of Thermocouple at 25 deg c
1238
38
Answ Question: What is output of Thermocouple at 25 deg C?
er
I'd flunk all of you except B0nz0 because only B0nz0
0 2013
-0817
understands thermocouple thermometry.

The answer is, you don't know because the cold junction
temperature is not specified. The question attempts to
find out if the concepts of a thermal gradient and cold
junction compensation are understood.
Which is why, I
assume, the question does not specify the type thermocouple.
B0nz0 is correct; any type thermocouple sitting on a desk
at 25 deg C; hot end = 25 Deg C, cold end = 25 Deg C, will
read 0.0mV because there is no thermal gradient.
The cold junction temperature is the same as the hot end
temperature.
Doesn't matter if it's a Type K or J or S.
With the same temperature at both ends, the output is 0mV.
But without specifying what the cold end temperature is, an
answer of 0mV assumes that the cold end is at 25 Deg C.
In the real world, it usually isn't.
The hot end can be at 25 Deg C with the cold end on a
terminal strip in control panel that's at 45 Deg C because
of the heat generated by the electronics in the control
panel. Then you'll read a negative voltage because the
cold end is hotter than the hot end!
The hot end can be at 25 Deg C and the cold end is
connected to handheld temperature calibrator in northern
Canada in the winter where the cold end terminal connection
might be at -30 Deg C.
In each case, it's the cold junction compensation that
corrects the temperature reading by measuring the
temperature of the cold end connection and taking that
temperature into account.
If I were to ask the question, I'd ask, "What is the output
of a thermocouple, both ends of which are at 25 deg C, and
why?".
The answer to the first part is 0mV.
Tell 'em Carl sent you.
Q#
I have observed in field instrumentation work... I remove the fuse of an analog
1250 transmitter then it shows 7.75 kg/sq cm (which is practically wrong value)in DCS and
88
when put the fuse it shows 0 in dcs. Then cheach the field transmitter termination and
found moister. clean that and then it shows 1.1 kg/ sq cm which is right value. Please
describe the above phenomenon.
ground current added to loop current through a
Answ Reason:
0 2013
ground
created
by
moisture.
er
-1226
The analog input on the DCS references ground at some point.
The moisture in the junction box or remote terminal panel
makes a connection to a local ground at that point. The
difference in potentials between the grounds causes a ground
loop - current added to the modulated loop current.
The
DCS's analog input 'sees' this current, even though the
transmitter is turned off, because the current is driven by

the potential of the ground loop, not the potential from the
power supply.
When the moisture (and hopefully, the dirt) is removed, the
local ground connection is broken and the loop is isolated,
except for the DCS's AI reference to ground.
So the DCS AI
'sees' only the loop current modulated by the pressure
transmitter and reports the correct loop pressure.
Some handheld calibration instruments can detect current
leakage in loop powered loops. An example is the Practical
Instrument Electronics (PIE) 334 Plus calibrator.
http://www.piecal.com/products/evolution/334Plus_mA.php
Carl Ellis
Measure First
Q#
pls any1 sugges me book for plc,dcs & scada..
1271
79
Answ Tony Kuphaldt's "Lessons in Industrial Instrumentation"
download URL:
er
http://www.ibiblio.org/kuphaldt/socratic/sinst/book/liii.pdf
0 2014
-0525
If the link breaks, search for the title and the author.
Better than the textbooks that cost a week's wages.
Carl Ellis
Measure First
Q#
i want to calibrate a transmitter in the range of -100 to 300 mmwc. How it is possible
1279 to measure -100 to 300?.
97
Answ Atmospheric pressure equals zero pressure (gauge).
er
Vacuum pressures are less than atmospheric so are negative with respect
to atmospheric pressure. -100mm would be a vacuum pressure.
0 2014
-0428
Pressures above atmospheric are positive with respect to atmospheric

pressure.
Carl Ellis
Measure First
Q#
what is difference between E/P positioner and I/P positioner. Why E/P fixed in below
1287 actuator and why I/P fixed in other place
62
Answ An E/P transducer is a voltage to position transducer, so its input
0 2014
signal
from
the
control
system
is
a
voltage
er
-078
signal, like 0-5Vdc.
Its output is a proportional pneumatic signal.
02
An I/P transducer is a current to position transducer, so its input

signal from the control system is a current signal, like 4-20mA.
Its
output is a proportional pneumatic signal.
E/P and I/P are not positioners and are not called positioners because
each is a transducer that converts an input signal to a proportional
pneumatic signal.
A positioner is a much more than a transducer; a positioner is a
controller.
A positioner senses valve position and regulates its pneumatic output to
control the valve position to the setpoint defined by the input signal.
Where an E/P or an I/P is mounted is a matter of opinion,plant standard
or convenience, it is not dependent on its function.
A positioner must receive a valve position feedback signal, so a
positioner must be mounted so mechanical linkage can sense valve position
or when mounted remotely from the valve (like in high ambient temperature
applications) a remote position sensor is used to feed a signal to the
positioner.
Carl Ellis
Measure First
Q#
1)unmovable objects have frequency or not?if that object have frequency,how do we
1293 measure and transmit? 2)how do u measure the continuity without multimeter? 3)we
83
put 24volt dc supply in railway track how many distance it is traveled without voltage
drop?
Answ How do you measure continuity without a multimeter?
er
Answer: with a continuity tester, which consists of a power
source (a battery)and an indicator like a lamp or LED
Q#
How to measure density of oil in your kitchen. i.e indirectly to verify the quality of
1308 oil using min. gadgets available in the kitchen/house.
02
Answ To determine the density/specific gravity of the oil:
er
Weigh an empty, clean measuring cup. The larger the volume of the
measuring cup, the better the precision.
Fill the measuring cup with the oil to a marked level, say, 500mL.
Weigh the measuring cup and oil.
Subtract the weight of the measuring cup.
The ratio of the weight of the oil to the weight of an equivalent volume
of water (1 gram/mL) is the oil's specific gravity: weight oil/weight of
water
Carl Ellis
0 2014
-0418
0 2014
-0520
Measure First
Q#
i want to control the temp of sand(welding flux) between the range of 150deg C to
1379 170deg C. sugges me sum temp control method without PID controller.
28
Answ An On-off controller with a setpoint of 160 Deg C and a
hysteresis of 10 Deg C will do this type of control.
er
Carl Ellis
Measure First
Q#
whats the problem will arrise if we rotate the hosing screw of the differential
1472 pressure transmitter?
54
Answ Rotating the electronics housing screw loosens or tightens
the screw that holds the housing in place in relation to the
er
pressure body.
0 2014
-0515
0 2014
-0105
Rotating the electronics housing (for access to the screw

covers or to orient the indicator display) with respect to
the housing body has to be done with care to avoid twisting,
crimping, bending, breaking, stretching or stressing the
wiring/cables that connect the sensor(s) elements in the
pressure body to the electronics in the transmitter head.
Most transmitters allow a +/- 180 degree rotation from a
position with the length of the head in axial alignment
with the bore of the pressure ports.
Carl Ellis
Measure First
Q#
Q- Which of the following is Close loop system - a-)respiratory System b-)traffic
1474 light system c-)washing machine d-)Room heater my option is A, what is our take on
80
option B & C
A room heater has a thermostat which senses room
Answ
temperature
and turns the heater elements on or off, as
er
needed.
It is close loop control.
A washing machine can have a closed loop feedback loop, for

example, water level, where a knob sets water level desired
[setpoint], a sensor detects level and turns off water
valve when satisfied.
But the overall wash, soak, rinse,
empty, fill, spin functions are sequenced on a timed basis,
which is classic, open loop, non-feedback control.
Likewise a traffic light system can sense the presence of a
vehicle at an intersection, which enables an upcoming light
change, but the sequences of light changes are timer based,
open loop, non-feedback control.
Carl Ellis
Measure First
10
0 2013
-0906
Q#
Can DP transmitter with orifice plate works on Beta ratio 0f 0.3 and differential
1479 pressure of 100 MMWC in liquid service application?
15
Answ An orifice plate (OP) creates a pressure drop in the flow
stream.
er
The question is whether an orifice plate 'works'.
Works how?
0 2014
-0101
An orifice plate will always 'work' by creating a pressure

drop; the proper questions are whether the permanent
pressure loss is excessive, whether the orifice plate has
been 'sized' for a specific medium at correct design
conditions, and whether the pressure drop (DP) is adequate
for instrumentation that senses the DP.
Orifice plates typically drop 100 inches water column at
100% flow rate, about 25 times the DP of 100mm water column.
A DP of 100mm water column at 100% flow rate is more
typical of an averaging pitot tube than an orifice plate. A
full scale flow rate of 100mm w.c. requires a low range
pressure transmitter, or one with a high turndown ratio.
A 0.3 Beta is acceptable.
Carl Ellis
Measure First
Q#
what is difference between two wire &three wire pt 100 ?
1494
90
Answ A 2 wire RTD has no means of compensating for lead wire
resistance so the reading from a 2 wire RTD will always have
er
some positive error due to lead wire resistance.
0 2014
-0613
A 3 wire RTD can be connected to an appropriate circuit that

compensates for the resistance of the lead wires by
accounting for the resistance of the 3rd wire, which is
presumably the same length and gauge as the other two wires
across the resistance element.
Carl Ellis
Measure First
Q#
wht is snap action switch?where it is used?is there any diff between snap action
1498 switch and normal pressure switch?
81
Answ A snap action switch requires very little mechanical
movement (a very short linear distance) in order to actuate
er
the electrical switch contacts.
Internally, the movement
and mechanical advantage of a lever is used to activate,
make or break, switch contacts.
The sensor elements in pressure switches: diaphragms,
pistons, bellows, all have move relatively small distances
11
0 2014
-0128
with changes in pressure. A snap action switch is used as

the electrical component in a pressure switch because it can
be actuated/tripped by the small movement of pressure switch
sensor.
Mechanical adjustments allow for an adjustable setpoint by
moving the snap action switch with respect to the sensor
element.
The name of the firm that invented snap action switches is
Microswitch, so snap switches are frequently called
microswitches, which is technically a brand name.
In contrast, ordinary switches, like a toggle switch or a
rotary switch, rely on the relatively large movement of an
operator handle/lever to actuate the electrical contacts.
Carl Ellis
Measure First
Q#
I have a steam flow DP transmitter that has output swinging. Steam valve is in
1540 manual.I have good steam pressure. The impulse lines have steam tracing on them.
28
The steam tracing has a hole in it that is blowing raw steam on the high side impulse
line only. Could this be causing the swinging?
Answ Answer:
Yes, live steam on an impulse line could cause pressure swings.
er
Blowing live steam on an impulse line could conceivably heat
the condensate in the impulse tubing enough to boil it.
Even if it doesn't boil, a deadheaded impulse line with have
thermal siphon flow occurring as the hot spot condensate
rises and its place is taken by cooler condensate.
0 2014
-0107
If boiling is occurring, then it could be intermittent

boiling with associated pressure pulses: as the steam
bubble(s) move away from the hot spot and cooler condensate
takes it place.
None of which should be happening in an impulse line.
The high side is 'seeing' these artifacts as forces on its
diaphragm which is creating pressure swings.
Carl Ellis
Measure First
Q#
could someone explain for me what is 32-bit Floating Point ? Thanks
1540
42
Answ Floating point numbers are also called 'real' numbers.
Floating point refers to the inclusion of a decimal point
er
and values to the right of the decimal point.
The number
is expressed in engineering or exponential notation, a
signed mantissa with an exponent.
12
0 2014
-0317
The IEEE Standard for Floating-Point Arithmetic (IEEE 754)

is a technical standard for floating-point computation
established in 1985 by the Institute of Electrical and
Electronics Engineers (IEEE).
A single precision IEEE 754 floating point is a 32 bit word
A double precision IEEE 754 floating point is 64 bit word.
A single precision FP consists of a one bit algebraic sign,
an 8 bit exponent and a 23 bit mantissa.
Floating point calculations can be done in hardware or software.
Floating point is widely used for Process Automation
Controllers (PAC) and in DCS controllers.
Double precision is frequently used in flow computers.
Single precision is typically the standard for other data an
operations. Single precision floating point is widely used
by serial data communication protocols like Modbus.
Carl Ellis
Measure First
Q#
How can corrosion alter the accuracy and precision of a C- Bourdon tube pressure
1547 gauge?
84
Answ The issue with corrosion of a bourdon tube is not accuracy,
it's safety.
er
Corrosion failure of a bourdon tube occurs when the elastic
element (Bourdon tube) has been weakened .
The potential corrosion hazard is leakage of the process
fluid, which may be hot, toxic or corrosive, from a
measuring instrument, process pipe or tank.
The other
corrosion hazard is catastrophic failure of the bourdon
tube, and the release of energy that can approach that of a
shot from a firearm.
Those failures due to corrosion dwarf the effect of
corrosion on accuracy.
A change in the bourdon tube
stiffness effects gauge accuracy whether that change comes
from temperature, corrosion, or overpressure.
The
likelihood that corrosion will destroy the bourdon tube
result in the ultimate certainty of "uncertainty" - total
non-accuracy due to failure to operate.
Whoever wrote this question missed the point entirely about
corrosion effects on pressure elements in piping.
The question should be, "How can corrosion alter the safety
of bourdon tube pressure gauge?"
Carl Ellis
Measure First
13
0 2014
-0324
Q#
what is LAS in foundation fieldbus protocol?
1576
28
Answ What is Foundation Fieldbus LAS?
er
Link Active Scheduler (LAS)

