Instrumentation & Controls Interview Preparation Guide
Instrumentation Design & Selection
Q: How do you approach instrument selection for high-pressure, high-temperature
service?
A: For high-pressure/high-temperature applications, select materials like Inconel/Hastelloy, use remote diaphragm
seals, and follow ASME B31.3 and IEC/ISA standards. For critical measurements, apply redundancy with dual
transmitters.
Q: What factors influence your choice between DP flow transmitters, Coriolis meters,
and ultrasonic flow meters?
A: DP is cost-effective for utilities but limited in turndown. Coriolis offers mass flow accuracy but is costly.
Ultrasonic suits large pipelines. Decision depends on accuracy, turndown, and lifecycle cost.
Control Systems & Strategies
Q: How do you decide between PID, Cascade, Feedforward, and Advanced Control
strategies?
A: PID for simple loops, Cascade for fast secondary variable control, Feedforward for measurable disturbances,
and MPC for multivariable control.
Q: What is your method for tuning a complex PID loop in the field?
A: Perform open-loop test, apply Ziegler–Nichols/Lambda tuning, start conservatively, fine-tune in closed loop,
and decouple if loops interact.
Safety & Compliance
Q: How do you ensure Safety Instrumented Functions (SIF) comply with SIL targets?
A: Use LOPA, certified instruments, redundancy, PFDavg calculations, and proof testing per IEC 61511.
Q: What are the differences between an Emergency Shutdown System (ESD) and a
Basic Process Control System (BPCS)?
A: BPCS is for normal control, SIS is independent and safety-driven per IEC 61511. SIS prevents hazards, while
BPCS manages operations.
Integration & Networking
Q: How do you integrate a PLC-based package system into a DCS?
A: Define I/O mapping, use Modbus/Profibus/OPC, develop interface responsibility matrix, and verify signals
during FAT.
Q: How do you ensure cybersecurity in industrial control systems?
A: Segregate networks, use firewalls, follow IEC 62443, disable unused ports, apply patching, and enforce
role-based access.
Troubleshooting & Case Scenarios
Q: A control valve in a critical loop is hunting. What steps do you take?
A: Check transmitter calibration, valve stiction or size, PID tuning, and process disturbances. Oversized valves are
common root causes.
Q: During commissioning, you notice intermittent loss of 4–20 mA signals. How do you
diagnose it?
A: Check cable continuity, grounding, shielding, and EMI from VFDs. Ensure single-point grounding and stable
power supply.
Leadership & Project Management
Q: How do you handle multi-discipline coordination in I&C; projects?
A: Conduct design reviews, manage interface matrices, use 3D models for clash checks, and hold regular
coordination meetings.
Q: What’s your strategy for managing FAT/SAT in large projects?
A: Prepare protocols, simulate signals, engage client, document deviations, and test redundancy, alarms, and
cause & effect matrices.
Case Study Examples
Q: Reactor Overpressure Protection (SIL 2)
A: Use 2oo3 pressure transmitters, safety PLC, fast shutdown valves, and proof testing. Ensure PFDavg meets
SIL 2 per IEC 61511.
Q: Distillation Column Control
A: Use cascade control (temperature→reflux), feedforward for disturbances, and MPC if budget allows for product
quality stabilization.
Q: Compressor Anti-Surge Control
A: Install DP & flow transmitters, surge control line logic, fast recycle valve, and independent PLC with <100ms
response.
Q: Refinery Tank Farm Automation
A: Radar gauges, high-high level switches, leak detection, overfill protection SIL 2, OPC integration, and fire/gas
system.
Q: Offshore Instrumentation
A: Select SS316/duplex materials, Ex-proof instruments, redundant networks, compact layouts, and UPS-backed
power for critical devices.
Q: Separator Level Instability
A: Check transmitter calibration, valve sizing, loop tuning, and process foaming. Replace oversized valve trim to
stabilize control.
