UNIT I - INTRODUCTION
9
Need for process control mathematical model of first order level, pressure and
thermal processes higher order process interacting and non-interacting systems
continuous and batch processes self-regulation servo and regulator
operations.
UNIT II - CONTROL ACTIONS AND CONTROLLERS
9
Basic control actions characteristics of on-off, proportional, single-speed
floating, integral and derivative control modes P+I, P+D and P+I+D control
modes pneumatic and electronic controllers to realize various control actions.
UNIT III - OPTIMUM CONTROLLER SETTINGS
9
Evaluation criteria IAE, ISE, ITAE and decay ratio determination of
optimum settings for mathematically described processes using time response and
frequency response Tuning Process reaction curve method Ziegler Nichols
method Damped oscillation method.
UNIT IV - MULTILOOP CONTROL
9
Feed-forward control ratio control- cascade control inferential control splitrange control introduction to multivariable control examples from distillation
column and boiler systems.
Page
http://studyzone.dgpride.com
UNIT-I INTRODUCTION
1. Define controlled variable, manipulated variable and load variable in process control.
Controlled variable: it is the quantity or condition of the control system which is directly
measured and controlled.
Load variable: the load variables of a process are all other independent variables except the
control variable and manipulated variable.
Manipulated variable: it is the quantity or condition which is varied by the automatic
controller so as to affect the value of control variable.
2. Distinguish between batch process and continuous process.
Batch process
Continuous process
1. A process in which the materials or work A process in which the materials or work
are stationary at one physical location while flows more or less continuously through a
being treated. Eg. Thermal type process.
plant apparatus while being treated. Eg.
2. This is suitable for different kinds for Storage vessel control.
product
Suitable for one or two products
3. The quantity of product is less
Quantity of product is large
4. The control system is simple.
The control system is complicated.
5. The Process variables are lumped
The pv is distributed over the entire system.
3. Define degrees of freedom.
The Degree of freedom is defined as the independent variable that must be specified in order
ro difine the process completely. The number of degree of freedom can be found by the
equation
f = V E Where
V = Number of independent variable describing a process
E - Number of independent equation physically relating the V variables.
4. What are the different mathematical models used in process control?
1. Experimental approach: In this case the physical equipment of the chemical process is
available and the various values of input (disturbance, manipulated variable) are change and
through appropriate measuring devices the outputs of process change with time. Such a
procedure is time and effort consuming and it is usually quite costly because a large number
of such experiments have to be performed.
2.Theoretical approach:
This is given in terms of mathematical equations (differential, algebraic) whose solution
yields the dynamic or static behavior of the chemical process that is examined.
Page
http://studyzone.dgpride.com
Page
14. A tank operating at 10 ft head, 5 lpm outflow through a valve and has a cross section
area of 10 sq. ft. calculate the time constant.
Given h = 10 ft. Q = 5 lpm, A = 10 ft 2.
Time constant T = AR but R = h / q = 10 / 5 = 2
T = 10 x 2 = 20 min.
http://studyzone.dgpride.com
15. A thermometer having a time constant of 1 min and is initially at 50 0C. it is immersed
in a bath and maintained at 1000C at t = 0. Determine the temperature reading at t = 1.2
min..
T = 1 min , A = 500C
Y(t) = A ( 1- exp ( - t / T) + 50 = 84.940C
16. What are
system?
a.
b.
c.
objectives
of
process
control.
Page
22. What are the 2 approaches employed tops obtain the mathematical model of a process?
Experimental approach and theoretical approach
Experimental approach: in this case the physical equipment of the chemical process is
available and the various values of input (disturbance, manipulated variable) are change and
http://studyzone.dgpride.com
Page
http://studyzone.dgpride.com
Page
http://studyzone.dgpride.com
15. Recommend control modes for flow process and thermal process.
The flow process has small time constant which gives fast response so the PI controller is
suitable the thermal process is sluggish in nature so derivative action should be present in
controller mode. So PID controller is suitable for thermal process.
16. Distinguish between Direct and reverse action of a controller.
Direct action controller
Reverse action controller
Use to produce and maintain the The process may be necessary when direct
desired quality of the product
control is difficult to accomplish.
17. What is dead time?
Dead time is a fixed interval of time between the change of an input to an element and the
beginning of response to the input.