A Link Active Scheduler (LAS) is a deterministic,
centralized bus scheduler that maintains a list of
transmission times for all data buffers in all devices that
need to be cyclically transmitted. Only one Link Master
(LM) device on an H1 fieldbus Link can be functioning as
that link's LAS.
0 2014
-0120
The Master and Primary Backup Link Active Scheduler (LAS)

shall reside in the host control system in redundant H1
network interface cards.
An additional backup LM Link Master (B/U LAS Link Active
Scheduler) shall be configured for all networks and shall
reside in the network device with the lowest field node
address. The Backup LAS should be placed in a separate
device that does not have controlling functions.
Primary and secondary interfaces should sit in separate
backplanes with separate CPUs, preferably in separate
control panels. Similarly, the primary and secondary power
supplies should not share the same backplane. Having
redundant interface cards, CPUs, and power supplies in the
same backplane is self-defeating since the backplane is a
single point of failure.
Each network shall be configured for automatic fail-over to
the Back-up LAS in the event of Master LAS failure.
Carl Ellis
Measure First
Q#
Explain, and give a real-world example of MODULATING control
1577
91
Answ 1) A light dimmer switch
er
2) the throttle on an automobile
Q#
What is require for PLC Programming?
1580
50
Answ You'd all fail my class for failure to mention these three
things:
er
- A project scope document
What is to be controlled, alarmed, displayed and
14
0 2014
-0507
0 2013
-1015
communicated? What is the purpose and what are the

functional criteria for the project? What are requirements
for acceptance of the project? What limits the
dreaded 'scope creep' ("Oh, I thought it would
include . . ." or "we need to add this")
I tell my pupils that the homework problem description
constitutes the 'scope' for purposes of a class, but in the
real world it might be a 400 page scope document, but
whatever form it takes, they should never accept a verbal
description, but should insist on a written document,
because that's what defines whether their programming meets
the standard of having been done properly.
- An I/O list is absolutely essential.
inputs, what are the outputs?
What are the
- The PLC's documentation

Nobody remembers all the little syntax or functional
details. It's up to the programmer to look this stuff up
because in the real world, there's no 'teacher' to answer
the question about the timer's minimum interval.
Those three things are essential.
constitutes negligence.
Lack of any of the 3
Lack of mention of any of the three in the 5 answers already

posted tells me your instructors are book people, not real
world PLC programmers.
-----------------------------Carl Ellis, Measure First
Q#
I want to know if flowrate increases in 16' pipe line what will happen to upstream
1590 pressure and why?
31
Answ I want to know if flowrate increases in 16' pipe line what
will happen to upstream pressure and why?
er
There can be flow only if there is a differential pressure
to create the flow.
To increase flow rate, the differential pressure has to
increase.
To increase the differential pressure:
- the downstream pressure can decrease
- the upstream pressure can increase
- both upstream and downstream pressures can move in the
same direction, but vary in the magnitude of the change so
that the DP increases.
This principle applies to any flow, the size of the pipe
doesn't matter.
Carl Ellis
15
0 2014
-0106
Measure First
Q#
Generally in which location ( JB or IO card or DCS) the thermocouple compensation
1601 is done.Also where they measure the atmosphere temp ( for compensation) in JB OR
56
DCS panel? How they compensating that atmosphere temp? is any circuit for that (
like in rtd wheatstone bridge)?
Answ Cold junction compensation (CJC) is done at the point where
0 2013
the thermocouple wire or thermocouple extension wire
er
-07connects to the thermocouple input, either an I/O card, a
09
temperature transmitter, or a thermocouple input on a
recorder/controller/indicator/alarm.
CJC.
Thermistors do not need CJC.
RTD's do not need
The purpose of CJC is to measure the temperature of the

terminal connection block with respect to the freezing
point of water (because that is the 'cold junction' and the
national standard thermocouple tables are referenced to) a
cold junction at the freezing point of water) and add that
value to the temperature value determined by the EMF/mV
output of the thermocouple.
The temperature of the terminal connection block is affected
by ambient, room, or atmospheric temperature but is also
affected by the heat generated by the device's electronics,
other electronics in close proximity, and whatever cooling
the installation provides. Because all of those factors can
vary in temperature, the CJC involves measuring the
temperature of the (terminal) connections.
Temperature-sensing ICs, thermistors, and RTDs are used for
CJC measurements. Thermocouples cannot be used for CJ
measurement.
So the answer is that the CJ measurement is made at the
thermocouple input, presumably the I/O card or temperature
transmitter, never at a junction box.
The actual temperature calculation, measured T/C EMF plus
CJC, can be done on the I/O card or in the 'system', a PLC,
temperature transmitter, controller, DCS, whatever,
depending on design.
CJ should not measure room temperature or atmospheric
temperature (although some poorly designed thermocouple
devices do so); CJ should measure the terminal temperature
where the thermocouple wires connect to the I/O.
A
temperature transmitter measures the CJC in order to do the
calculation for temperature.
There are special techniques for CJC for high accuracy
calibration involving an ice bath, but industrial devices
use integrated CJC.
Q#
what are the installation requirement is common to all flow meter when volumetric
1603 flow rate is being measured
16
51
Answ The (mostly unstated and assumed) common requirement for all
commercial flow meters is a full pipe.
er
The presence of air or gas in a liquid line not only causes
an inaccuracy in the measurement, in many cases it can cause
the measurement to fail altogether.
0 2014
-0612
A close second for common requirements is to avoid vertical

downflows for liquids.
Carl Ellis
Measure First
Q#
why we use 24 vdc in instruments mostly?
1604
40
There is no national or international standard for 24Vdc in
Answ
industrial
instrumentation and control.
er
The use of 24Vdc has evolved out of common practice and has
seen global use and acceptance as a 'de facto' convention,
as opposed to a formal standard. The acceptance goes
beyond loop powered transmitters, it goes into discrete
control as well.
The reasons are many.
1) 24Vdc is a low enough voltage to be considered 'safe'.
It is accepted as a voltage level that does not shock human
beings through contact with dry skin.
2) 24VDc is a high enough voltage to do real work with
currents that are practical.
3) An enormous array and variety of field instruments and
controls can be designed and operated intrinsically safe at
24Vdc, not just loop powered transmitters.
4) Loop powered field instruments powered by 24Vdc can
drive 500-600 ohms of load resistance, enough for one valve
positioner (split ranging 2 valve positioners with a single
current output driven by 24Vdc is difficult).
5) Lead acid batteries are useable for battery back-up or
UPS supplies.
6) On the discrete side, 24Vdc is sufficient voltage to
break through oxide coating on switch and relay contacts
7) For discrete control, 24Vdc offers a tolerance band
around binary 'high's and binary 'low's of more than a
couple volts, which allows for operation in a moderate
level of electrical noise.
8) Statistically, 24Vdc devices have failure rates about
17
0 2013
-1007
half of that of 120/240Vac actuation devices (relays and

solenoids). This a serious consideration for emergency
shutdown or SIS systems.
Carl Ellis
Measure First
Q#
generally transmitter power supply having some range(12v to 35v) but the out put(41621 20 mA) must same for given input.If we vary the power supply voltage then output
15
mA also to be change according to V=IR. Is there any voltage regulator in the
transmitter ?
Answ Yes, V=IR, but that happens because the transmitter
0 2014
functions as a transistor, varying its resistance in order
er
-02to regulate the loop current.
08
It is expected that the power supply voltage remains constant.
The transmitter acts as a transistor and regulates the loop
current as long as there is sufficient power supply voltage
to drive the current through the loop resistance (ohms law).
If the power supply voltage is not adequate, the loop
current will be limited to something less than a full 20mA
and in some cases the transmitter power-cycles itself and
starts through repeated initializations, trying to drive
current, but failing to do so.
Changing the power supply voltage will not change the loop
current as long as the power supply voltage change is above
the minimum needed, because that is the design
intent/purpose of 2 wire loop transmitters: to regulate the
loop current to match the process variable the transmitter
is measuring.
Any excessive power supply voltage is
'dropped' in the transmitter in order to regulate the loop
current.
Every 2 wire loop powered transmitter has either an equation
for calculating the voltage required for a given loop load
resistance or a graph called a 'load line' that shows
voltage versus loop resistance. The minimum required
voltage to light up the transmitter is called "lift-off"
voltage, which is the minimum required when a power supply
is directly connected to the transmitter, like on the shop
bench, with no load; no analog input, no appreciable wire
resistance.
A typical 24Vdc power supply will drive 500 ohms of loop
resistance with most 2 wire transmitters.
Carl Ellis
Measure First
Q#
You are looking at the RS-485-side of an RS-232/RS-485 converter and the power
1629 supply voltage for the converter is +5V. Under idle conditions (no transmission), and
43
assuming you have enabled the RS-485 output: what would you expect at: (a) Output
A measured against output B (b) Output A measured against ground (c) Output B
18
measured against ground

Answ You are looking at the RS-485-side of an RS-232/RS-485
converter and the power supply voltage for the converter is
er
+5V. Under idle conditions (no transmission), and assuming

you have enabled the RS-485 output: what would you expect
at: (a) Output A measured against output B (b) Output A
measured against ground (c) Output B measured against ground
0 2014
-0419
With a supply voltage of 5V, the sink driver is usually able

to pull the voltage on each conductor fairly close to signal
ground (0.5V), but the source driver usually has a voltage
drop of approximately 1-1.5V. The voltage swing on each
conductor is therefore typical 3-3.5V, but it may be as low
as approximately 2V.
Answer a)
Hence, output A (-) measured with respect to output B (+)
would read approx -3V to -3.5V ( a negative voltage) in the
idle state. (The logic is inverted: a negative voltage is a
mark or logic 1)
Answers b and c)
Output A (-) measured with respect to ground: ~3.5V to 4V
Output B (+) measured with respect to ground: ~0.5V to 1V
This is a 3V differential, with 2.5V Vcm common mode, where
common mode is the mean of the differential plus the Vcm
common mode above the reference ground.
Carl Ellis
Measure First
Q#
Profibus DP is a multi-master system. Would it work on RS-485 4W or not, and
1629 justify your answer
44
Answ The Profibus DP specification defines the hardware transport
physical layer as 2 wire RS-485. The communications
er
protocol and the transport layer are both part of the
Profibus DP specification (the separate 2 wire cable for
24Vdc power supply is not involved with the communications).
Any device that passes Profibus DP certification will
conform to the Profibus DP specification.
Therefore, a 4 wire RS-485 device will not work on a
Profibus DP network because it won't be a Profibus DP
device, it does not meet the Profibus DP spec, which is 2
wire RS-485.
Attempting to operate a 4 wire RS-485 device on a Profibus
DP network will only disrupt Profibus DP communications on
the network.
Carl Ellis
Measure First
19
0 2013
-1226
Q#
how to connect the HART protocal with control valves
1650
86
Answ HART can be used to write setpoints to or to read position
or diagnostic information from HART enabled positioners on
er
control valves.
0 2014
-0323
But it takes either a very high end PLC with HART I/O or a
DCS with HART I/O and the accompanying software application
to do so.
On the other hand, HART is routinely used to configure valve
positioners, for instance, either basic setup or more
sophisticated tasks, like entering a set of values for a
valve position characteristic table.
Carl Ellis
Measure First
Q#
How a rtd work, and what volts/current goes to a RTD to measure the resistence?
1656
39
Answ The source current, a fixed constant current, supplied to
an RTD resistive element is called the excitation current.
er
The excitation current through the RTD's resistive element
the copper lead wire develops a voltage drop.
0 2013
-1021
The voltage drop across the third wire in a 3 wire RTD is

