Top 100+ Instruments Interview Questions and Answers for Engineers

Published on July 3, 2025 | Category: answer
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Instrumentation engineering plays a crucial role in industries like oil & gas, pharmaceuticals, power plants, manufacturing, and automation. Whether you’re a fresher preparing for your first job or an experienced professional aiming for a better opportunity, having a solid grasp of instrumentation basics and practical knowledge is essential.

This comprehensive guide provides a curated list of 100+ top instruments interview questions and detailed answers covering the most important topics in instrumentation. It includes questions on sensors, transmitters, controllers, process variables, PLC, SCADA, HART protocol, calibration techniques, pressure switches, thermocouples, RTDs and more.

All questions are structured to help you understand both the theoretical concepts and real-world industrial applications of instrumentation. This list is designed to help you succeed in technical interviews for roles such as:

Use this page as your go-to preparation resource for interviews in leading companies and government sectors.

Topics Covered in this Interview Guide:

Let’s dive into the most important and frequently asked instrumentation interview questions and answers that will help you stand out in your next interview.

1. What is Instrumentation?

Instrumentation is the science of measuring and controlling physical quantities such as pressure, flow, temperature, level, and distance. It involves sensors, transmitters, and control systems used to automate industrial processes.

2. What is the Importance of Instruments?

Instruments are essential for:

They are the backbone of modern industrial automation.

3. What is the Role of Instruments in Safety, Process Control, and Feedback?

Instruments provide real-time measurements to:

4. Name Some Instruments You Work With

Commonly used instruments include:

5. What is Temperature Measurement?

Temperature measurement refers to detecting the degree of heat in a process or object using sensors like thermocouples, RTDs, or infrared sensors.

6. What are the Types of Temperature Measuring Instruments?

7. What is a Thermocouple?

A thermocouple is a temperature sensor formed by joining two dissimilar metals. When heated, it generates a small voltage proportional to temperature.

8. What are the Types of Thermocouples?

9. What is the Output of a Thermocouple?

The output of a thermocouple is in millivolts (mV), typically ranging from 0 to 50 mV depending on the type and temperature.

10. How Does a Thermocouple Connect to a PLC?

Thermocouples are connected to PLCs using:

11. How Does a Thermocouple Work?

It works on the Seebeck effect, which states that a voltage is generated when two different metals are joined and their junctions are at different temperatures.

12. What is the Working Principle of Thermocouple (Seebeck Effect)?

When two dissimilar metals are joined at one end (hot junction) and the other ends (cold junction) are kept at a reference temperature, a voltage (Seebeck voltage) is generated based on the temperature difference. This voltage is proportional to the temperature.

13. What is the Hot and Cold Junction in Thermocouples?

14. What is the Temperature Range of Different Thermocouple Types?

15. Which is Preferred for Temperature: RTD or Thermocouple?

Use RTD for high accuracy in lower temperature ranges (up to 600°C). Use Thermocouple for wider temperature range and high-temperature environments.

16. Can We Connect a Thermocouple Directly to PLC?

No, thermocouples need a dedicated thermocouple input module that provides cold junction compensation and signal amplification.

17. What Type of Module is Required for Thermocouple Connection to PLC?

A dedicated Thermocouple Input Module is required. It must match the thermocouple type (e.g., K-type, J-type) and provide CJC.

18. What Are the Various Temperature Ranges of Temperature Instruments?

19. What is the Difference Between RTD and Thermocouple?

FeatureRTDThermocouple
OutputResistance (Ohms)Voltage (mV)
AccuracyHighMedium
Range-200 to 600°C-200 to 1600°C
CostMore expensiveCheaper

20. What is RTD?

RTD stands for Resistance Temperature Detector. It measures temperature by correlating the resistance of the RTD element with temperature. The most common RTD is the Pt100.

21. Types of RTD

22. How Many Types of Wires Are in RTD?

23. Why is RTD Preferred Over Thermocouple?

RTDs provide better accuracy, stability, and repeatability, especially in the range of -50°C to 500°C. They are ideal for quality-sensitive applications.

24. RTD Basic Formula for Temperature Conversion

RTD resistance changes with temperature and follows this formula:
R(T) = R0 × (1 + α × ΔT)
Where:
R(T) = Resistance at temperature T
R0 = Resistance at 0°C (usually 100 ohms)
α = Temperature coefficient of resistance (~0.00385/°C)

25. For Pt100 RTD, What is the Normal Temperature Range?

The typical operating range of a Pt100 RTD is -200°C to +600°C.

26. Explain RTD Working Principle

RTD works on the principle that the electrical resistance of metals increases with temperature. As temperature rises, the resistance of the RTD element (like platinum) increases, which can be measured to determine temperature.