18. Define decay ratio.
The ratio of the amounts above the ultimate value of two successive peaks is called as decay
ratio. The decay ratio is expressed as, Decay ratio = exp ( -2 / 1 2)
19. Give the optimum settings for PID controller.
The optimum settings for PID controller by Z N method is
Kc = Ku / 2
I = P u / 2
D = P u / 8
By C C method,
Kc = / K td ( 4/3 + td / 4 )
I = td ( ( 32 + 6td )/ / (13 + 8td/)
D = 4td / ( 11 + 2td / )
20. What do you meant by optimum controller settings?
Having decided the type of controller for a given system, and given the performance
criteria for the closed loop response(eg., minimum peak error, decay ratio, IAE etc.)
optimum controller settings are the best suited values of the controller(Kp, Ti, Td) which
satisfies the performance criteria set by the designer and selecting these values is called
controller tuning.
21. What are the advantages and disadvantages of 2-position control?
Advantages: Easy to design , Low cost
Disadvantages: Cycling, FCE is subjected to high frequency of oscillation
Page
22. Discuss how the stability is affected for integral and derivative control?
Integral control: as the order of the system increases, response becomes more sluggish
increasing the integral control action and the response of the closed loop system becomes
more sensitive. But such trends lead to instability of the closed loop response.
Derivative control: derivative control action does not change the order of the response. As kc
increases the effective time constant increases and the response becomes progressively
slower which means the derivative control produces more robust behavior by the controlled
process.
http://studyzone.dgpride.com
26. What is meant by differential gap? What are its effects? Is it a desirable factor?
A differential gap in two-position control causes the manipulated variable to maintain its
previous value until the controlled variables has moved slightly beyond the set point. In
actual operation it is the same as hysteresis. A differential gap is caused in the twoposition controller if small friction exists at the bearing on the float arm.
27. Why is integral control action recommended for zero and lower order process?
Integral control actions are recommended because a minimum value of deviation is
obtained without encountering excessive oscillation and also there is no offset or the
offset is reduced.
Page
P-control
Adv: it amplifies the error signal which increases the loop gain. This improves the
steady state tracking accuracy, disturbance signal rejection and relative stability. It
makes the system less sensitive to parameter variations.
Disadv: constant steady state error.
I-control.
Adv: it removes or reduces the steady state error without the need for manual reset.
Disadv: it may lead to oscillatory response of increasing or decreasing amplitude
which is undesirable and the system may become unstable.
28. What is the equation of a pid controller? What are the advantages and disadvantages of
PID control actions?
Equation of a pid controller = KP e(t) + KI + KD
KI = (KP) (1/I) e(t)
KD = (KP) (d ) de/ dt
http://studyzone.dgpride.com
29.
D-control.
Adv: controller gives 90 degree phase shift.
Settling time decreases.
Disadv: No control action for steady error.
Not suitable for noisyt processes.
Give the advantages, disadvantages and applications of three-mode control:
Three-mode control is PID control
Advantages: Stability due to p action, Ability to remove offset due to p, Ability to
remove peak error and large settling time due to d action. It is the best control if
properly tuned.
Disadvantages: Tuning is difficult, more components are used and it has a complex
circuit.
Applications: Since it combines P, Iand D modes of control, it can be used in all
control applications except where d action is not acceptable. Opening or closing
restrictions can implement any composite action.
30.
31.
Draw the circuit of electronic pi controller that gives a proportional gain of 4 and
reset
time of 20ms?
Kp=r2/r1 ,=20=r2c,R2c=20,C=1f
Vout=(r2/r1)ve+(r2/r1)1/r2c integral 0 to t (vedt+vout(0))
R2c=20,R2=20,Kp = r2/r1 =4,20/4=r1,R1 =5K,R2= 20K,C=1f
Page
http://studyzone.dgpride.com
Page
10
http://studyzone.dgpride.com
Page
20. Merits and demerits of single seated and double seated control value?
Single -seated control value
Merits:
It has only one port opening between seat and plug
Simple in construction.
Can be shut-off to provide zero flow.
Demerits :
large force acts a value because of differential head acting across port and seat area.