subtracted from the combined voltage drop of the RTD
element and the 2nd wire, which eliminates the voltage drop
of the copper wire and leaving only the voltage drop across
the RTD element.
Carl Ellis, Measure First
Q#
what is the tempareture conpensation?what is the use of this?
1660
92
Answ
What is temperature compensation? How is temperature used in
er
instrumentation?
Answer:
Temperature compensation is an adjustment to instrument
readings to account for known physical changes due to
temperature.
Temperature and pressure compensation to a differential
pressure measurement can produce an inferred mass flow rate
measurement, rather than a volumetric flow rate.
20
0 2014
-0109
Most high end instruments have internal temperature

compensation that affects the measurement that is reported,
for instance, DP transmitters measure pressure body
temperature and electronic body temperature.
Fuel storage tanks will measure temperature gradient from
the top to the bottom of a tank and calculate volume and
mass adjustments accordingly, for inventory purposes.
Thermal dispersion flow meters adjust their flow rate
calculations according to the flow medium's temperature.
Carl Ellis
Measure First
Q#
1673
01
Q#
If i want use the 6 kg/cm2 pressure gauge then how to
167301 calculate its pressure gauge range?
Answer The general rule of thumb is to put the
working range in at the mid-range of the scale
of the pressure gauge.
Remember, a bourdon tube is damaged beyond
repair when overpressurized.
Alternative rules are
If the working Range is
- Steady: the working range can be 3/4 of full
scale value
- Fluctuating: the working range should be 2/3
of full scale value
- Full scale value: the gauge is working near
its limit.
Short duration at full scale value is advised.
Replacement with a higher range gauge is
advised.
Typical standard dual scale gauge dial ranges
are shown below:
kg/cm2
0-1.06
0-2.1
0-4.2
0-7
0-10.6
0-11.0
0-14
0-21
0-28
psi
0-15
0-30
0-60
0-100
0-150
0-160
0-200
0-300
0-400
The 0-11 bar-Kg/cm2 range puts a 6 kg/cm2

working value just
21
2014-0105
above mid range.

Yeah, yeah, I know. 1 bar is not exactly 1
Kg/cm2 but we're
talking mechanical gauges here.
Carl Ellis
Measure First
Q#
Why ues 250 ohms Resistor during hart type
167364 instruments calibration with hart protocol in details ?
Answer My friend Dan has an article on why HART needs
a minimum resistance in the loop to work.
2013-0817
2014-0423
http://blog.lesman.com/2011/10/06/add250-ohmresistors-to-make-hart-work/#more-68
Anzal, above, is on the right path. The loop
power supply is a low pass filter. The 1200Hz
HART signal needs a
minimum resistance to develop a signal that the
HART receiver can 'see'.
Tell Dan Carl sent you.
Q#
what do you mean by Loop checking ? What are the
167794 cold loop check and hot loop check? what are the
difference between these two loops?
Answer Answer:
A Cold Loop check is cold because it is done
without powering the loop.
A cold check consists of checking wire

continuity from the field instrument through
junction boxes and through DCS/PLC marshalling
panel terminals to the control panel. Once
continuity has been confirmed, then a Hot Loop
Check is
performed on the Loop's I/O.
A Hot loop check is 'hot' because it is done
with the loop
powered up.
A Hot loop check consists of
- simulating a process input at the field
instrument and
then checking the instrument's output and the
response to
the process signal input at DCS/PLC.
- simulating outputs at the control end and
checking for
correct response at the field end.
Carl Ellis
Measure First
22
Q#
in my plant 100% feedwater control v/v is air to close
167937 but due to instrument air fail,the valve opens but
instead of drum level high its get tripped in low low
drum level.the urv of level tx is 0 and lrv is -800.pls tell
me the reason. for such behaviour.
Answer Air-to-close means that the valve fails open.
2014-0106
2014-0522
A boiler feedwater valve should 'fail open' so

that the drum level never drops too low, which
can be an unsafe condition
and/or a damaging condition.
For that same reason, a boiler's feedwater
valve should be driven open on a low-low drum
water alarm to prevent the
drum level from dropping too low and creating
an unsafe condition and/or a damaging
condition.
Carl Ellis
Measure First
Q#
if a dp transmitter has range 100 in H2O and flow is
170066 20mmcf and if the flow is changed to 25 mmcf then
what is the formula to determine new range of
transmitter
Answer design max flow rate = 20 mmcf
design max DP = 100 in H2O
new max flow rate = 25 mmcf

new max flow rate = ?
The max flow rate increases by 125% over the
design max flow
rate:
25/20 = 125% increase
DP calculations are done in normalized
percentages. 125% = 1.25
To calculate the corresponding DP at a max flow
rate 125%
higher than the original, where X = DP
sq rt of X = 1.25
percentage
of DP)
(square root of normalized
X = 1.25^2 = 1.562
1.562 = 156.2%
percentage)
(work in normalized
23
156.2% of 100 inH2O = 156.2 in H2O at a max

flow rate of 25 mmcf
Carl Ellis
Measure First
Q#
i am confusing about differential pressure transmitter
170852 as i seen so many DPTs in different ranges how can we
calculate level and flow with mmh20 plz tel me
When the primary flow element (orifice plate,
Answer
venturi, averaging pitot tube) is sized to

design conditions, the result is a DP value
corresponding to 100% flow rate. That value is
used to configure the DP transmitter.
2013-1221
2014-0101
For level, measurements are made from the

transmitter datum or installed position to the
maximum level, with compensation for the
medium's specific gravity. When remote seals
are used, the specific gravity of the fill
fluid is accounted for in a compensating
calculation.
Carl Ellis
Measure First
Q#
What is the procedure of changing a Faulty Module
172451 of Allen Bradley PlC without stopping the Process
Answer The situation is not unique to Allen Bradley;
many controller brands have I/O modules that
can be replaced without powering down the
controller which might require stopping the
process.
The marketing term is the acronym RIUP, Removal

and Insertion Under Power
The guys in the shop call it, "hot swap", hot
meaning "while powered", swap meaning to change
out.
RIUP (Removal and Insertion Under) means that
while the rack is powered, any of the I/O
Modules can be removed or inserted:
With no physical damage to the module, to the
rack, or to other modules in the rack
Without disturbing the functions of other I/O
modules in the rack or in the system.
It does not mean that the process will not be
disturbed.
If an I/O card needs to be changed out under
power, it means that something is wrong with
the I/O card and the process
has already been disturbed.
24
Under carefully controlled circumstances, this

feature enables the user to remove and insert
an I/O module without completely shutting down
a running system. However, it must be
recognized that removing or inserting an I/O
module under power is potentially hazardous
to property and to personnel.
Circumstances that dictate prudent actions
depend on conditions and specific process
applications at each user facility. It is the
responsibility of site personnel to know all
potential consequences of RIUP, and to take
actions to prevent all adverse consequences
before removing or inserting an I/O module
under power.
Each plant or installation needs to develop
guidelines for establishing appropriate 'hot
swap' procedures because
a) there are potentially lethal voltages on
Terminal Boards associated with I/O Modules.
b) each signal at each of the terminals for an
I/O module has a specific function. Any or all
of the signals may be vital for safely
controlling a process.
Carl Ellis
Measure First
Q#
What is the use of +/- 20ma in analog
172761 measurement,and which instrument gives +/-20ma
output
Answer 192 views of this thread up to this point, yet
no one's answered by Jan 2014.
I have read a reference to motor speed and

direction controller that use or used a bipolar
+/- 20mA as an input
demand signal, but that's the only use I've
ever heard of.
Bipolar +/- current signals are rare in the
process industries.
Even the TTY
teletypewriters of yesteryear used a unipolar
current loop, not a bipolar current.
That's not to say that it can't be done, and
many industrial analog inputs have bipolar +/DC voltage functionality,
like -50 to +50mV, -1.0V to +1.0V, or -12 to
+12V dc, and Phoenix Contact has an
instrumentation signal isolator that
has bipolar current output at +/- 20mA, but I
25
2014-0104
haven't a clue what one would use the bipolar

function for.
Of course, pumping a bipolar current through a
precision dropping resistor would provide a
bipolar +/- dc voltage
signal.
Carl Ellis
Measure First
Q#
how to calculate the temp. of RTD&Thermocouple
173430 when we got some mV r Ohms?if anybody has d chart
pls mail the chatrs to me...
Answer 1) You can't calculate temperature from
millivolts from a thermocouple without cold

junction compensation. The thermocouple tables
only apply when the reading is cold junction
compensated.
2013-1223
2013-1219
2) To determine temperature from a resistance

value, several data are required
- the type of RTD (Pt, nickel, copper)
- the temperature coefficient (the alpha) in
Ohms/ohm/Deg C must be given - 0.00385?
0.00392?
- the RTD Standard, IEC, US DoD, DIN 43760
With the base and the alpha tables are
available on the web.
- the Ro, the nominal resistance at 0 deg C
The table you request is specific to the RTD in
question. No data, no table.
Carl Ellis
Measure First
Q#
173723
Answer
What is Burnout feature in a recorder?

Burn-out is a fail-safe setting, normally
associated with control equipment, but also
used on monitoring devices like recorders to
indicate the loss of a valid input signal.
For controllers, burn-out drives the calculated
output to a condition that is considered safe
for the process, typically to a state where
energy is not put into the process.
Burn-out is configured to go up scale (full
scale), or down scale (full scale).
For control purposes, when a signal that is a
process variable in a control loop goes full
upscale, the controller's output will drop to
zero in a reverse action
26
controller.
Similarly, when a signal goes full scale down
scale, a controller's output will drop to zero
in a direct action controller.
Carl Ellis
Measure First
Q#
173747
Answer
What kind of feedback is used in DP cells.

What kind of feedback is used in DP cells?
2014-0515
2014-0208
2014-0316
In electronic DP transmitters there is no

feedback. Field sensors measure a physical
phenomenon but do not use feedback.
Closed loop controllers use feedback (the
process variable reflecting the change in the
controller's/final control element output) and
valve positioners use position feedback.
Carl Ellis
Measure First
Q#
174057
Answer
What is the load line in control valve?