27. Which Wiring is Mostly Used in RTD Configuration?

The 3-wire RTD configuration is most commonly used in industry as it provides good accuracy while compensating for lead wire resistance.

28. How to Connect PLC to RTD?

To connect an RTD to a PLC:

29. Basic Principle of RTD

RTD operates on the principle that a metal's resistance increases with temperature. This linear resistance change helps accurately determine temperature.

30. How Does PLC Work with RTD?

The PLC reads resistance from the RTD via the analog RTD input module. It converts the resistance to temperature using internal scaling logic or formula.

31. What is the Output of RTD?

RTD does not generate voltage. Its output is resistance (in ohms) which changes with temperature.

32. Maintenance of RTD

33. What is the Maintenance of a Thermocouple?

To maintain a thermocouple:

34. How to Install an RTD?

Steps to install an RTD:

35. How to Install a Thermocouple?

Installation steps:

36. How to Check If RTD is Working or Not?

37. How to Check If Thermocouple is Working?

38. What is a Pyrometer?

A pyrometer is a non-contact temperature measuring instrument used to measure high temperatures from a distance using infrared radiation.

39. How Does a Pyrometer Work?

A pyrometer measures temperature by detecting the infrared energy emitted by a hot object and converting it into a readable temperature value.

40. Basic Principle of Pyrometer

It works on the principle of blackbody radiation. All objects emit infrared radiation based on their temperature. The pyrometer detects this radiation and calculates temperature.

41. What is the Output of a Pyrometer?

Pyrometers typically provide:

42. How to Maintain a Pyrometer?

43. How to Check if a Pyrometer is Working Properly?

44. Can We Connect a Pyrometer to a PLC?

Yes, pyrometers with 4–20 mA or RS485/Modbus output can be directly connected to a PLC using analog or communication modules.

45. What is PID?

PID stands for Proportional-Integral-Derivative. It is a control algorithm used in automation to maintain a process variable (like temperature or pressure) at a desired setpoint.

46. What Are the Different Types of PID Controllers?

47. Why is PID Used in Automation?

PID provides continuous, real-time control of process variables and adjusts outputs to maintain stability and accuracy in automated systems.

48. How Does PID Work?

PID uses three terms:

It calculates the output to minimize error over time.

49. Why is PID Preferred in Industry?

Because it offers:

50. When Do We Use PID?

Use PID when precise control is required in:

51. What Type of Data is Required for PLC PID?

PID in PLC requires:

52. Where Do We Use PID?

PID is used in:

53. What is a PID Controller?

A PID controller is a device or software that automatically adjusts control outputs using PID logic to maintain the process variable near the setpoint.

54. Can We Make a PID Program in PLC?

Yes, most PLCs provide built-in PID instruction blocks which you can program to control loops like temperature, flow, or pressure.

55. What is the Difference Between PLC PID Instruction and External PID Controller?

AspectPLC PIDExternal PID Controller
IntegrationDirect in PLC logicSeparate hardware
FlexibilityMore flexible programmingLimited options
WiringMinimalRequires external wiring

56. Which One is Preferred: External PID or PLC PID?

PLC PID is preferred for integrated automation systems, especially when multiple loops need control. External PID is useful for standalone or local control.

57. Can PID Help to Run Process Smoothly?

Yes, PID controllers ensure smoother operation by reducing fluctuation, minimizing error, and maintaining the setpoint, especially in dynamic processes.

58. What is a Switch?

A switch is an electrical device used to open or close a circuit. It can be mechanical, proximity-based, or digital.

59. What is an Emergency Switch?

An emergency switch (E-stop) is used to immediately stop machinery or a process during hazardous situations. It is a safety device.

60. What is a Momentary Push Button?

A momentary push button is a switch that only stays active while being pressed. Once released, it returns to its normal state.

61. What is a Limit Switch?

A limit switch is a mechanical switch used to detect the physical position or limit of a machine component (like actuator or conveyor end).

62. What is the Output of a Limit Switch?

Limit switches give a digital output — either ON or OFF (1 or 0) — based on mechanical position.

63. How to Maintain a Limit Switch?

64. What is LVDT?

LVDT stands for Linear Variable Differential Transformer. It is an electromechanical sensor used to measure linear displacement or position. LVDT converts mechanical movement into an electrical signal and is commonly used in automation, aerospace, and testing equipment. It is highly accurate, reliable, and operates without physical contact, which increases its lifespan and stability.

65. What is the Working Principle of LVDT?

The LVDT has one primary coil and two secondary coils wound on a hollow cylindrical form. A movable magnetic core (made of soft iron) is placed inside the coil assembly and is connected to the object whose position is to be measured.