11
19. Why derivative mode of control is not recommended for a noisy process?
The derivative control mode is not recommended for a noisy process because even when
the pv settles down at the set point the derivative control gives the control action for
noises that are at higher frequencies, so the pv moves around the set point.
http://studyzone.dgpride.com
7.
Page
6.
Briefly explain about multivariable control.
When many inputs (manipulated variables) and many controlled variable (measured outputs)
are present in a loop the multi variable control is suitable. The variables may be interacting,
interconnecting and decoupling. This may be controlled by this method.
12
5.
What kind of processes stand to benefit the most from feed forward control? Why?
Feed forward control configuration measures the disturbance directly and takes control action
to eliminate its impact on the process output. Therefore; feed forward controllers have the
theoretical potential for perfect control.
http://studyzone.dgpride.com
The combination of feed forward and feedback is more effective than feed forward or
feedback control. Say true or false.
True. The feed forward control take care of all disturbances affecting the system and the
feedback control, controls the measured parameters.
10. Ratio control is a specific case of feed forward control. Say true or false.
True. The Ratio control is a special type of feed forward control.
11. What is the advantage of cascade control over conventional control?
The cascade control has two loops. When any load changes the inner loop corrected before
they affected the primary loop. This control gives high performance when the load is
frequency changes. The tuning of the control is easy compared to conventional feedback
control.
12. What are the differences between Feed Forward and Feedback controllers?
Feed forward control
Feed forward control
1) It is useful for slow process.
It is unsatisfactory for slow processes
2) It does not introduce instability in the It may create instability in the closed loop
closed loop response.
response
3) It requires identification of all It does not require identification and
possible disturbances and their direct measurement of any disturbance.
measurement.
It is insensitive to parameter changes
4) It is sensitive to process parameters
13. Mention an application where Ratio control is used.
The ratio control are used in the air fuel mixture control in combustion, reflux control of
distillation columns, mixture of hot and cooled water in heat exchangers and etc.
Page
13
14. State any two conditions under which the cascade control is much effective?
The cascade control is recommended whenever high performance is mandatory in the face of
frequent load changes, where the secondary part of the process contains an undue amount of
phase lag or non-linearity.
http://studyzone.dgpride.com
When cascade control will give improved performance than conventional feedback
control?
The cascade control is recommended whenever high performance is mandatory in the face of
frequent load changes or where the secondary part of the process contains an undue amount
of phase lag or non-linearity.
Page
14
21. Explain how the quality of control is improved when Feed forward control is added with
feed back control?
The combined form of the two will retain the superior performance of feed forward control
and the insensitivity of the feed back control to uncertainties and inaccuracies .The deviations
caused by the feed forward control will be corrected by the Feed back controller as it directly
monitors the behavior of the controlled processes.
http://studyzone.dgpride.com
26. Why are fuel and air sent at a specified ratio into a combustion chamber?
Fuel & air are sent at a specified ratio into a combustion chamber in order to obtain
complete combustion. (i.e., if the inflow increases the air ratio also increases & hence the
input is min. & o/p is max).
27. What is the significance of the sizing of control valves?
The proper sizing of the control valve is important because of the effect on the operation
of automatic controllers. if the control valve is oversize, for eg, the valve must operate at
low lift and the minimum controllable flow is too large. In addition, the lower part of the
flow-lift characteristics is most likely to be non-uniform in shape. On the other hand if
the control valve is undersize, the maximum flow desired for a process may not be
provided.
Page
29. When
is
inferential
control
used?
Inferential control is used when the controlled output is unmeasured in the presence of
unmeasured disturbances. Since this is a rare case, inferential control can only be used.
15
28. What are the advantages and disadvantages of feed forward control?
Adv: acts before the effect of a disturbance has been felt by a system, Good for slow systems
and does not introduce instability in closed loop response.
Disadv: requires identification of all possible disturbances and their direct measurement,
Cannot cope with unmeasured disturbance, Sensitive to process parameter variations and
requires good knowledge of the process model.
http://studyzone.dgpride.com
35. What is the different ways in product composition control in distillation column?
The different ways in product composition control in distillation column are feed forward
control, feed back control, and inferential control.
Page
2.
What is the function of an actuator? What are the different types of actuators?
An Actuator is used to translate the output signal of the automatic controller into a position of
a member exerting large power and often it is employed as a power amplifying mechanism.