A Load line shows the valve's pressure drop at
different flow rates. When graphed, the flow
rate is typically on the y axis, the pressure
drop on the x axis.
Typically the load line starts high at low flow
(high DP)and decreases as the flow increases to
a low DP when the valve is wide open.
Carl Ellis
Measure First
Q#
IF TX SHOWS SLOW RESPONSE, WHILE A
174060 CLOSE LOOP AND WHEN WE PUT THE
CONTROLLER ON MANUAL THE PROBLEM
RECTIFIED, SO WE CAN SAY THE PROBLEM IS
IN
Answer The problem is in the controller's PID tuning,
which is tuned to be too sluggish.
All of the loop's control components work

properly:
- the transmitter reports the process variable
- the controller responds to an error (albeit
too sluggishly)
- the control valve responds to the
27
controller's output, as evidenced by switching

to manual mode
The PV response as reported by the transmitter
depends on the controller's appropriate
response to error. If the
controller's response to error is sluggish,
then the loop's PV response will be sluggish.
Manual mode offers a means of overriding the
PID's calculated output value and driving the
output to where it needs to be.
This question qualifies as one of the best
interview questions I've read on this site.
I'll be sure to use this question when I
interview candidates.
Carl Ellis
Measure First
Q#
1)why we are using mostly Ultrasonic Flow meters to
175260 measure flow, rather than Radar waves? 2)why we are
using Ultrasonic waves and Radar waves to measure
the Level?
Answer Most fluids will 'conduct' ultrasonic energy.
Conduction is necessary because the energy

needs to originate in a
transmitter transducer, pass through the liquid
and be received by a receiver transducer.
The
movement of the
fluid changes the sonic velocity of the energy,
which is measured to then calculate a flow
rate.
Many fluids either reflect the radar frequency
signal or absorb the signal so that there is
not enough energy left to
measure.
Radar frequencies reflect when a radar signal
encounters a dielectric difference. So radar
easily passes through air, with a low
dielectric constant, but reflects back from
water, which has a high dielectric.
So radar is useful for level detection with
liquids or solids that have a dielectric higher
than the minimum required to reflect energy
back to the transducer.
Ultrasonic energy reflects from most liquids
and solids so it can be used for level
measurement.
Carl Ellis
Measure First
28
2014-0609
Q#
Is it possible to convert 4 wire transmitter to convert
175636 to 2 wire with additional relay.Please send detial with
drawing,i will appreciate.
No, it is not possible to convert a 4 wire
Answer
device (power on 2 wires, output signal on 2
wires) to a 2 wire, loop
powered transmitter.
2013-0915
2014-0610
2013-1219
A 2 wire loop powered transmitter uses 3.7mA of

the current loop to runs its electronics.
That's why the 'live zero'
starts at 4.0mA, so that there's some power
available to the transmitter's electronics.
There's lots of technologies that cannot run on
the limited power of approximately 3.7mA at
24Vdc. Thermal dispersion flow meters, most
wet cell gas detectors, thermal ionization
detectors, to name a few, which have to be 3 or
4 wire devices in order to have sufficient
power to operate.
Carl Ellis
Measure First
Q#
I have a LT of 10000mmwc range. can i use this LT in
177555 1000mmwc range of tank?? if yes than what
happened???
Answer I have a LT of 10000mmwc range. can i use this
LT in 1000mmwc range of tank?? if yes than what

happened???
A change from a range of 10000 mmwc to 1000
mmwc is a turn down of 10:1
If your transmitter supports a minimum range of
1000 mmwc within the accuracy spec you require,
then re-range the
transmitter and use it.
Most smart DP transmitters from major
manufacturers will support this.
Carl Ellis
Measure First
Q#
I want condensate pots vent position erection of flow
177698 transmitter ?
Answer A 'vent' or 'fill port' is installed at the
top of a condensate pot, facing upwards, so the

water can be poured
through the vent's opening to fill the impulse
tubing/piping and the condensate pot.
29
Carl Ellis
Measure First
Q#
177775
Answer
What is i/e or o/p transmitter(ma/v)?

An i/e converter is a current to voltage
converter.
2014-0320
2013-0619
A current to voltage converter is a resistor.

Electrical current through a resistance
develops a voltage.
Ohms Law
determines the voltage drop, E = I/R.
An i/e resistor is typically used in the
process world in 4-20mA current loops as the
component installed across the
(+) and (-) terminals of an analog input
because analog inputs expect a voltage input.
The majority of DCS, PLC, recorder, controller
and indicators use 250 ohms as an input but
other values are used, 1 ohm, 10 ohms, 62.5
ohms, 50 ohms, 100 ohms.
Do not assume an
analog input is 250 ohms.
Carl Ellis
Measure First
Q#
178766
Answer
what is meaning of static pressure

Static pressure is the line pressure (gauge
or absolute) at the high port when measuring a
differential pressure.
Static pressure affects the DP measurement
(with current technologies) at pressures
greater than 1,000 psig (69barg).
Some commercial DP transmitters (Honeywell and
Yokogawa)use an absolute pressure sensor
sensing the high side port pressure which is
used to correct for static pressure error when
static pressure is greater than 1,000 psig.
A separate calculation for static pressure
error is provided for DP transmitters (by the
major vendors) as part of a total uncertainty
calculation.
Multivariable transmitters (a DP transmitter
with a temperature sensor and an absolute
static pressure sensor)
use the same technique of measuring (absolute)
static line pressure for calculating inferred
30
mass flow for gases.

Carl Ellis
Measure First
Q#
if field commnictor 475 does not communicate with
179067 transmitter what will you do ?
Answer 1) Check for 24Vdc? Yes, but assuming the
power supply is 24Vdc, don't expect the
voltmeter to read 24v, unless you're
back in the control panel where the power
supply is.
If you're out in the field where the

transmitter is, you are not close to the
(-) side of the power supply, so where do
you put the black voltmeter probe?
The only
place for it on the transmitter's
(-) terminal, but measuring voltage
across the transmitter's (+) and (-) terminals
only shows what the transmitter's voltage drop
is, not what the source voltage is.
There is the voltage drop across all parts of
the loop, the transmitter, the load and the
wiring. So checking voltage across the
transmitter's (+) and (-) terminals will never
show a full 24Vdc because of the voltage drops
in the loop.
With short wiring runs and a 250 ohm load
resistor, the voltage across the (+) and (-)
transmitter terminals might be as high as 23V @
4.0mA output, but could be as low as 10V with a
20mA output across 500 ohms.
2) Checking to confirm that the transmitter is
a smart transmitter is a good idea. There are
protocols other than HART or Foundation
Fieldbus (Honeywell's DE), and there are lots
of 'dumb' transmitters, too.
Some brands, like Siemens, allow HART to be
enabled or disabled, so the transmitter may be
HART capable but have the HART comm disabled.
3) Connecting a resistor in series is a good
idea if the load resistor is an unknown.
The article at the link below tells why a HART
loop needs at least 230 ohms of resistance:
http://blog.lesman.com/2011/10/06/add250-ohmresistors-to-make-hart-work/#more-68
The temporary use of a 250 ohm resistor is
typical because they're so common in a process
31
2013-0709
plant.
4) Is the HART device at address 0 (zero)?
The communicator can talk to any address, but
when connecting point-to-point on home run
wired transmitters, the expectation is that the
transmitter will be at HART address 0.
5) Experience will show that there are the
inevitable problems like
- broken or corroded communicator leads or
clips that can go 'open' or be intermittent.
- power supply ripple or EMF induced noise on
the loop circuit can conflict with HART's 1200
baud FSk digital
communications
- some loop device, like a loop isolator or
HART-unfriendly loop indicator has stripped off
the HART signal with a low pass filter, leaving
only the 4-20mA current signal
- wrong version DD so the communicator will
connect but only perform the so-called "common
commands".
Q#
what is input and output cards of plc needs to be hot
179567 swappable mean
Answer To 'swap' is to 'exchange'.
2013-0817
2013-0817
'Hot' means electrically live and powered.

The term "hot swappable" means that an I/O card
can be replaced while the PLC/PAC/controller
rack/chassis is powered and running.
The assumption is that the controller will
recognize or 'see' the replacement card and do
whatever initialization is required to bring
the I/O card back online.
An I/O card that is not 'hot-swappable'
requires a cold start, power-up, initialization
sequence for the controller to recognize the
card.
Q#
179619
Answer
How does milli volt is created in themocouple?

The difference in temperature between the hot
end and the cold end, call a thermal gradient,
of a pair of wires made from dissimilar metals
produces a voltage.
32
Q#
179776
Answer
what is loop folder?

A loop folder is a manila folder or an
electronic folder that contains an assortment
of documents related to the
instrumentation for a specific process control
loop.
2014-0208
2013-0819
2013-08-
The exact contents of a loop folder are defined

in a project's standards/requirements.
A
-
loop folder typically includes

instrument manufacturer's spec/data sheet
P&ID
loop diagram
loop check test sheet/checklist
instrument calibration cert
plot plan/location diagram
It can include
- loop test procedure
- hook-up diagram/instructions
- control/function narrative
- alarm setpoint list
- construction completion certificate
- interlock diagram
- flow sizing sheet
- CoC Certificate of Conformance
- COE Certificate of Origin
- MRT Material Test Report
- NACE certificate
- instrument configuration
(Compliments to Iris)
Carl Ellis
Measure First
Q#
What is difference between magnetic flow transmitter
179846 & Electromagnetic flow transmitter?
Answer Nothing. One is a shortened form of the other
term.
Magmeter is an even shorter form that means the

same thing.
Carl Ellis
Measure First
Q#
please explain clearly in PID controller if We increase
179853 P only what will be action of the contrlere.
Answer Any given amount of error will produce less
output change than before the proportional band
33
was increased.
17
Increasing the proportional band will make the

controller less sensitive to the deviation of
the process variable
(PV) from the setpoint (SP).
Q#
yokogawa Temperature transmitter showing Error
179893 15 which is Reverse Cal Fail (confirmation calculation
result is bad) in manual they mentioned reasion That
the output goes to the value set by hardware failure
mode jumper. How can solve this problem ? anybody
can say solution
Answer In the manual (from which you cited) the user
action for error 15 is 'contact service
personnel'.
2013-0817
2013-0819
You can try that, but I suspect that it means,

for all practical purposes, replace the
transmitter. I don't know if Yoko offers a
spare 'puck' that can be replaced in order to
salvage the housing and display, or not.
You'll have to ask.
You might try cycling power to it to see if an
electrical spike on the loop wiring adversely
affected the processor, and cycling the power
might re-initialize it, but the likelihood of
success is very small.
When a transmitter goes to fail-safe mode, it's
usually the last act of the last performance,
the actors are clasping
hands, and taking a final bow before the show
closes.
tell 'em Carl sent you
Q#
Why drum level range is given -500 to 0 mmwc pls
180004 give me that answer
How does any DP cell make a measurement?
Answer
Ans: High side pressure minus low side
pressure
What does a drum level DP cell measure?
A DP transmitter measures the difference in
pressure between
- the water level in the drum (and steam
pressure) and
34
- the water in a static column (and steam

pressure), also called the Reference Leg.
The DP's low side is connected to the reference
leg which extends to the top and is filled with
water.
The DP's high side is connected to a low point
in the boiler drum.
What happens (algebraically) when a large
number is subtracted from a small number?
For instance, 5 - 10 = -5
What are the relative values that are being
subtracted from each other in the DP cell?
Carl Ellis
Measure First
Q#
How many problems can be occurring in solenoid
180065 valve? And how it can be rectified?
The answer warrants an entire discussion.
Answer
See Plant Engineering's article on
troubleshooting solenoid valves
here: http://tinyurl.com/kvmefcm
2013-0824
2013-0824
Carl Ellis
Measure First
Q#
Why we use the double acting control valve in flow
180071 line?
Part of your problem is your terminology.
Answer
Valves are chunks of machined metal and
elastomers, valves are not single action or
double action, the actuator that moves the
valve stem is.
So your Google search should be for double
action actuator, which will provide you an
answer.
Carl Ellis
Measure First
Q#
180079
Answer
how to calibrate temprature switch and flow switch ?

