Instructor’s Manual with Test Bank
PROCESS TECHNOLOGY TROUBLESHOOTING
Charles E. Thomas
,CHAPTER 1
INTRODUCTION TO PROCESS INSTRUMENTATION & TROUBLESHOOTING
OBJECTIVES
• Describe the basic instruments used in the process industry.
• Describe key terms associated with process control and troubleshooting
• List the various types of control loops.
• Explain how symbols and diagrams are used by process technicians in the
chemical processing industry.
• Describe the various troubleshooting models.
• Describe the methods used in troubleshooting process problems.
REVIEW QUESTIONS
1. Describe the two different types of analyzers and explain how each is
designed to work.
Analyzers can calculate both quantitative and qualitative variables.
Quantitative variables are most closely associated with the amount or
percentage present in a process. Qualitative analyzers simply determine
whether a substance is present or not. Examples of this are analyzers that
are designed to detect the presence of methane gas.
2. List the primary elements and sensors associated with flow.
Examples of flow elements include; turbine flow meters, magnetic flow
meters, ultrasonic flow meters, vortex flow meters, thermal flow meters,
coriolis meters, and orifice plates.
3. List the primary elements and sensors associated with temperature.
Examples of temperature elements include: thermometers, bimetallic
thermometer strip, filled thermal bulb, resistance bulb, thermocouple type J
& K,
4. List the primary elements and sensors associated with pressure.
Pressure Elements, shows several examples of these instruments.
Examples of process instruments include:
• Pressure elements—sense changes in pressure and convert to
mechanical motion
- Bellows bourdon tube
- C type bourdon tube
- Diaphragm capsule pressure elements
- Helical bourdon tube
, - Pressure transmitter
- Spiral bourdon tube
• Pressure gauges—psia, psig, psiv, psid, bar, pascal, kilopascal, etc.
• Vacuum gauge expressed in inches of mercury (in Hg)
• Manometers- A manometer is a device that can be used to measure
pressure or vacuum. A manometer operates under hydrostatic
pressure principles; a column of water always exerts a specific force.
• Pressure Transmitter- A pressure transmitter uses a pressure
element to sense pressure and sends a signal to a controller or
recorder.
5. List the primary elements and sensors associated with level.
Examples of level elements and instruments include:
• Displacer— buoyancy devices
• Sight glass—transparent tube mounted on the side of a tank.
• Float and tape—float rests on the surface of the fluid. Tape moves
up and down depending on the level.
• Conductivity probes—high and low level alarms. Use electricity to
complete lower leg circuit. If liquid reaches the higher leg, the circuit
is broken. This type of system is designed to keep the level between
the high and low conductivity probes. Typically used on non-
flammable material.
• Capacitance probes—radiation devices, load cells.
• D/P cell (Transmitter)—converts pressure difference to a level
indication. Measures hydrostatic pressure difference between two
points on a pressurized vessel.
• Continuous level detector gauge—pressure sensitive. Measures
hydrostatic pressure in open vessels.
• Bubbler system—forces air through a tube that is positioned in the
liquid. The liquid’s resistance to flow registers on a pressure
sensitive level gauge. Measures hydrostatic pressure in open
vessels.
6. Explain why the skills required to be a jet fighter pilot are similar to those
skills required to be a process technician.
A process technician’s role can be compared to that of a jet fighter pilot.
The pilot not only needs to be familiar with his or her aircraft, but must also
be able to use it in a variety of combat situations. The skills needed to
make a good fighter pilot are the same skills required to make a good
process technician.
7. How do increases and decreases in pressure inside an enclosed vessel
impact the boiling point of a substance?
When a liquid exceeds atmospheric pressure it will boil. Measurements of
boiling point for individual substances takes place at a given temperature
and at atmospheric pressures. When pressure is added to an enclosed
, container the boiling point is artificially shifted to a higher point until it is hot
enough to exceed the pressure.
8. Why is it so difficult to develop for educators a pure “process
instrumentation” textbook?
When the curriculum for the process technology program was originally
designed, it was decided that an introductory course in “process”
instrumentation should be included in the required core classes. The
design of this course would be different from any that was presently being
offered at community colleges or universities. During this time period
instrumentation courses were taught from the aspect of an
instrumentation technician, since several community colleges had well-
developed instrumentation technician training programs. The founding
members of the process technology program decided that the
instrumentation class needed to be taught from a process technician’s point
of view. This type of course did not exist at the time.
The transition to the development of a “process” instrumentation course has
been difficult since old habits are hard to let go of. A number of texts have
been developed, unfortunately, each still reads like required course work for
an instrumentation program. The needs of a process technician are
drastically different than those of an instrument and electrical “I & E”
technician, since each approaches the job from a different perspective or
point of view. It is important to point out, however, that instrumentation is
the foundation upon which advanced troubleshooting is based. A basic
knowledge of the process equipment and systems combined with modern
process control provide the building blocks upon which these skills are
developed.
Process technology and modern process instrumentation for process
technicians should merge around the concepts of the control loop,
equipment systems and the control room. Course work needs to resemble
real time process simulations. It is important to point out that process
technicians are uniquely different from other occupations. A process
technician operates the equipment and processes using modern
instrumentation and electronics. Maintenance technicians are important
members of the team who specialize in the maintenance, repair, and
installation of equipment, instruments, electrical and instrument systems.
Developing a true process instrumentation course has proven to be very
difficult since it would require a paradigm shift from the more traditional
approach.
9. What is temperature defined as?
Temperature is defined as the degree of hotness or coldness of an object
or environment.