Different types of actuators used in control valve are pneumatic actuators, hydraulic
actuators, electro-pneumatic actuators, and electric motor actuators.
16
1.
What is the function of valve positioner?
The valve positioner are use to minimize the effect of lag in large-capacity actuators, stem
friction due to tight stuffing boxes, friction due to viscous or gummy fluids, process line in
pressure changes.
http://studyzone.dgpride.com
3.
What are the advantages and disadvantages of pneumatic actuator over other
actuators?
The pneumatic actuator is used in wide range of pressure. The pneumatic signal is easily
available which can transmit quite long distance without and transmission losses. No wear
and tear problem is needed as in hydraulic actuators. The main drawback in pneumatic
actuators is it requires signal conversion when the process is automated. This type of
actuators is dependable and difficult in construction.
4.
Define range-ability of a control valve.
The range ability of a control valve is the ratio of maximum controllable flow to minimum
controllable flow.
5.
What are the advantages and disadvantages of rotary type motion valves over linear
stem motion type valves?
The rotary type stem motion valve is providing high capacity flow with minimum pressure
drop. They are used to handle slurries or fibrous materials. They require minimum space for
installation and they are used in low pressure services. The rotating type valves have low
leakage tendency and the range ability is limited.
6.
Page
17
9.
What are the different types of flow-characteristics of a control valve?
The flow lift characteristics of a control valve fall into three approximate categories
a. Decreasing sensitivity type
b. Linear type
c. Increasing sensitivity type.
http://studyzone.dgpride.com
comes
out
as
vapour.
This
phenomenon
is
called
Flashing.
11. Suggest suitable control valves for use on slurries and fluids with suspended particles.
Gate valves, ball valves and Pinch valves are suitable for control of slurries and fluid with
solid particles
12. When a Butterfly valve is used?
The butterfly valve is most often used in sizes from 4 to 60 inch for the control of air and gas.
It is also used for liquid flow if the pressure differential is not large.
13. Relate valve flow coefficient and liquid flow rate.
For control valve the flow rate is given by m = Ka 2g(h1 h2 )
where m flw rate ft3 / sec
K1 a flow coefficient
a area of control valve port, ft 2.
g = acceleration sue to gravity, ft/ sec2.
h1 upstream static head of flowing fluid, ft
h2 downstream static head of flowing fluid, ft
14. Mention the two distinct characteristics of an equal percentage valve.
The equal %valve has increasing sensitivity and linear Characteristics. When the valve
pressure drop is small or when the process gain decreases with increasing flow this valve can
be used.
15. What is the function of the spring in a control valve?
The spring is used to bring back the actuator in static position. The spring develop Inertia and
static force which may use to get the force balance in control valve.
16.
What are I/P and P/I converter? State the stand and valves for P and I in
instrumentation practice.
I/P and P/I converter are signal converters which are use to convert current to pneumatic and
vise versa in process system. The standard Pneumatic value is 3 15 psi and the current is 4
20 mA DC.
17.
Page
18
http://studyzone.dgpride.com
23. List the merits and demerits of using a positioner in a control valve?
Merits: Hysteresis is reduced and linearity is improved, Actuator can handle higher static
forces
and speed of response is improved.
Demerits: Does not improve the ability of actuator to handle inertia or thrust forces. Requires
maintenance.
24. Derive the expression for flow through an equal percentage valve?
The expression for flow is, [ m / M] ={ R(x/X) - 1}
where, m = outlet flow rate, M = desired maximum outlet flow rate
R = rangeability ,
x / X = ratio of lift
25. What is equal percentage in the equal percentage valve?
The equal percentage characteristics is so named because for equal increments of stem travel
at constant pressure drop, an equal percentage change in existing flow occurs (i.e.) The same
% change increase in flow will occur when the stem position changes from 40% to 50% of
travel.
Visit dgpride.com
19
The upstream pressure of control value is 4kg/cm and the downstream pressure
varies 51kg/cm. The port diameter of the control value is 5 cm. Find the actuator
force required?
Given : p =4kg/cm , p2= .51 kg/cm ,d= 5cm , a= /4*d^2 ,
Ans: F=(4-.51)*/4*8^2= 68.5kn
Page
26.
http://studyzone.dgpride.com