The key to 'calibrating' a temperature switch
is it is a switch, it is not a continuous
analog sensor. So there's
no need to mess around with a zero and span
value, like you would on temperature
transmitter.
35
All that matters is setting the switch's trip

point, the setpoint, and in some cases, the
reset (deadband/hysteresis) point. There is no
need to mess around anything but the trip
point, it's time consuming enough to get a
precise setpoint on switch.
You need to know
- the setpoint
- in some cases, the reset
(deadband/hysteresis) point values
- whether the setpoint (SP) is for a rising or
falling temperature. Because they're
mechanical switches, a SP for falling is NOT
same as a SP for rising.
- switch functionality - Does the switch close
or open on rise or fall. There are
applications for all the variations: close on
rise, close on fall, open on rise, open on
fall.
Check how to change the setpoint on the switch.
Some switches have a setpoint lock (nut). Some
are blind adjustments, some are adjustments
with indicated temperature values.
Some have
a separate deadband/hysteresis adjustment. The
latest temperature switches are digital, and
the setpoint and hysteresis reset point are
entered as values.
Many procedures require an actual test with a
calibrating heat/cold (dry block calibrator or
oil bath) source and a
temperature "standard" is needed for a
reference temperature, to prove the mechanical
setting is correct.
Sometimes the standard is a certified dry block
with a readout, sometimes it's a mercury
thermometer, sometimes its certified RTD with a
certified readout. Older cal equipment has
stand-alone electrical equipment, like an
indicator lamp or an ohmmeter that is used to
indicate switch closure on the temp switch,
more modern cal equipment has built-in
connections and an indicator for that.
Make the setpoint adjustment, run the
temperature source, heat or cool, and note the
trip and reset points. If needed, make
adjustments and re-run the test until the
setpoint (and reset point) are within the spec
needed.
Record the results, put a cal sticker or tag on
the beast, and you're on to the next one.
36
Q#
Furnace draft transmitter range is -50 to +50 mmwc. why the impulse
1801 line connected in hp side?
32
Answ A draft range measurement is typically a gauge pressure
0201
measurement, referenced to atmosphere.
er
308Draft range is very, very low pressure, so DP transmitters
31
are typically used because they're readily available in a
'draft' range with the large diaphragms necessary for low
pressure measurements.
The high side is connected to the process with an impulse
tube. The low side is exposed to atmospheric pressure.
Good practice puts a filter, like a scintered pneumatics
filter on the low side, so that dirt doesn't fill the low
side cavity and air movement (wind, passing vehicles) is
buffered and damped to prevent the forces of air movement on
the low side from affecting the draft measurement.
If the impulse line were connected to the low side, the DP
would be negative, a DP subtracts the low side pressure from
the high side pressure (atmosphere minus some positive
pressure = negative pressure).
Convention says that draft range is positive so the impulse
connection is to the high side, to get a positive value.
Q#
Good Evening all.My question is - For a feed water line to an
1801 equipment if i need to measure the flow we will use orifice
89
/magnetic/vortex depend on cost/spec.If i need to measure a
''Alarm''signal and ''Interlock'' from one point i think we can use
orifice type in one location with 2 different tapping points - one for
alarm and one for an interlock to flow valve..If in case i need to have
both these signals(Alarm & interlock) from magnetic flow meter,is it
possible??will 2 seperate sensors will be located inbuilt r we can
program it ??..i thk we can have one transmitter with these 2
signals...need to know any technical issues are there?pls clarify
Answ If this is not SIS (safety instrumented), the 4-20mA from
a single flow transmitter can feed a separate I/O modules
er
0201
3(4-20in, relay out) an alarm module and a separate interlock
09module.
05
Or, depending on the converter/transmitter model, most
magmeters have at least one assignable relay output, some
have two relay outputs.
I've always used orifice flange unions that have only one
set of taps. There might be a double tap flange unions, or
I suppose you can drill and weld the pipe for taps. But
again, unless this is SIS, why would you? Decisions made on
a 4-20mA flow signal on a PLC/DCS/Controller/I?O modules can
37
do multiple functions.
If your situation is SIS, you should state that.
Carl Ellis
Measure First
Q#
Good Evening all.My question is - For a feed water line to an
1801 equipment if i need to measure the flow we will use orifice
89
/magnetic/vortex depend on cost/spec.If i need to measure a
''Alarm''signal and ''Interlock'' from one point i think we can use
orifice type in one location with 2 different tapping points - one for
alarm and one for an interlock to flow valve..If in case i need to have
both these signals(Alarm & interlock) from magnetic flow meter,is it
possible??will 2 seperate sensors will be located inbuilt r we can
program it ??..i thk we can have one transmitter with these 2
signals...need to know any technical issues are there?pls clarify
Answ It seems you are using a flow meter's relay(s) to generate 0201
alarm signals at various amplitudes: low, low/low, hi,
er
3hi/hi.
0905
The flow meter doesn't really use these alarm signals
itself, rather it generates the alarm signals and provides
the alarm signals to other devices, for whatever purpose,
alarm, annunciation or an interlock.
There might be a flow meter with 3 alarm relays.
know. That's a shopping issue.
I don't
Most places will use a PLC, a controller or a DCS to

generate alarms from the analog flow signal.
But if your flowmeter doesn't have enough relays, then use a
"DC alarm trip" I/O module with the flow meter's 4-20mA
analog output.
The modules have an analog input and one or two relay
outputs with adjustable setpoints.
There's probably a dozen models on this page:
http://www.api-usa.com/signalconditioners_alarms.php
These I/O modules are not used "in a magmeter", they're
external I/O modules.
They place a small burden resistance in the 4-20mA circuit,
need an enclosure and AC or DC power to operate, but they
accomplish the task of providing multiple alarms at various
setpoints.
The 4-20mA signal is wired in series with the I/O module and
any other receiver devices.
Carl Ellis
Measure First
38
Q#
How to calibrate electronic type level switch low?
1801
96
Answ Calibrating a point level switch
er
0201
3Contact level switches detect the presence or absence of the
09medium, whether solid or liquid, by direct contact with the
06
medium. The switch output for most devices is an on/off
binary signal
medium. Some
not modulate,
depending its
that reflects the presence or absence of the

level switches use a 4-20mA output that does
the current signal is either 4mA or 20mA,
detection state.
Most level switches offer some form of sensitivity

adjustment (depends on the technology) and some have an ondelay or off-delay adjustment of the output relay trip, used
to avoid nuisance trips.
Calibration consists of
- testing whether the switch output changes state when the
presence or absence of the medium is changed and adjusting
the sensitivity setting for the specific medium used with
the switch.
- whether the on-delay and off-delay settings comply with
the requirements of the installed application
Depending on the technology, there might be sensitivity
adjustments or on-delay or off-delay adjustments, which are
specific to the installed application, and a calibration
would cover.
A non-contact level switch, like Siemen ultrasonic ULS200,
can be tested in place by comparing the reading with a
physical distance measurement (tape measurement) or out-ofprocess by shooting against a solid target and measuring the
distance to check the trip and reset setpoints.
Carl Ellis
Measure First
Q#
1 How to calculate dp transmitter steam and water? 2 impulse line for
1802 liquid steam and gas
04
Answ The DP pressure/flow transmitter is mounted above the pipe 0201
for gas applications (empty impulse tubing).
er
309The DP pressure/flow transmitter is mounted below the pipe
06
for liquid applications (liquid filled impulse tubing)
Steam flow applications using DP pressure transmitters were
historically mounted below-the-pipe (water filled impulse
tubing, frequently with condensate/seal pots), until
Emerson/Rosemount recently discovered that within certain
temperature limits, a DP transmitter close coupled on a
39
coplanar manifold to an Annubar averaging pitot tube can

survive steam temperatures mounted above-the-pipe.
See this link for Emerson's white paper on steam service
installation recommendations:
http://www2.emersonprocess.com/siteadmincenter/PM%20Rosemoun
t%20Documents/00870-0200-4809.pdf
Carl Ellis
Measure First
Q#
please tell me how to convert double acting ytc positioner yt-1200 into
1803 single acting ytc positioner ?
37
Answ Many manufacturers make all positioners a double acting
0201
positioner and install a plug in the 2nd port and call the
er
3model with the plugged 2nd port a single acting positioner.
09No guarantee that all manufacturers do so, but it's true for 24
some of them.
You have a double action positioner - install a plug in the
2nd output port, plumb it to air and an actuator, give it
try as a single acting positioner and see if it works.
What do you have to lose?
Carl Ellis
Measure First
Q#
On drum level, why we are using air to close Control valve?
1803
45
Answ If the valve's actuator is Air-to-Close, what state does
it fail-safe state?
er
Check out the article, "How to destroy a boiler - Part 1"
at this link:
http://www.nationalboard.org/index.aspx?pageID=164&ID=238
and scroll down a couple pages to the section entitled "Low
Water Conditions".
The description will provide details that help you
understand what the fail-safe state due to the loss of a
control signal on a boiler feedwater control valve should
be.
Carl Ellis
Measure First
Q#
if temperature transmitter is showing wran. sensor 2 fail how can you
1803 remove from the transmitter display m/n.3144p rosemount
62
40
0201
30924
Answ It is very likely that the original question has not

correctly copied the error code.
er
"wran sensor 2" is most likely "WARN SENSOR 2"
0201
30923
It is impossible to search electronic pdf documents if the

error message is spelled incorrectly.
This is why employers look for things like misspellings in
documents submitted by job candidates, it shows whether the
candidate pays attention to details.
Here is what the 3144P manual says about the WARN error
message:
"The transmitter is still operating, but something is not
correct. Possible causes of this condition
include, but are not limited to, an out-of-range sensor, a
fixed loop, or an open sensor condition. In the
case of a Sensor 2 failure with Hot Backup enabled, the
Process Variable line displays WARN, and the
Process Variable Unit line alternates between SNSR 2
and RANGE. "
Carl Ellis
Measure First
Q#
To calculate temperature, why we multiply 25 with mV?
1804
07
Answ Apparently, your temperature signal is linear across a mV 3201
range, coming from some type of temperature transmitter, and 3er
the mV value represents temperature/25.
0925
If your source is a raw thermocouple signal, then
multiplying by 25 does NOT result in a true temperature
value because
- cold junction compensation has not be applied
- thermocouples are not linear
Temperature transmitters perform both of those tasks, cold
junction compensation and linearization of the output
signal.
Carl Ellis
Measure First
Q#
what are the possible reasons if a control valve fails to open/close?
1804
30
Answ I seen 10 to 20 causes for each of these categories, but
I've only listed one as an example.
er
Reasons for valve not closing or opening:
intentional or unintentional
41
5201
30927
- lack of energy - air/electric/hydraulic (Fuse blown)

- insufficient energy - (supply air regulator turned down)
- control system issue (control signal interlocked)
- positioner or I/P issue (locked in manual)
- actuator crippled (punctured diaphragm)
- positioner-to-actuator linkage/plumbing issue (tubing
failed)
- actuator-to-valve linkage issue (sheared roll pin)
- valve trim damage
- foreign object blocking movement (how does all that junk
get in the piping in the first place?)
- change in design process conditions (actuator can't close
against increased line pressure)
Not all failures to actuate/move are faults - a valve could
be intentionally locked in place for safety reasons access
to the piping/tank.
Q#
why temperature transmitter is showing ambienttemp.but 21.5ma.
1804 alarm AO showing at the display &how to sloves this problem.
83
Answ When you need troubleshooting assistance you need to
supply certain critical information:
er
1) Has the device ever worked correctly before for some
time period and then failed?
Or is this a first time commissioning issue?
2) What is the brand name and model number of the device?
3) Because all devices have an input and an output, exactly
what each is (is your sensor one thermocouple, two
thermocouples, or one RTD?)
- You do tell us the output is 21.5mA.
4) What are the error codes or what the error symptoms?
- You mention the display shows ambient temperature
5) What you've done to troubleshoot the problem, like
substitute a known source (simulator) and the result
was . . . . ?
Evaluation:
ambient temperature: A short circuit (a wire) across the
terminal inputs of a thermocouple input will display nearto-ambient temperature, specifically the temperature of the
terminal block connectors. The value is the cold junction
compensation (CJC) temperature.
Some high end transmitters will show the CJC temperature.
Is the display stuck on the CJC temperature, rather than
its input?
42
0201
30929
Is there a short across the (+) and (-) input terminals?

