Full Name: ……………………………………………………….

THEORY SCORE
Student Number: …………………………………………….

FACULTY OF ENGINEERING AND THE BUILT

ENVIRONMENT
Department of Electronic & Computer
Engineering
TEST 2
SEMESTER 1, 2023
INSTRUCTIONAL PROGRAMME: BET BNELC1
INSTRUCTIONAL OFFERING: PROCESS INSTRUMENTATION 3A
SUBJECT CODE: PINA301
DATE: 11 MAY 2023
DURATION: 60 MINUTES
TIME: 1PM
TOTAL MARKS: 30 MARKS
NUMBER OF PAGES: 2(INCLUDING COVER PAGE)
EXAMINER: DR. N. PILLAY
MODERATOR: PROF. V. SRIVASTAVA

INSTRUCTIONS:
1. MAKE SURE THAT YOUR FULL NAME AND STUDENT NUMBER IS WRITTEN NEATLY AT THE TOP
OF THIS PAGE.
2. PROGRAMMABLE CALCULATORS OR COMPUTERS MAY NOT BE USED. ALL MOBILE ELECTRONIC
DEVICES MUST BE SWITCHED OFF.

3. ALL ANSWERS TO BE WRITTEN IN PEN. DARK PENCIL MAY ONLY BE USED FOR DIAGRAMS.
4. DO NOT DETACH ANY PART OF THE QUESTION PAPER.
5. BORROWING OF ANY ITEMS WILL NOT BE ALLOWED DURING THE ASSESSMENT.
6. UNTIDY WORK WILL NOT BE MARKED – THE LEARNER WILL BE AWARDED ZERO MARKS FOR
ANY UNTIDY ANSWERS.

7. FINAL CALCULATED ANSWER MUST BE GIVEN IN TWO (2) DECIMAL PLACES.

Do not turn the page before permission is given.

Page 1 of 6
Question 1 (Instrumentation Engineering)

1.1 What is industrial intrinsic safety, and how does it work to protect workers and
equipment in hazardous environments? [2]

Industrial intrinsic safety is a method of protecting workers and equipment in

hazardous environments, such as those with explosive gases or dust, by limiting
the amount of electrical energy that can be introduced into the area. It involves the
use of specially designed electronic equipment, including intrinsic safety barriers,
which are installed outside the hazardous area and limit the amount of electrical
energy that can be introduced into the circuit.

1.2 Discuss the key components of an industrial intrinsic safety system, and how are
they designed to prevent the ignition of hazardous materials. [4]

1. Intrinsic Safety Barriers: These are devices that are installed outside the hazardous area
and are designed to limit the amount of electrical energy that can be transmitted to the
equipment or instrument located in the hazardous area. They are typically used to
reduce the voltage, current, and power of the electrical signal to a level that is too low
to cause ignition.
2. Intrinsically Safe Field Devices: These are devices that are specifically designed and
tested to ensure that they do not generate enough electrical energy to ignite hazardous
materials. They include sensors, transmitters, switches, and other field devices that are
installed in the hazardous area.
3. Explosion-Proof Enclosures: These are enclosures that are designed to contain any
sparks or explosions that may occur within the equipment or instrument. They are
typically made of heavy-duty materials, such as steel, and are designed to withstand the
pressure and heat generated by an explosion.
4. Wiring and Cable: Wiring and cable used in an intrinsic safety system must be
designed and tested to ensure that they are incapable of generating enough electrical
energy to ignite hazardous materials. They must be properly grounded and shielded to
prevent the transmission of electrical energy between the hazardous area and the non-
hazardous area.

1.3 Describe three classes that define what hazardous materials may be present in the
hazardous zone. [3]

1. Class I: Flammable Gases and Liquids - Class I hazardous materials are those that have
a flashpoint below 100°F (37.8°C) and can ignite and burn easily. These include
materials such as propane, butane, gasoline, and ethanol.
2. Class II: Combustible Dust - Class II hazardous materials are those that are capable of
producing combustible dust that can ignite and cause an explosion. These include
materials such as coal, sawdust, and grain.
3. Class III: Ignitable Fibers and Flyings - Class III hazardous materials are those that
include ignitable fibers and flyings, such as cotton, wool, and lint. These materials can
easily ignite and burn, causing a fire or explosion.