When an AC voltage is applied to the primary coil, it induces voltages in both secondary coils due to mutual induction. The difference in voltage between the two secondary coils is the output. When the core is in the center (null position), both secondary voltages are equal, and the output is zero. As the core moves, the voltage difference increases, indicating direction and distance of movement.

66. What are the Types of LVDT?

67. What is the Output of LVDT?

The output of an LVDT is an AC voltage that varies with the position of the core. After demodulation, it provides a DC voltage proportional to displacement. The output has:

68. How to Connect LVDT to a PLC?

Since LVDTs produce analog voltage output, they are typically connected to a PLC via an analog input module. The steps are:

69. How to Maintain an LVDT?

To ensure long life and accurate measurement, the following maintenance practices should be followed:

70. Where is LVDT Used?

LVDTs are used wherever precise linear displacement measurement is required. Common applications include:

71. What are the Applications of LVDT?

72. How to Troubleshoot an LVDT?

If the LVDT is not functioning properly, check the following points:

73. What is RLT (Radar Level Transmitter)?

RLT stands for Radar Level Transmitter. It is a non-contact level measurement device that uses radar (microwave) signals to detect the level of liquids, solids, or slurries in a tank or vessel. RLTs are widely used in industries like oil & gas, water treatment, food & beverage, and chemicals due to their accuracy and reliability.

74. What is the Basic Principle of RLT?

RLT works on the principle of time-of-flight. It emits high-frequency radar waves toward the material surface. The waves reflect back to the transmitter, and the time taken for the signal to return is used to calculate the distance from the radar to the surface. This distance is then converted into level.

75. What Are the Types of Radar Level Transmitters?

76. What is the Output of an RLT?

Radar level transmitters typically provide an analog output of 4–20 mA proportional to the measured level. Some transmitters also support HART, Modbus, or Profibus for digital communication.

77. How to Install an RLT?

Steps for proper installation:

78. What is the Basic Setup of an RLT?

After mechanical installation, perform the basic setup:

79. How to Wire an RLT?

Typical wiring involves:

80. What Are the Wiring Standards for RLT?

Common wiring practices include:

81. How to Maintain an RLT?

To ensure accuracy and longevity:

82. What Are Common Troubleshooting Tips for RLT?

83. Where Is RLT Used?

Radar level transmitters are used in:

84. How to Troubleshoot a Radar Level Transmitter (RLT)?

If your radar level transmitter is not working properly, follow these steps to troubleshoot common issues:

Pro Tip: Most modern RLTs have a diagnostic function via HART communicator or configuration software. Use it to view live signal strength, echo curve, and device health.

85. What is an Ultrasonic Level Transmitter (ULT)?

An Ultrasonic Level Transmitter is a non-contact sensor that uses high-frequency sound waves to measure the level of a liquid or solid inside a tank. It calculates level based on the time taken for the ultrasonic pulse to travel to the material surface and reflect back.

86. What is the Working Principle of ULT?

ULT operates on the Time-of-Flight (ToF) principle. It emits an ultrasonic pulse toward the surface. The time it takes for the echo to return is used to calculate the distance, which is then subtracted from the tank height to determine the level.

87. What is the Output of ULT?

Ultrasonic transmitters typically provide:

88. What Are the Applications of Ultrasonic Level Transmitters?

89. How to Install ULT?

90. How to Wire ULT to PLC?

91. What is the Basic Setup of ULT?

92. What Are the Types of Ultrasonic Level Sensors?

93. How to Maintain ULT?

94. Where is Ultrasonic Level Transmitter Used?

95. How to Troubleshoot Ultrasonic Level Transmitter?

96. What is a Pressure Transmitter?

A Pressure Transmitter is an instrument that measures pressure in gases or liquids and converts it into an analog electrical signal (typically 4–20 mA). It is widely used in process industries for monitoring and control.

97. What is the Working Principle of a Pressure Transmitter?

It works on the principle of a strain gauge or piezoresistive effect. When pressure is applied to a diaphragm, it deforms and changes resistance, which is converted into an electrical signal proportional to the pressure.

98. What Are the Types of Pressure Transmitters?

99. What is the Output of a Pressure Transmitter?

Most pressure transmitters give:

100. What Are the Applications of Pressure Transmitters?

101. How to Install a Pressure Transmitter?

102. How to Wire a Pressure Transmitter to PLC?

103. What is the Standard Setup of a Pressure Transmitter?

104. How to Maintain a Pressure Transmitter?

105. Where Are Pressure Transmitters Used?

106. How to Troubleshoot a Pressure Transmitter?