21.5mA is a very common fail-safe alarm level, outside the
normal 4-20mA range, but indicating that there is a serious
fault in the transmitter setup or operation.
If the fail-safe is configured for fail high, an open input
(among many other things) could cause the fault.
Smart transmitters generate an error code and save it.
If the transmitter has HART, the error code is in one of the
diagnostics registers, but a HART communicator is needed to
access the error code.
Carl Ellis
Measure First
Q#
why temperature transmitter is showing ambienttemp.but 21.5ma.
1804 alarm AO showing at the display &how to sloves this problem.
83
Answ A short circuit (both thermocouple wires touching each
other) in the thermocouple extension wire leads will create
er
0201
3an ambient or near-ambient temperature reading, but I am
unaware of any temp transmitter that can detect that problem 0930
and go to fault mode at 21.5mA.
Carl Ellis
Measure First
Q#
what does mean by analog output trim and where this one used for?
1805
41
Answ Analog output trim is done on all process field
transmitters that do not communicate over a digital
er
protocol like Profibus or Foundation Fieldbus.
Modern electronics use an A/D to digitize a value from a

sensor, a microprocessor to process the value and a D/A to
output the process value as an analog signal.
Adjusting the zero and span of the D/A is commonly
called 'trim'. It trims the D/A output a small amount,
generally about 1% at the zero and at the span
(separately), generally to match a variation or deviation of
an analog input's resistance value.
Trim is NOT setting the URV and LRV values to correspond to
process inputs, as was once done with analog electronic
transmitters.
Carl Ellis
Measure First
43
0201
31006
Q#
what sud u do if u dont get feedback from control valve?
1805
57
Answ There's two kinds of feedback from a control valve:
a) the change of the process variable because the valve
er
position changes
b) position feedback directly from the positioner to the

controller/control system.
0201
31006
We'll assume that the question is directed at the loss of

position feedback signal from the loop's positioner.
1) Position feedback cards are options on smart
transmitters and need to be initialized after installation.
Has it been initialized?
2) DC power is typically loop power for position feedback.
Is the loop power supply still functioning?
3) Has the position feedback card or its wiring been
disabled or removed?
4) If the position feedback loop is intrinsically safe, is
the loop's I/S barrier open circuited?
5) Has the loop wiring been changed in some manner so as to
affect the position feedback signal integrity?
Carl Ellis
Measure First
Q#
Explain , how timer based pneumatic control valve will work ?
1806
87
Answ The timer forces the on-off pneumatic control to drive
open or closed based on the timer's output state.
er
The timer's output relay activates or deactivates a 3 way
solenoid valve that supplies air to the valve's actuator.
In one timer state, the solenoid valve passes supply air to
the actuator driving the valve to its 'not-failed' state.
In the other timer state, the solenoid stops the air supply
and dumps the existing actuator pressure to atmosphere,
letting the valve assume its 'failed' state, whether open or
closed.
Carl Ellis
Measure First
Q#
what are the documentation and instrument identification system
1806 used to identify the correct device to be calibrated? name atleast three.
44
0201
31015
92
Answ - P&ID: tag name/number for the instrument in question,
but not the location
er
- Loop diagram shows tag name/number, has a location
description (field, panel, I/O rack, control room) and
wiring terminals ID (are wires 1578 and 1579 connected to
the instrument in question?)
0201
31015
- ISA's instrument spec sheet has a section for calibration

with input/output, but more importantly, the following
section has Component Identification by manufacturer and
model number. The serial number isn't there because this
document defines the functionality, not a specific device.
- The company's "Instrument Specification Data Form" should
have a field for a location and instrument serial number
- Calibration data sheet should have a field for "Location",
tag and serial number.
- There should be a stainless tag on a field instrument
- The handheld communicator displays the tag name when
connected. The instrument's tag name should match the work
order's tag.
- The local "Calibration status label" on or inside the
instrument always has a tag ID.
Carl Ellis
Measure First
Q#
what will happen if transmitter wire get shoted?
1807
81
Answ Part I.
Let's assume the question involves a 2 wire, loop powered
er
transmitter powered by a 24Vdc power supply in series with

the transmitter and a load resistor across the analog input
of the receiver device.
The loop current is nominally 4-20mA.
The power supply negative is wired to the analog input
negative.
The short puts a positive 24Vdc on the (+) side of the
analog input.
The load resistor for the analog input is across the (+)
and (-) terminals, so the resistor now 'sees' 24Vdc across
its 250 ohms.
Part II. extra credit. Calculate the wattage spec needed
for a 250 ohm resistor to survive the short circuit in the 2
45
0201
31023
wire, loop powered cable.

Carl Ellis
Measure First
Q#
what is maximum temprature in instrumentation
1807
92
Answ Whatever the manufacturer says the maximum process or
ambient temperature is on the relevant specification sheet.
er
Carl Ellis
Measure First
Q#
What is live zero and dead zero
1808
21
Answ No, no, no.
er
A live zero is where the signal's value of zero engineering

units is an electrical signal value larger than zero.
0201
31024
0201
31121
For example, 4-20 mADC, 1-5 VDC, 10-50mV, etc., are all
examples of live zero. 4mA = 0 eng units. 1Vdc = 0 eng
units.
On the other hand, a dead zero is where the signal's value
of zero engineering units is also zero electrical units.
0-20 mADC, 0-100 mV, 0-1Vdc, 0-5 Vdc, 0-5Aac are examples of
zero engineering units equaling zero electrical units.
0mA = 0 eng units; 0Vdc = 0 eng units
The value of a live zero is that zero electrical units
indicates a failed circuit; which could be lack of power, an
open circuit, a short circuit or failed signal source.
Neither live nor dead zero has an bearing on the linearity
or non-linearity of what the electrical signal represents.
Linearities are application specific.
Carl Ellis
Measure First
Q#
I HAVE PRESSURE TRANSMITTER WITH TWO WIRES 24
1811 VOLTS SUPPLY.IF TRANSMITTER WILL GIVE SIGNAL TO
07
THE DCS WHAT HAPPEN TO THE 24 VOLTS POWER SUPPLY
IT WILL DROP OR REMAIN TO 24 VOLTS POWER SUPPLY.
Answ The measured voltage across a regulated power supply will
remain at 24Vdc. If the voltage across the power supply
er
0201
3drops below 24Vdc, then either the power supply is too small
11to carry the combined load or it is faulty.
46
The measured voltage across the transmitter will vary

according to the loop current.
26
Carl Ellis
Measure First
Q#
I HAVE PRESSURE TRANSMITTER WITH TWO WIRES 24
1811 VOLTS SUPPLY.IF TRANSMITTER WILL GIVE SIGNAL TO
07
THE DCS WHAT HAPPEN TO THE 24 VOLTS POWER SUPPLY
IT WILL DROP OR REMAIN TO 24 VOLTS POWER SUPPLY.
Answ You describe a situation with a 24Vdc power supply, a 250
ohm dropping resistor and a 2 wire loop powered transmitter
er
at 4.0mA
To get the voltage to vary across the transmitter, you have

to change whatever the transmitter is measuring to get its
output to change, or force an output with a HART
communicator. The loop current does not vary on its own, it
varies in response to whatever the transmitter is measuring.
0201
31203
Carl's Loop Rules

The voltage across the power supply remains constant: 24Vdc.
The voltage drops across the transmitter and analog input
vary with the current in the loop.
Assuming a bench setup with very short wire runs and a very
low wire resistance, then if the analog input dropping
resistor is 250 ohms, then
at 4.0mA the transmitter drops 23.0V, the AI resistor drops
1.0V
at 12.0mA the transmitter drops 21.0V, the AI resistor
drops 3.0V
at 20.0mA the transmitter drops 19.0V, the AI resistor
drops 5.0V
The sum of the voltage drops must equal the power supply
voltage.
You can bank on it.
Carl Ellis
Measure First
Q#
Dear all... I have 1 0-400 duplex type RTD, I connected the A side to
1812 the temperature indicator and B side to the PLC panel, but when I
03
have observed then found that The PLC side temp has the variation.
and it was distub to other RTD temp also. so what can I do.
Answ The RTD element is ALWAYS isolated from the sheath. Dual
element RTDs should be isolated from each other.
er
47
0201
4-
Therefore, there should be no common electrical connection

between any wire in a dual element RTD.
0610
The fact that a connection to one receiver (the PLC)

disturbs the other receiver's RTD reading means either
a) the RTD elements or lead wires are shorting to either
the sheath, the other RTD element or a lead wire; meaning
the RTD assembly is damaged internally.
b) the field wiring for one RTD is shorting to the field
wiring of the other RTD
Carl Ellis
Measure First
Q#
Dear all... I have 1 0-400 duplex type RTD, I connected the A side to
1812 the temperature indicator and B side to the PLC panel, but when I
12
have observed then found that The PLC side temp has the variation.
and it was distub to other RTD temp also. so what can I do.pls help me
Answ An offset in readings from separate RTD's can indicate
0201
a
difference
in
calibration
of
the
analog
input
devices
er
3- a bad RTD element, one that has drifted out of spec
- a common ground issue with ground loops between the analog 1209
input devices
An RTD is supposed to be ungrounded and the two RTD's in a
duplex element are supposed to be electrically isolated from
one another, so it is unlikely the ground loop is unlikely
unless poor wiring of the extension wire or head wiring has
created a connection to ground.
If you're complaining about a small difference of the
indicated temperatures, then get out your cal gear and cal
the inputs.
To check for a bad RTD, I'd take an ohmmeter and see if any
leg on the A side has any connection to the B side by
disconnecting the wiring from each analog input and check
the resistance. If there's a low resistance, it indicates
some connection from A to B. If the extension wires are
then disconnected and the resistance is checked on the RTD
lead wires and the resistance remains, then it's a bad RTD.
If the resistance goes high (open circuit) then the
extension wire is shorting or making a low resistance
connection somewhere.
Carl Ellis
Measure First
Q#
Can we used Condensate Pot on flow transmitter which is using on
1812 liquid having sluge and DP transmitter is in pit and below the process
15
line,Can we used Condensate pot for accamulate the Sluge?
Answ Yes, you can use a condensate pot to accumulate the
0201
48
er
sludge.
It's just a version of a "drip leg" that extends down
vertically below the tap or port for the impulse line (at
the datum elevation) to the DP transmitter.
Other methods
are just constructing a drip leg from pipe fittings that are
rated for the temperature and pressure.
31206
A consideration is whether the drip leg or pot can be

drained to remove the sludge, because it will fill up over
time.
Carl Ellis
Measure First
Q#
Can we use a 10000 Lph Flow Transmitter in 100 LPH flow line to get
1812 20mA O/P by adjusting SPAN ?
55
Answ You can do whatever you want to with the span adjustment,
0201
but
what
do
you
think
the
results
are
going
to
be?
er
31210000:100 is a 100:1 turndown.
10
Which flow meter technology that uses an analog adjustable
20mA span has 100:1 turndown?
Which flow meter technology has a HART configurable URV with
a 100:1 turndown?
Flow meter accuracy curves ALWAYS bend exponentially upwards
towards increasing uncertainty as the flow approaches zero
low flow.
The lower the flow, the greater uncertainty.
Where do you suppose 100 Lph is on the accuracy curve of a
meter designed for 10000 Lph?
Carl Ellis
Measure First
Q#
What is the relationship between GAIN and PROPORTIONAL
1812 BAND.
67
Answ Proportional Band * gain = 100
er
Proportional Band = 100/gain
Gain = 100/proportional band
Carl Ellis
Measure First
Q#
1812
68
What is the purpose of valve positioner. Explain 4 uses.
49
0201
31219
Answ
What is the purpose of valve positioner. Explain 4 uses.
er
1) Use supply air pressure to ensure the correct valve
position through feedback control to overcome stiction or
forces on the valve plug.
0201
40208
2) Characterized the non-linear valve movement with respect

to the input signal, for instance, equal percentage or quick
opening
3) Provide position feedback to the control system via
conditioned process signal (4-20ma)
4) Provide adequate seat loading force to ensure tight
shut-off.
Carl Ellis
Measure First
Q#
What will the new flow factor if D/P Transmitter is RE-RANGED
1812 from 25" WC to 50" WC
75
Answ Answer:
The flow rate at 50.0"wc will be 141.4% of the flow rate at
er
25.5"wc.
Reason:
The design maximum flow rate at 25.0" is 100.0% flow rate.
0201
31219
Flow rate is the square root of the percentage of flow at a

given DP.
The flow rate at 25.0"w.c. DP is the square root of 1.00 (or
100%)
If the DP doubles from 25.0 to 50.0, then the DP increases
from 100% at 25.0"wc to 200% at 50.0"wc
The flow rate at 200% DP increases by 141.4% because the
square root of 2.00 (or 200%) is 1.414.
Carl Ellis
Measure First
Q#
What is open loop and close loop?
1814
21
Answ An open loop has no feedback, like a timed operation. For
instance, an irrigation system operates for 45 minutes per
er
day, starting at 10:15 AM.
It does this whether the water
is needed or not, because the controller, the timer, has no
feedback about the need for water.
A closed loop uses feedback. In the irrigation example, a
soil moisture sensor provides feedback to a controller to
let the controller make a decision as to whether irrigation
50
0201
40108
is needed and for how long.

