14 12 31 10 44 12 2935 Elamurugan

EI 2352 Process Control Department.
Of EIE
EI 2352 – PROCESS CONTROL

PART-A Question and Answers
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 are A process in which the materials or work flows more or
stationary at one physical location while being treated. less continuously through a plant apparatus while being
Eg. Thermal type process. treated. Eg. Storage vessel control.
2. This is suitable for different kinds for 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.
5. What is meant by self-regulation?

Self regulation of a process is defined as the process is one in which either inflow and outflow is dependent to the
controlled variable. Most of the causes the flow is self regulating because of its steady state is increased by
increasing the outflow.
6. What is non-self regulation? Give an example.

A non-self regulating process is one in which both inflow and outflows are independent of the controlled variable
this type of process has no steady state gain. The example of the non self process is a simple liquid level system
with constant outflow.
7. Define the term resistance in liquid level system.

The resistance is defined as the ratio between the rate of change of head to the rate of change of flow. This may be
classified based on flow, turbulent or laminar resistance. The turbulent resistance is not linear but laminar resistance
is linear.
8. Calculate the thermal capacitance of a 30-gal water tank.

The thermal capacitance is defined as C = WP
Prepared by:P.Elamurugan,AP/EIE,CNCET 1
EI 2352 Process Control Department. Of EIE
Where W – weight of the water, gal. P – Specific heat of water, Btu/lb deg-1
i.e C = 30 lb x 8.3 Btu/ deg lb-1 = 249 Btu / deg.
9. Distinguish between servo and regulator operation of control system.

Servo problem Regulator problem
1. The set point is variable and load disturbance the load disturbance is variable and set point is kept
are kept constant. constant
2. This method is desired by operator. this may happen any time in the system
3. Tracking of missiles and automatic controlling of temperature and flow rate are
machining are examples of this type. examples of the type.
10. Enlist the distinguishing features of process control systems.

i.) Increase in quantity of number of products.
ii.) Improved in quality of products.
iii.) Saving in processing materials.
iv.) Saving in plant equipment.
v.) Decrease in human drudgery.
11. Distinguish between parameters and variables of a process.

Process parameters Process variables
1. This is the quantity which is known and it is This is quantity to be measured in the process.
constant.
2. This is supplied by external world. This is developed in the process itself.
3. This has definite value ( set point, Controller This does not have definite value
parameters )
12.List any four objectives of process control.

i.) Safety
ii.) Product specification.
iii.) Environmental regulations.
iv.) Operational constraints
v.) Economics.
13. Define interacting system and give an example.

The term interacting is often referred as loading. When two tanks are connected at same datum level if level of any
one tank increases simultaneously another tank head also increase.
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 ft2.
Time constant T = AR but R = h / q = 10 / 5 = 2
T = 10 x 2 = 20 min.
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 the assumptions made to get the mathematical model of an non interacting system?
a. The liquid to be of constant density
b. The tanks to have uniform cross sectional area.
c. The flow resistance to be linear.
17. How the mathematical modeling of higher order process obtained?

The mathematical modeling of higher order process are obtained in three ways
a. N first order processes in series
b. Processes with dead time

c. Processes with inverse response.
18. What is the need for process automation?

Process automation is employed to maintain a controlled variable at a desired value. The main advantage of
automatic control is that a machine can perform the task more rapidly and consistently than a human being.
19. Difference between batch process and continuous process?

Batch process:
A process in which the materials or work are stationary at one physical location while being treated. Eg. Thermal
type process.
Continuous process:
A process in which the materials or work flows more or less continuously through a plant apparatus while being
treated. EgStorage vessel control.
20.list any four objectives of process control.

A. safety
B. Production specifications.
C. Environmental regulations.
D. Operational constraints
E. Economics
21. What is the significance of "degree of freedom"?