Page 2 of 6
1.4 You are required to design an intrinsic safety circuit to wire a temperature probe
to the electronics located in the main control room. The temperature probe is
mounted on a gas pipeline in a hazardous zone. Assume the temperature probe has
a 4-20 mA, 2-wire system. Draw a neat label wiring diagram for the system
described above. [3]

Subtotal [12]

Question 2 (Control Valves & Pumps)

2.1 What is an industrial control valve characteristic curve, and how does it impact
the performance of the valve in a process control system? [2]

An industrial control valve characteristic curve is a graphical representation of the

relationship between the valve's flow capacity and the corresponding valve position or
signal input. It shows how the valve responds to changes in the control signal, such as
changes in pressure, flow rate, or temperature. The characteristic curve is typically
plotted as a graph with flow rate on the x-axis and valve position or signal input on the
y-axis.

The shape of the characteristic curve is determined by the valve's design, including its
flow path, trim size, and actuator type. There are three main types of characteristic
curves: linear, equal percentage, and quick opening.

Page 3 of 6
2.2 Construct a table to show any four different types of industrial control valves and
their applications. [4]

Type of
Valve Applications

Used for regulating the flow of liquids and gases in pipelines. They are
Globe commonly used in the chemical and petrochemical industries, as well
Valve as in power generation and water treatment plants.

Used for on/off control of fluids in pipelines. They are often used in
the oil and gas industry, as well as in chemical and food processing
plants. They are also used in HVAC systems and in domestic water
Ball Valve and gas pipelines.

Used for regulating the flow of fluids in pipelines. They are commonly
Butterfly used in the chemical, pharmaceutical, and food processing industries.
Valve They are also used in HVAC systems and in water treatment plants.

Used for regulating the flow of corrosive and abrasive fluids in

pipelines. They are commonly used in the chemical and
pharmaceutical industries, as well as in water treatment plants. They
Diaphragm are also used in the food and beverage industry for handling viscous
Valve fluids.

2.3 How can the use of digital valve positioners impact the performance of control
valves and their characteristic curves in industrial applications? [2]

Digital valve positioners can have a significant impact on the performance of control
valves and their characteristic curves in industrial applications. These devices are
electronic controllers that are used to precisely position control valves, which can help
improve the accuracy and responsiveness of the valve in the process control system.

The use of digital valve positioners can improve valve performance in several ways:

1. Accurate positioning: Digital valve positioners can provide accurate and

repeatable positioning of control valves, which helps to ensure that the valve is
operating within its specified range and is responding to changes in the process
variable.
2. Monitoring and diagnostics: Digital valve positioners often include monitoring
and diagnostic features that can help identify potential issues with the valve,
such as wear or sticking, before they lead to process problems.

Page 4 of 6
2.4 A flow control valve is installed in a water pipeline that extends 200 m long. On
the valve upstream is a centrifugal pump and downstream the water exists the
pipe into an open-ended tank. Draw a neatly labeled sketch to describe the
relative pressures at the pump, valve inlet, and outlet sections, and at the
pipeline outlet as the valve is gradually opened. Assume that the pipeline has
frictional losses. [2]

2.5 Describe the operation of a centrifugal pump. [3]

The operating principles of a centrifugal pump are as follows:

1. Suction: The fluid enters the pump through the suction nozzle or inlet and flows
into the eye of the impeller. The impeller rotates at a high speed, creating a
low-pressure zone at the center of the impeller. This low pressure zone causes
the fluid to be drawn into the impeller.
2. Impeller: The impeller is a rotating wheel with a series of curved blades or
vanes that spin at high speed. The impeller imparts energy to the fluid by
centrifugal force and increases the velocity and pressure of the fluid as it moves
radially outward towards the volute casing.
3. Volute casing: The volute casing is a stationary component of the pump that
surrounds the impeller and directs the flow of fluid from the impeller to the
discharge nozzle. The volute casing is shaped like a spiral or snail shell, and its
shape converts the high velocity, low-pressure flow from the impeller into a
lower velocity, higher pressure flow at the discharge nozzle. The pressurized
fluid flows out of the discharge nozzle and into the discharge piping, which
carries the fluid to the desired location.

Overall, centrifugal pumps operate by converting mechanical energy from the rotating
impeller into kinetic energy of the fluid, which is then converted into pressure energy
in the volute casing, resulting in a high-pressure, high-flow fluid discharge.

Subtotal [13]

Page 5 of 6
Question 3 (Industrial Boilers)

3.1 With the aid of a labeled sketch, discuss the control strategy that can be used for
two different types of fuel in a combustion boiler system. Both fuels are
measurable. [5]

The FRC signal is sent to FRC103 which is the main flow controller for
both fuels.
The output of the controller is sent to two flow control valves via FK
which adjust the precise amount of control signal that is required for
each individual valve.
The flow rate of both fuels are summed by FY and send to FRC103 and
also provides indication of total fuels consumed.

Subtotal [5]

Final Total = [30]

Page 6 of 6