Carl Ellis
Measure First
Q#
Where we cant instal mass flow meter.
1815
48
Answ These remarks refer to the use or non-use of a coriolis
mass flow meter.
er
A coriolis mass flow meter should not be used
- where tight shutoff valve(s) cannot be installed upstream
and downstream for the purpose of stopping all flow so that
zeroing the coriolis flow meter can be accomplished (turning
off power to the pump is NOT the same as shutting off the
flow with a ball valve). Otherwise zero shift will plague
the operation.
- in a batch operation where the meter starts empty, then
fills, and at the end might run partially filled, unless
appropriate piping is implemented to keep the Coriolis flow
meter filled with fluid all the time.
- with suspended solids in a liquid medium that are abrasive
[abrasives erode the thin tube(s)]. Reducing the flow
velocity tends to reduce abrasion and erosion. A Coriolis
tube will quickly fail when it carries suspended solids like
sand. Unless of course, frequent replacement is just the
cost of doing business.
- with a corrosive medium that will corrode the flow tube
- with medium that is above the manufacturer's stated
process medium temperature (burns up the electronics)
- with a two phase media (liquids and gas or liquids that
will flash to vapor at the operating pressures and
temperatures)
- with a medium that tends to solidify (Coriolis tubes are
very thin, very light and don't like to be brush
cleaned)unless periodic solvent cleaning is feasible.
- with a medium that tends to coat the tube, unless the
required solvent or mechanical cleaning is feasible.
- where the flow tube is subject to mechanical vibration
- when the meter is mounted where the flow is vertical down
- when the meter is mounted in horizontal piping at a high
51
5201
40124
point where gas/air can be trapped at a high point

- where the pressure drop across the flowmeter is higher
than the process can tolerate
- when the location is too close to another coriolis meter;
where each meter can be affected by crosstalk vibrations
from the other coriolis meter.
- hazardous or classified zones where the Coriolis' power
requirements exclude it from meeting hazardous area
approval.
- for flow measurement requiring pipe sizes larger than
commercial coriolis meters (10 or 12" in 2014)
Carl Ellis
Measure First
Q#
Why we use 3-15 psi air for control valve input?
1815
60
Answ Because it's a standard, widely used conventional
pneumatic
er
control transmission range.
The 3-15 psi signal is a standard (ISA SP7) that came from
widespread use even before that standard came into being.
As early as the 1920's pneumatic regulators, pressure and
temperature controllers were using 15 psi at the high end.
Various low end 'live' or elevated zero values were used
before standardization.
Any pneumatic control or transmission signal starts with an
'elevated' or 'live' zero' at 3 psi because there is
internal friction and a fair amount of hysteresis in the
movement of pneumatic components, the flapper, nozzle,
diaphragms, spring preloads, pivots and bellows that make up
the transmitters and receivers. This friction and
hysteresis manifests as non-linearity below 3 psi.
A 3 psi minimum pressure puts the transmission signal into a
linear response range. Obviously, control system
measurements, signal transmission and the receivers need a
linear response to effect accurate and precise control.
Not all pneumatic control signals are in the 3-15 psi range.
The ISA SP7 standard (1996) that addresses instrument air
quality standards also lists 5-25 psi, 6-30 psi, 3-27 psi as
standard pneumatic transmission ranges, along with the
minimum supply pressure associated with each range. These
ranges all include an elevated zero.
Carl Ellis
Measure First
52
Q#
Why we use 250 ohm resister in series hart
181571 communicator?
HART communications requires a minimum of
Answer
230 ohms to develop a sufficient voltage drop

for the 1200 baud FSK HART signal to be 'seen'
by a HART communicator/modem.
The capacitance
low pass filter
FSK HART data.
needed for HART
2014-0117
2014-0208
in a DC power supply acts as a

which filters/strips off the
Additional loop resistance is
communications to take place.
If there is insufficient loop resistance, the

HART communicator/modem will fail to establish
HART communications.
In normal field work, it is assumed that the
analog input to which the field instrument is
wired will provide the
minimum resistance necessary.
Most DCS analog
inputs have an input resistance of 250 ohms.
But not all devices do.
And when bench testing/configuring HART
instruments it is not uncommon to connect a DC
power supply, but not an analog
input.
A HART communicator/modem will not
work with just a power supply powering a HART
field instrument.
The loop requires a minimum
of 230 ohms.
A 250 ohm resistor is commonly used for a bench
test/configuration because they're commonly
available in the instrument shop.
Carl Ellis
Measure First
Q#
Why we use 250 ohm resister in series hart
181571 communicator?
Answer Answer #2 is not correct because the HART
communicator is not an analog input, it does

not use a 1-5Vdc signal. A HART communicator
gets and display a transmitter's primary
variable (or other variables) as a digital
value; NOT as an
analog value, not as a 1-5Vdc signal developed
across an analog input's resistor.
I repeat,
HART communications is NOT analog in nature, it
is digital.
The HART Foundation specifies a minimum
resistance of 230 ohms, as described in answer
#1, in order to develop the 1200 baud HART
signal, that rides on top of the DC loop
current signal.
53
It's easy to prove that 250 ohms (for 1-5Vdc)

is not a requirement for HART communications as
a bench test.
Take a 2 wire loop powered HART transmitter,
connect a DC power supply and use a 330 ohm
resistor in series in the
loop.
The communicator will work and the
primary process variable will be correct.
Then try a 470 ohm resistor. The 470 ohm
resistor will work, as well, and the primary
variable will be correct.
Q#
while stroke checking of a linear control valve ,found
181778 its travel is in non linear ,what can be possible reason ?
( please answer send in mannanali65@gmail.com) pls
pls pls if any body know
The positioner is configured for quick
Answer
opening, equal percentage, or some custom nonlinear characterization.
2014-0206
2014-0324
Carl Ellis
Measure First
Q#
My rtd working well at the same time r/i converter is
181946 not working properly.when power is given to rtd..it is
giving 30mA and getting 2.4 mA if i remove the
compensate leads No matter how many ohms.why it is
happening like so?what is the solution?rtd range-0200deg c& 4-20 mA o/p.please give me solutiin
anyone......
Answer Any 2 wire, loop powered 4-20mA transmitter
that puts out 30mA is broken.
The only
transmitter that puts out 30mA is
a legacy 10-50mA transmitter from 20-30 years
ago.
While the upper end of the 4-20mA signal range

is 20.0mA, most 2 wire, loop powered
transmitters allow for some slight
signal over-range, typically 20.5mA.
NAMUR standards use 21.0 mA to signal a fault
or failure mode. Other vendors use other
values, 20.8mA, 21.2mA or some value in the
range of 21mA.
But no vendor uses 30mA as a
fault mode.
The transmitter is broken or dysfunctional.
Carl Ellis
Measure First
54
Q#
182000
Answer
what is control valve and how is work

What is a control valve and how does it work?
2014-0306
2014-0328
2014-0415
A control valve is a mechanical device that

removes energy from a hydraulic (liquid, gas,
or steam) flow stream.
It works by partially or fully blocking the
flow stream.
Carl Ellis
Measure First
Q#
182257
Answer
How to convert mA into Percentage?

formula to convert 4-20mA to 0-100%
(mA - 4.00)/16*100 = %
Carl Ellis
Measure First
Q#
can i calibrate DP transmitter online (while Tx in
182438 Service) if yes ,how?
Answer In order to 'wet' calibrate a transmitter (by
applying reference pressure), the transmitter

needs to be powered, but if the transmitter's
output signal is an input to a control loop or
alarm, then those functions need to be disabled
(loop put in manual, alarm disabled) because
the
transmitter's output is not representative of
the process during calibration.
The transmitter has to be isolated from the
process, so that cal pressure can be applied.
This done through isolation
valving; typically a 3 or 5 valve manifold for
a DP transmitter.
So, is a transmitter 'in service' if it's
powered, but its signal is not representative
of the process and is, in fact, isolated from
the process?
My answer is no, a transmitter being calibrated
is not 'in service'.
Carl Ellis
Measure First
55
Q#
I have a orifice installed in plant which is design for
182440 0~100 inH2O for 0~80MMSCFD, now due to process
change the maximum flow is change to 120 MMSCFD
so for this new process value what will be the DP
across orifice.
Answer 100 in H2O = 80 MMSCFD
x
= 120 MMSCFD
2014-0416
2014-0423
Maximum flow rate is the square root of the

normalized percentage of the maximum DP (at the
maximum flow rate)
The maximum flow rate increases 150% of the
original max flow rate:
120/80 = 1.50, so 120 MMSCFD is 150% of 80
MMSCFD, or a 50% increase in maximum flow rate
To calculate the corresponding DP at a max flow
rate 150% higher than the original, where X =
DP
sq rt of X = 1.50 (square root of normalized
percentage of DP)
X = 1.50^2 = 2.25
2.25 = 225%
(work in normalized percentage)
225% of 100 inH2O = 225 in H2O at a max flow

rate of 120 MMSCFD
Carl Ellis
Measure First
Q#
without color coding, without nameplate, without
182481 multimeter how can you find the type of
thermocouple???
Answer Let's assume base metal elements only, since
noble metal elements are so expensive that they

are under lock and key;
adequate protection from loss of
identification.
For types T, J and K, (and by exclusion, E) the
options are
-a spectropscopic assay which will positively
reveal the alloys' composition, but given that
the cost of an assay is
probably 20x times the value of a base metal
element, it's not likely to happen.
- visual identification of a type T by the
copper color of its positive leg which is
copper. The alloy leg is a shiny 'metallic'
56
color.
- testing Types J or K with a magnet.
The Type J positive leg is made of iron which
has a very strong magnetic attraction.
The Type K negative leg is made of a nickel
alloy which is mildly magnetic.
Type E is non magnetic, but so are other types.
It can be tricky to distinguish mild attraction
on thin gauge wire.
Testing with a multimeter can be very
misleading, because of the difficulty in
determining both the hot junction AND the
cold junction temperatures. Without accurate
temperature values, of what use is a mV
reading?
Carl Ellis
Measure First
Q#
i want the equation of this question. Tranmitter range
182543 is 120 mmwc and dcs flow range is 1700 nm3/hr. if i
want to change dcs range from 1700 to 2400 nm3/hr
then how much dp i have to enter in transmitter
Answer Answer: 239.2 mmH2O
Present max flow rate = 1700 nm3/hr
Present max DP (at max flow rate) = 120 mm H2O
New max flow rate = 2400 nm3/hr
New max DP (at new max flow rate) = x
2400/1700 = 1.412 or an increase of 141.2% in
flow rate.
The DP and the flow rate relationship is a
square root relationship, but the calculation
is based on normalized percentage.
X = 1.412^2*120
X = 1.993*120
X = 239.2 mmH2O
The increase in max DP from 120 to 239.2 mmH2O
is an increase of 239.2/120 = 1.993 or 199.3%
increase in max DP at max flow rate.
Sq root of 1.993 = 1.412 or 141.2% increase in
max flow rate (2400/1700)
57
2014-0602
Carl Ellis
Measure First
Q#
Difference between ultrasonic flow meter and radar
182624 type flow meter
Answer Difference between ultrasonic flow meter and
radar type flow meter
2014-0612
2014-0508
That's easy. Radar (radio frequency) energy is

not widely used, if at all, in commercial
industrial flow meters.
Commercial ultrasonic flow meters use acoustic
energy above the range of human hearing to
measure flow velocity of
liquids and gases.
The measurement is
inherently a velocity measurement.
Transit time technology for liquids with no
suspended solids or bubbles, or doppler
technology can be used for liquids with
suspended solids or bubbles. In-Line transit
time ultrasonic is accurate enough to be used
for custody transfer. Doppler has limited
accuracy.
Carl Ellis
Measure First
Q#
WHAT IS A SYMPTOM OF FAULT WITH THE
182647 SPAN OF AN INSTRUMENT? 1)ZERO-POINT AND
100% ARE CORRECT BUT NOT A MID-RANGE.
2)ZERO-POINT IS CORRECT ,BUT 1005 INPUT IS
NOT GIVING 100% OUTPUT. 3)LINEARITY PRBS.
4)1005 O/p IS CORRECT BUT ZEO POINT IS
WRONG.
Answer The correct answer is 2, but number 4 also
requires a span correction.
1) The "Zero-point and 100% are correct, but

not a mid-range value" problem is a linearity
problem.
2) The "Zero-point is correct, but 100% input
is not giving 100% output" is a span problem.
4) The "100% output is correct but zero point
is wrong" is a zero offset AND a span problem
because when the zero point is corrected with
the addition of a bias/offset, the 100% point
will shift up or down the same amount as the
zero
shifted with the bias/offset correction.
So the 100% point will no longer be correct
58
once the zero is corrected.