Degree of freedom is the independent variables that must be specified in order to define the process completely.
Consequently the desired control of a process will be achieved when and only when all the degree of freedom has
been specified. A good understanding of degree of freedom is inherent in a process and they are very crucial for the
design of effective controllers.
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 through appropriate measuring devices the
outputs (temperature, pressure, flow rate, concentration) of chemical 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.
Theoretical approach: to design the control system for a chemical process before the process has been constructed,
we cannot rely on the experimental procedure, so a different representation of the chemical process is needed in
order to study its dynamic behavior. 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.
23.How does the control of unit operation affect the quality of product?
Unit operations play an important role in the development of chemical process. They provide building blocks, or
process segments, that can be analysed and designed individually and then combined into larger processing system.
24.Define process variable, load variable and manipulated variable.

Process 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.
25. What is the need for process control? (May/Jun 2013)
There are three general classes of needs : 1. Suppressing the influence of the external disturbances, 2.Ensuring the
stability of a chemical process, 3. Optimizing the performances of a chemical process.
26.A self regulatory system does not require a controller. True/ False. justify the answer. (May/Jun 2013)
Ans: True. A self regulatory system transfer function itself has an integrator term between its input and output.
27. Why do you need to develop mathematical model of the processes you want to control? (Nov/ Dec 2012)
The physical component of the process we want to control have not been constructed.
We cannot determine how the system responds to various input and output and therefore we cannot design
appropriate system. but even if the process equipment is available the procedure is very costly. Therefore we need a
mathematical model.
28.What is a second order system? Write its general form of equation.
UNIT II - CONTROL ACTIONS AND CONTROLLERS
1. What are the basic control actions in process control?

The basic control actions used in process control is
a).On – off control b) Proportional control c).Proportional – Integral control
d).Proportional - Integral - Derivative control
2. Define proportional band.

Proportional band (PB) is defined as the error ( expressed as a percentage of the range of measured variable )
required to move the valve from fully closed to fully open. The Pb and Proportional gain (Kp) is given by PB = 100
/ K p.
3. Define reset time

The time required for the output of a proportional – Integral controller to change an amount equal to the amount of
proportional response provided by a step change of actuating signal.
4. Define differential gap. Why is it introduced in a process?

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 two-position controller if small friction exists at the bearing on the float arm.
5. What are the applications of on-off control?

The on – off control are used in electric heater , thermostats, rapid operation switches, electrical contacts, simple
water level control and etc.
6. What is meant by offset? How can you eliminate the offset in a process?
The difference between the set point and the steady state value of the controlled variable is referred as offset. This is
commonly happened when the proportional only controller is used. This can be eliminated by adding integral term
in the controller.
7. What is meant by integral wind up?

The reset action in a PI controller causes its output to go an changing as long as the error is non-zero For various
reasons the error cannot be eliminated quickly in many situations and therefore if the time interval is long enough,
develops due to reset action leading finally to saturation known as the reset action or integral windup.
8. What is anticipatory control? Why is it called?

The derivative control action is anticipatory control. .With the presence of the derivative term (de / dt), the PID
controller anticipates what the error will be in the immediate future and applies a control action which is
proportional to the current rate of change in the error. Due to this property the derivative control action is sometimes
referred to as anticipatory control
9. What are the advantages and disadvantages of PI control?

Advantages :
1. It removes or reduces the steady state error without the need for manual reset.
2. it removes or reduces the steady state error without the need for manual reset.
Disadvantages :
1. It may lead to oscillatory response of increasing or decreasing amplitude which is undesirable
and the system may become unstable.
2. Constant steady state error.
10. What is meant by single speed floating control? (May/Jun 2013)

If the error is zero the output will not change but remains (floats) at whatever setting it is, when the error goes to
zero. The output of the control element changes at a fixed rate when the error exceed the neutral zone
11. Write the transfer function of PID controller and sketch its step response.
The transfer function PID controller is
U(s) / E(s) = Kp ( 1 +( 1/ Tis ) + Tds)
12. Derivative control cannot be used alone. Justify your answer.