PROCESS TECHNOLOGY TROUBLESHOOTING
Charles E. Thomas
,CHAPTER 1
INTRODUCTION TO PROCESS INSTRUMENTATION & TROUBLESHOOTING
OBJECTIVES
• Describe the basic instruments used in the process industry.
• Describe key terms associated with process control and troubleshooting
• List the various types of control loops.
• Explain how symbols and diagrams are used by process technicians in the
chemical processing industry.
• Describe the various troubleshooting models.
• Describe the methods used in troubleshooting process problems.
REVIEW QUESTIONS
1. Describe the two different types of analyzers and explain how each is
designed to work.
Analyzers can calculate both quantitative and qualitative variables.
Quantitative variables are most closely associated with the amount or
percentage present in a process. Qualitative analyzers simply determine
whether a substance is present or not. Examples of this are analyzers that
are designed to detect the presence of methane gas.
2. List the primary elements and sensors associated with flow.
Examples of flow elements include; turbine flow meters, magnetic flow
meters, ultrasonic flow meters, vortex flow meters, thermal flow meters,
coriolis meters, and orifice plates.
3. List the primary elements and sensors associated with temperature.
Examples of temperature elements include: thermometers, bimetallic
thermometer strip, filled thermal bulb, resistance bulb, thermocouple type J
& K,
4. List the primary elements and sensors associated with pressure.
Pressure Elements, shows several examples of these instruments.
Examples of process instruments include:
• Pressure elements—sense changes in pressure and convert to
mechanical motion
- Bellows bourdon tube
- C type bourdon tube
- Diaphragm capsule pressure elements
- Helical bourdon tube
, - Pressure transmitter
- Spiral bourdon tube
• Pressure gauges—psia, psig, psiv, psid, bar, pascal, kilopascal, etc.
• Vacuum gauge expressed in inches of mercury (in Hg)
• Manometers- A manometer is a device that can be used to measure
pressure or vacuum. A manometer operates under hydrostatic
pressure principles; a column of water always exerts a specific force.
• Pressure Transmitter- A pressure transmitter uses a pressure
element to sense pressure and sends a signal to a controller or
recorder.
5. List the primary elements and sensors associated with level.
Examples of level elements and instruments include:
• Displacer— buoyancy devices
• Sight glass—transparent tube mounted on the side of a tank.
• Float and tape—float rests on the surface of the fluid. Tape moves
up and down depending on the level.
• Conductivity probes—high and low level alarms. Use electricity to
complete lower leg circuit. If liquid reaches the higher leg, the circuit
is broken. This type of system is designed to keep the level between
the high and low conductivity probes. Typically used on non-
flammable material.
• Capacitance probes—radiation devices, load cells.
• D/P cell (Transmitter)—converts pressure difference to a level
indication. Measures hydrostatic pressure difference between two
points on a pressurized vessel.
• Continuous level detector gauge—pressure sensitive. Measures
hydrostatic pressure in open vessels.
• Bubbler system—forces air through a tube that is positioned in the
liquid. The liquid’s resistance to flow registers on a pressure
sensitive level gauge. Measures hydrostatic pressure in open
vessels.
6. Explain why the skills required to be a jet fighter pilot are similar to those
skills required to be a process technician.
A process technician’s role can be compared to that of a jet fighter pilot.
The pilot not only needs to be familiar with his or her aircraft, but must also
be able to use it in a variety of combat situations. The skills needed to
make a good fighter pilot are the same skills required to make a good
process technician.
7. How do increases and decreases in pressure inside an enclosed vessel
impact the boiling point of a substance?
When a liquid exceeds atmospheric pressure it will boil. Measurements of
boiling point for individual substances takes place at a given temperature
and at atmospheric pressures. When pressure is added to an enclosed
, container the boiling point is artificially shifted to a higher point until it is hot
enough to exceed the pressure.
8. Why is it so difficult to develop for educators a pure “process
instrumentation” textbook?
When the curriculum for the process technology program was originally
designed, it was decided that an introductory course in “process”
instrumentation should be included in the required core classes. The
design of this course would be different from any that was presently being
offered at community colleges or universities. During this time period
instrumentation courses were taught from the aspect of an
instrumentation technician, since several community colleges had well-
developed instrumentation technician training programs. The founding
members of the process technology program decided that the
instrumentation class needed to be taught from a process technician’s point
of view. This type of course did not exist at the time.
The transition to the development of a “process” instrumentation course has
been difficult since old habits are hard to let go of. A number of texts have
been developed, unfortunately, each still reads like required course work for
an instrumentation program. The needs of a process technician are
drastically different than those of an instrument and electrical “I & E”
technician, since each approaches the job from a different perspective or
point of view. It is important to point out, however, that instrumentation is
the foundation upon which advanced troubleshooting is based. A basic
knowledge of the process equipment and systems combined with modern
process control provide the building blocks upon which these skills are
developed.
Process technology and modern process instrumentation for process
technicians should merge around the concepts of the control loop,
equipment systems and the control room. Course work needs to resemble
real time process simulations. It is important to point out that process
technicians are uniquely different from other occupations. A process
technician operates the equipment and processes using modern
instrumentation and electronics. Maintenance technicians are important
members of the team who specialize in the maintenance, repair, and
installation of equipment, instruments, electrical and instrument systems.
Developing a true process instrumentation course has proven to be very
difficult since it would require a paradigm shift from the more traditional
approach.
9. What is temperature defined as?
Temperature is defined as the degree of hotness or coldness of an object
or environment.