Hence, the zero AND the span will need to be
corrected.
Carl Ellis
Measure First
Q#
Can a pneumatic control valve work without
182728 positioner?
Answer Yes, a pneumatic actuator can drive a valve
without a positioner.
2014-0518
2014-0521
In the HVAC world it's done all the time

because the service conditions
(temperature/pressure/wear factor) for, say, a
chilled water valve does not necessarily demand
the precision control that a positioner offers.
An I/P (a current to pneumatic transducer) is
used to convert a 4-20mA control signal to a
pressure control signal.
The service required in heavy process
industries is usually sever enough that a
positioner is used on a control valve.
Company and industry practice will determine
the use of a positioner.
Q#
WHAT IS SELF CLEAN ELCTRODE IN
182751 MAGNETIC FLOWMETER?? WHAT DO YOU
MEAN BY THIS TERM??
Answer A magmeter cleaning unit can be used for
applications where deposits accumulate on the

liner material and electrodes.
Non-conductive deposits will reduce the
electrode signal, while conductive deposits
will partially short circuit the electrode
signal, in both cases deteriorating the
accuracy of the meter (depending on the
character and thickness of the deposits).
The cleaning unit is used for electrochemical
cleaning of the sensor (electrodes) by applying
voltage for approx. 60 seconds. Metering is
resumed after another 60 seconds when cleaning
is complete.
During cleaning (120 seconds) the
transmitter/converter typically maintains the
last flow reading in the display and
in the signal outputs until metering is
resumed.
59
AC cleaning is used to remove fatty deposits

from the electrodes. These fatty deposits are
seen in waste water
applications, in abattoirs and water
applications with oil residuals.
During the cleaning process, the surface of the
electrodes get warmer, which tends to soften
grease particles and the gas bubbles generated
mechanically lift deposits away from the
surface of the electrodes.
DC cleaning is used to eliminate electrically
conductive deposits in the measuring pipe
influencing the measuring accuracy.
Particularly in district heating applications
an electrically conductive deposit
(magnetite)may occur and short-circuit the
electrode signal. In this case the accuracy of
the meter decreases and the signal/noise
conditions of the meter become inferior.
The problem only arises if the conductivity of
the water is less than approx. 250 uS/cm.
During DC cleaning electrolysis
takes place where the flow of electrons removes
the particle deposits from the electrode area.
Setup parameters determine the frequency of a
cleaning process.
It is mandatory that liquid fills the pipe
during the cleaning process. The empty pipe
detection should be used to detect when the
cleaning process should be interlocked.
Carl Ellis
Measure First
Q#
why to use 3 wire at RTD ? what's the reason for
182811 common wire ?
Answer It is correct that an RTD indicates a change
in temperature by a change in resistance of an

element.
The change in resistance must be monitored
electronically and any circuit connected to an
RTD will include copper lead wires which will
add resistance to the circuit.
The problem is not that the lead wires will
have different lengths, the problem is that any
copper lead wire has some resistance which will
contribute to a voltage drop from the source
current and appear to be the resistance of the
RTD element. Any contribution of resistance to
the measurement is an error.
60
2014-0603
Two lead wires connect to the RTD element and a

3rd lead wire is used to compensate for the
added lead wire resistance so that the lead
wire resistance is eliminated
and only the RTD resistance is measured and
used to calculate temperature.
Carl Ellis
Measure First
Q#
How to convert gpm into inches of eater.I nerd
182888 formula with example so pls help me.
Answer The pressure differential (h) [inches of water
column]developed by a differential pressure
flow element is measured, and the volumetric
flow rate (Q) [gpm] can be
calculated using the following generalized
formula:
2014-0612
2014-0609
Q = kA(h/D)^0.5
k is the discharge coefficient of the element
(which also reflects the units of measurement),
A is the cross-sectional
area of the pipe's opening, and D is the
density of the flowing fluid.
The discharge coefficient k is influenced by
the Reynolds number (see Figure 1-5) and by the
"beta ratio," the ratio between the bore
diameter of the flow restriction and the inside
diameter of the pipe.
Nothing can be determined from only 2 data,
volume in gpm and DP in inches w.c. There is
insufficient data and probably insufficient
attention in the classroom to think that one
converts to the other.
Carl Ellis
Measure First
Q#
Pls.could any one Clarify the following with an
182911 example. 1.At What condition Close on Rise and Close
on Fall Pressure Switch contacts are used. 2.If
Pressure is abnormal as per set pressure,if connecting
Terminal of pressure switch breaks,how the voltage
extends to Relay base. 3.Are these contacts come under
fail safe philasaphy.
Answer 1. >At What condition Close on Rise and Close
on Fall Pressure Switch contacts are used.
Close on Rise: the goal is to detect
overpressure in normal operation.
61
Common to NO is
logic high state.
Common to NC is
logic low state
Common to NC is
fail-safe
mode that detects
'made' in the alarm state,

open in the alarm state, a
open in the alarm state, the
a logic low state.
Close on Fall: the goal is to detect and signal

loss of pressure in normal operation
Common to NO
Common to NC
Common to NC
fail-safe mode
is 'made' in the alarm state.

is open in the alarm state
is open in the alarm state, the
that detects a logic low state
2. >If Pressure is abnormal as per set

pressure, if connecting Terminal of pressure
switch breaks, how the
voltage extends to Relay base.
A pressure switch is wired directly to the
wiring terminals on the microswitch inside the
pressure switch.
There is no 'relay base'
that I'm aware of.
For normal operation (the Common and the NO
contact), either broken wire will leave the
electrical circuit in a logic low state (no
voltage).
In normal operation an alarm state is a logic
high condition (the presence of voltage).
That means that a
can not conduct a
circuit will have
fail to detect an
broken wire or open circuit

voltage, which means that the
a logic low state and will
alarm condition.
If the circuit is wired fail-safe (the Common

and the NC contact) a broken wire creates an
open circuit that cannot
conduct voltage so the circuit will be in a
logic low state (the absence of voltage) which
is the same as an alarm condition, a logic low
state.
3. >Are these contacts come under fail safe
philasaphy.
Fail Safe is accomplished by
a) wiring to the Normally Open (NO) contacts
(Common to NO is 'made' when there is an
absence of pressure) and
b) having the logic solver look for an alarm
condition or a fail condition in the logic low
62
state.
Either the absence of pressure or an alarm
state will produce a logic low, whether the
setpoint is set for close-on-rise or close-onfall.
Fail-safe pressure switch wiring can not detect
failure conditions like a plugged impulse line
or a valve-blocked impulse line, with the
exception of United Electric's ONE series
electronic pressure switch which has plugged
port detection and an I-AM-WORKING signal mode.
Carl Ellis
Measure First
Q#
how to set calibration range in a DP transmitter to
182917 measure level for a closed tank and for an open
tank,and also please explain me how to set calibration
range for a DP flow transmitter in a line ?
Answer Configuring the range for a DP transmitter
Open tank:
- Flanged DP transmitter
- high side at lower flange
- no remote seals:
- units: water column units = uwc
- LRV = 0.00 uwc
- URV = physical upper level elevation (uwc) *
specific
gravity of fluid
Closed tank:
- flanged DP transmitter
- high side at lower flange
- no remote seals
- dry leg from vapor space above liquid is
piped/connected
to the low side
- LRV = 0.00 uwc
- URV = physical upper level elevation (uwc) *
specific
gravity of fluid
When the receiver (DCS/PLC/indicator/recorder)
receives the
level signal, it converts to physical level
elevation by dividing the process level signal
by the specific gravity and scaling to physical
level units.
Volumetric flow rate with DP transmitter on DP
flow element:
- units: water column units = uwc
- LRV = 0.00
- URV = maximum DP value at the maximum flow
63
2014-0610
rate stated
on the sizing sheet of the DP flow element
Whether the signal is square rooted in the
transmitter or in the receiver for conversion
to flow rate is up to the
plant convention/standards.
Q#
While giving Power Supply of 24 VDC to a
182923 Transmitter,why Shield Terminal is connected either
at Transmitter or at ISB.Why not Shield Terminal
connected at both ends.If the Reason is to avoid Noise
interference,which type of noice that is interfering.Is
the Noice from the 24 VDC supply terminals or from
any external source.
Answer 1) A shield (screen) connected at both ends
will carry ground loop current due to the
difference in ground potentials at each end.
shield (screen) carrying current
will induce noise into the wires it is
shielding.
Historically, shields (screens) have been

connected at one end only, typically at the
receiver (DCS/PLC/PAC/RTU/controller) end.
Current thinking as outlined in
IEC 61000-5-2 Electromagnetic compatibility
(EMC) - Part 5 Installation and mitigation
guidelines - Section 2: Earthing and cabling,
recommends grounding the shield at each
end for point-to-point and at every point for
multi-drop.
Two point grounding provides protection against
EMC and for safety as well. However, this
method assumes that all
points are on the same ground (i.e. use an
equipotential grounding grid).
Typically, Siemens has adopted this
recommendation for Profibus DP, an RS-485
multi-drop network. Of course, the
gotcha is "all points at the same ground
potential".
Not in the real world, Mr.
Siemens.
2) Although 24Vdc power supplies can be noisy,
major manufacturers produce DC power supplies
with very little ripple and excellent
regulation.
DC power supplies used for HART need to meet
the HART spec:
64
Maximum ripple (47 to 125 Hz) = 0.2V p-p

Maximum noise (500 Hz to 10 kHz) = 1.2 mV rms
Maximum series impedance (500 Hz to 10 kHz) =
10 ohm
24Vdc power supplies are not typically the
source of noise
Carl Ellis
Measure First
65

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This document includes Carl Elliss responses to the questions posed on Allinterview.

The lamp lighting proves that

2014 Carl Ellis, Measure First

2014 Carl Ellis, Measure First

Prfungen" (non-destructive examinations). The abbreviations

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the capillary effect, this agent penetrates any surface

A cold junction is created at the point where non-compensation wire is

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2014 Carl Ellis, Measure First

Control components in the pipeline typically need agency

Corrosive fluid destroys the thin sensor membranes.

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understands thermocouple thermometry.

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transmitter is turned off, because the current is driven by

Pressures above atmospheric are positive with respect to atmospheric

2014 Carl Ellis, Measure First

signal, like 0-5Vdc.

Its output is a proportional pneumatic signal.

An I/P transducer is a current to position transducer, so its input

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Rotating the electronics housing (for access to the screw

It is close loop control.

A washing machine can have a closed loop feedback loop, for

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An orifice plate will always 'work' by creating a pressure

A 3 wire RTD can be connected to an appropriate circuit that

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with changes in pressure. A snap action switch is used as

If boiling is occurring, then it could be intermittent

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The IEEE Standard for Floating-Point Arithmetic (IEEE 754)

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Link Active Scheduler (LAS)

The Master and Primary Backup Link Active Scheduler (LAS)

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communicated? What is the purpose and what are the

What are the

- The PLC's documentation

Lack of any of the 3

Lack of mention of any of the three in the 5 answers already

2014 Carl Ellis, Measure First

RTD's do not need

The purpose of CJC is to measure the temperature of the

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A close second for common requirements is to avoid vertical

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half of that of 120/240Vac actuation devices (relays and

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measured against ground

+5V. Under idle conditions (no transmission), and assuming

With a supply voltage of 5V, the sink driver is usually able

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The voltage drop across the third wire in a 3 wire RTD is

2014 Carl Ellis, Measure First

Most high end instruments have internal temperature

The 0-11 bar-Kg/cm2 range puts a 6 kg/cm2

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above mid range.

A cold check consists of checking wire

2014 Carl Ellis, Measure First

A boiler feedwater valve should 'fail open' so