When the error is constant the derivative action is zero. The derivative action Anticipates future errors and
introduces appropriate Action. When the process has noise the derivative control amplifies the noise and makes the
noisy one. It introduces a stabilizing effect on the Closed –loop control response of a process
13. Explain the principle of multi-position control.

In the Two position (On – Off) controller the control action is only in two states. In the multi position control
several intermediate position are used. This control mode is used to reduce the cycling and overshoot and
undershoot. This mode is represented as
P = Pi e > | ei | i = 1,2,………n
14. What are the main disadvantages of a proportional controller?

The major drawback or proportional controller is offset. When the proportional gain is increase the controller will
oscillate which tends to unstable system.
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 desired quality The process may be necessary when direct control is
of the product 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 ( -2ζπ /  1 – ζ2)
19. Give the optimum settings for PID controller.

The optimum settings for PID controller by Z –N method is
Kc = K u / 2 I = Pu / 2 D = Pu / 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, ¼ 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
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.
23. What are the advantages, disadvantages and applications of PD controller?(Nov/Dec2012)

Advantages: Offset can be reduced without reducing settling time.
Disadvantages: Offset is not eliminated.
At steady state PD acts as a P controller (i.e.) Steady state error is not eliminated
Applications: Used in large delay process / processes with large dead time.
24. What is the need for feed forward control? Briefly explain feed forward control with example.
Feed forward control: 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.
Example: Feed forward control of a heat exchanger: the objective is to keep the exit temperature constant by
manipulating the steam pressure. There are two principal disturbances that are measured for feed forward
control: liquid flow rate and liquid inlet temperature.
25. Explain two-position control with a suitable example. Where is it used?

Two position control (on-off control): Two-position control is a position type controller action in which the
manipulated variable is quickly changed to either maximum or minimum value depending upon whether the
controlled variable is greater or less than the set point. The minimum value of the controlled variable is usually
zero (off).
Example: (electric-level control) - A float in the vessel operates an electric switch, which controls power to a
solenoid valve. When the liquid level rises, the switch contacts are closed the solenoid valve closes, and the
inflow is cut off. When the liquid level falls, the switch contacts are opened, the solenoid valve opens, and the
inflow resumes.It is widely employed in home-heating systems and domestic water heaters.
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 two-position 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.
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 (May/Jun 2013)
KI = (KP) (1/I)  e(t)
KD = (KP) (d ) de/ dt
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.
D-control.
Adv: controller gives 90 degree phase shift.
Settling time decreases.
Disadv: No control action for steady error.
Not suitable for noisyt processes.
29. 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. Design an electronic p-controller with a proportional gain 5.

Given: kp = 5
Kp = r2/r1
5 = r2/r1
Ans: r2 = 10kΩ and r1 = 2Kω
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=1μf
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=1μf
32. What is meant by Neutral Zone in ON-OFF controller?(Nov/Dec 2012)
A deadband (sometimes called a neutral zone) is an interval of a signal domain or band where no action occurs (the
system is dead). Deadband is used in voltage regulators and other controllers. The purpose is common, to
prevent oscillation or repeated activation-deactivation cycles (called 'hunting' in proportional control systems).
UNIT III – OPTIMUM CONTROLLER SETTINGS
1. What is meant by tuning in process control? (May/Jun 2013)

To adjust the controller parameters is referred as tuning. The controller may tune using the simple criteria such as ¼
decay ratio, minimum setting time, and minimum error. Using time integral performance such as ISE, IAE, ITAE
the controller may tune. The popular method of controller tuning is Process reaction curve and Z-N method.
2. What is meant by ultimate period Pu of a controlled process?

The ultimate period Pu of sustained cycling is defined as Pu = 2π / phase cross over frequency.
3. What is a process reaction curve?

This is a plot drawn between the measurement output and time when the closed loop system is disconnected
between the controller and final control element and is manually operated with step change.
4. State the relation between maximum overshoot and decay ratio.

The relation between maximum overshoot and decay ratio is, decay ratio = (overshoot) 2.
5. Give the optimum controller settings for a PID controller based on Zeigler-Nicholas method.
The optimum controller settings for a PID controller based on Zeigler-Nicholas method is the proportional gain Kc
= Ku / 1.7 , Integral time I = Pu / 2 & Derivative time D = Pu / 8
where the Ultimate gain Ku = inverse of the amplitude ratio
Ultimate period of oscillation Pu = 2π / phase cross over frequency
6. What is ITAE and when to go for it?

ITAE is integral of the time weighted Absolute error and it is defined as ITAE =  t | e(t) | dt.
To suppress errors that persist for long times, the ITAE criterion will tune the controllers better because the
presence of large t amplifies the effect of even small errors in the value of the integral.
7. What is ISE and when to go for it?

ISE is integral of the square error and it is defined as ISE = | e2(t) dt.
To suppress large errors the ISE is better, because the error is squared and thus contributes more to the value of the
integral.
8. What is IAE and when to go for it?

IAE is integral of the Absolute error and it is defined as IAE =  | e(t) | dt.
To suppress small errors IAE is better than ISE because when square small numbers ( < 1) they become even
smaller.
9. Write Ziegler Nichols tuning formulae. (Nov/Dec 2012)

Kc I ( min) D ( min)
P only Ku / 2
P-I Ku / 2 Pu / 1.2
P-I-D Ku / 2 Pu / 2 Pu / 8
where Ku = ultimate gain, Pu = ultimate period of oscillation
10. Why is it necessary to choose controller settings that satisfy both gain margin and phase margin?
(May/Jun 2013)
It is necessary to choose controller settings that satisfy both gain margin &phase margin in order to avoid
unstable behavior by the closed loop of a process
11. What is tuning a controller based on quarter – decay ratio? (Nov/Dec 2012)
It’s the tuning of parameters of the controller so as to obtain a step change in the load (error). The response gives
decay ratio of ¼.it is defined as the ratio of successive amplitude of the peaks decay ratio=C/A.
12. Write the Cohen – Coon controller settings PID controller.

For the PID controllers the parameters are,
Kc =  / K td ( 4/3 + td / 4 )
I = td ( ( 32 + 6td )/  / (13 + 8td/)
D = 4td / ( 11 + 2td / )
where  ratio of steady state output and slope of the sigmoidal response
K = ratio of steady state output to the steady state input
td – time elapsed until the system responded.
13. Write the Cohen – Coon controller settings PI controller.

For the PI controllers the parameters are,
Kc =  / K td ( 0.9 + td / 12)
I = td ( (30 + 3td / ) / (9 + 20td/)
14. When do you go Process reaction curve method for controller tuning.
1. For the multi capacity processes whose response is sigmoid
2. Process with very short time delay
3. The process whose response is overdamped
15. What is cycling?

An important mode of dynamic variable error is the oscillation of an error about zero. This means the variables
is cycling above or below zero set point.
16. Briefly explain about Damped oscillation method

Using only proportional action and starting with low gain adjust the gain adjusted until the transient response of the
closed loop shows a decay ratio of 1 / 4. The optimum setting of damped oscillation method is more accurate than
ultimate method.
17. Under what circumstances derivative control action is added or removed in a controller?
The derivative action is recommended for temperature and composition control where there is a sluggish and Multi
capacity processes. The derivative action Anticipates future errors and introduces appropriate Action.It introduces a
stabilizing effect on the Closed –loop control response of a process.
18. Explain the continuous cycling method.

The continuous cycling method or on-off control is a position type control action in which the mv is quickly
changed to either a max or min value depending on whether the controlled variable is greater or less than the set
point.The equations for two-position control are:
m = m1 when e > 0: m = m0 when e < 0: Where, m = mv
m1 = max value of mv (on)
m0 = min value of mv (off)
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.
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.
double-seated control value
Advantages: Net force acting on value stem is small
Disadvantages: Cannot be shut off tightly because of differential pressure and temperature expansion of value
plug and valve body.
21. What is tuning a controller based on quarter – decay ratio?

It’s the tuning of parameters of the controller so as to obtain a step change in the load (error). The response
gives decay ratio of ¼.it is defined as the ratio of successive amplitude of the peaks decay ratio=C/A.
.
UNIT IV – MULTILOOP CONTROL
1. What is ratio control? Where is it needed?

Ratio control is special type of feed forward control where two disturbances are measured and held in a constant
ratio to each other. It is used to control the flow rates of the two streams
2. What are the advantages and disadvantages of feedback and feed forward controllers?
Advantages : 1. Acts before the effect of a disturbance has been felt by a system.
2. Good for slow systems.
3. Does not introduce instability in closed loop response.
Disadvantages:1. Requires identification of all possible disturbances and their direct measurement
2. Cannot cope with unmeasured disturbance.
3. Sensitive to process parameter variations.
4. Requires good knowledge of the process model.
3. What are the advantages and disadvantages of cascade control?

The Cascade control is useful in reducing the effect of a load disturbance that moves through the control system
slowly. This type of control gives very high performances than conventional control. the draw back of this type of
control is the two loop should be tuned properly with fine tuning methods.
4. Define and explain the concept of feed forward control.

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.
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.
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.
7. State the conditions for the cascade control to be effective.

Cascade control is useful in reducing the effect of a load disturbance that moves through the control system slowly
since the inner loop has the effect of reducing the lag in the outer loop with the result that the cascade system results
more quickly with a higher frequency of response. For cascade control process of the inner loop should be faster
than the outer loop. For cascade control to be effective the control action of the inner loop is often proportional with
the gain set to a high value. The action of the primary controller is generally PI or PID.
8. Give the applications of cascade control.

The cascade control are used in CSTR’s ( Continuous Stirrer Tank Reactors ), distillation column, value position
control, boilers and etc.
9. 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 closed It may create instability in the closed loop response
loop response. It does not require identification and measurement of
3) It requires identification of all possible any disturbance.
disturbances and their direct 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.
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.
15. Differentiate between feedback and feedforward control.

Feed Back control: It is useful for slow process.
It does not introduce instability in the closed loop response.
It requires identification of all possible disturbances and their direct measurement.
It is sensitive to process parameters.
Feed forward control: It does not require identification and measurement of any disturbance.
It may create instability in the closed loop response.
It is unsatisfactory for slow processes
It is insensitive to parameter changes.
16. 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.
17. When the split range control is needed in a process?

In a split –range control we can control a single Process output by coordinating the actions of several Manipulated
variables, all of which have the same effect on the controlled output. The split range control are used, when the
additional safety and operational optimality whenever necessary.
18. What is inferential control? Give an example:

Inferential control uses secondary measurements to adjust the PV, as CV cannot be measured. An estimator in the
inferential control computes the estimate of values of unmeasured cv from material and energy balance and the
measured outputs.
Eg. Distillation column fig 2.2c pg. 17 Stephanopoulos
19. How is the controlled variable of inner loop chosen in a cascade control system?
The inner loop in a cascade control is the secondary loop. When the process has a variable that need not be
controlled, but whose value affects the CV, then we have a secondary controller so as to control that value so that
they don’t affect the CV.
20. Describe split-range controller with an example.

In a split –range control we can control a single Process output by coordinating the actions of several Manipulated
variables, all of which have the same effect on the controlled output.
Eg: in a split range control of the pressure in a steam Header, several boilers discharge steam in a common Steam
header and from there to the process needs .Here instead of controlling the steam flow from each boiler, the firing
rate and steam production rate at each boiler is controlled .The control objective is to maintain constant pressure in
steam header when steam demand at various processing units increase.
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.
22. Give the Objectives of ratio control, with eg.

Ratio control is special type of feed forward control where two disturbances are measured and held in a constant
ratio to each other. It is used to control the flow rates of the two streams.
23. What is inferential control? How is it implemented?

Inferential control uses secondary measurements (because the controlled variables cannot be measured) to adjust the
values of the manipulated variables. The estimator uses the values of the available measured outputs, together with
the material and energy balances that govern the process, to compute mathematically (estimate) the values of the
unmeasured controlled variables. The controller to adjust the values of the manipulated variables, in turn, uses these
estimates.
24. Under what conditions feed forward is added with feedback?

Feed forward is added with feedback because of the following:
 Feed forward requires the identification of all possible disturbances and their measurement. Any changes in
parameters of a process by a feed forward controller cannot be compensated because their impact cannot be
detected.
 Feed forward control requires a very good model for the process.
 Feedback control is insensitive to the above 3 drawbacks but has poor performance and possibly unstable.
25. Discuss the situations to select a cascade control and discuss when it will become effective.
Cascade control is useful in reducing the effect of a load disturbance that moves through the control system slowly
since the inner loop has the effect of reducing the lag in the outer loop with the result that the cascade system results
more quickly with a higher frequency of response. For cascade control process of the inner loop should be faster
than the outer loop. For cascade control to be effective the control action of the inner loop is often proportional with
the gain set to a high value. The action of the primary controller is generally PI or PID.
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.
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.
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.
30. Write down the principle of distillation.
The distillation columns is use to separate different distillate and bottom products with different temperature and
different concentration.
31. Name the different types of distillation.

The types of distillation are Binary distillation column and Multi compound distillation column.
32. What is distillation?

Distillation separates a mixture on the basis of a difference in composition between a liquid and the vapor formed
from the liquid. In the process industry, distillation is widely used to isolate and purify volatile materials.
33. What is purpose of the tower or column in distillation equipment?

The tower or column has two purposes: First, it separates a feed into a vapor portion which ascends the column and
a liquid which descends the column. Second, it achieves intimate mixing between the two counter-current flowing
phases.
34. Identify the input and output variables of Distillation column.. (May/Jun 2013)
a. Column pressure
b. Feed flow rate
c. Feed composition(or feed quality)
d. Heat added(boil-up)
e. Bottom product flow rate
f. Heat removed(reflux)
g. Distillate product flow rate
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.
36. How to select secondary controller in cascade contol scheme. (May/Jun 2013)
The dynamics of the secondary loop are much faster than those of the primary controller. And the phase lag of
the closed secondary loop will be less than that of the primary loop. The crossover frequency of the secondary
controller will be
37. What is meant by Reflux Ratio?(Nov/Dec 2012)
The ratio of the amount of condensate being refluxed to the amount being withdrawn as product. Generally, the
higher the reflux ratio, the greater is the degree of separation of the components in a distillation system.
UNIT V – FINAL CONTROL ELEMENT

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.
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.
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. What are the different types of process parameters to be considered in selection of control valves?
Different types of process parameters to be considered in selection of control valves are the pressure drop across the
value, range ability, flow rate coefficient, control valve size and etc.
7. What are the different types of factors to be considered in control valve sizing?
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.
8. Differentiate flashing and cavitations in a control valve.

In a control valve when the pressure at venacontracta goes below the vapour pressure and also at the pressure is
below the liquid vapour pressure. So the fluid enters the port as a liquid & comes out as a vapour. This phenomenon
is called Flashing. It occurs in a valve when the pressure drop across the orifice first results in the pressure is being
lowered to below the liquid’s vapour pressure and then recovering to above vapour pressure. This
pressure recovery causes on implosion or collapse of the vapour bubbles formed at the venacontracta. This
Phenomenon is called Cavitation.
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.
10. What do you mean by Flashing?

In a control valve when the pressure at venacontracta goes below the vapour pressure and also at the pressure is
below the liquid vapour pressure. So the fluid enters the port as a liquid & comes out as a 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, ft2.
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. Why installed characteristics of control valve are different from inherent characteristics? (May/Jun 2013)
The inherent characteristics of control valve are desired by the manufacture with standards, but the installed
characteristics are change when the control valve is in usage. Because the control value may apply many
applications its coefficient may not be same for all conditions.
18. What is meant by cavitation in a control valve?

It occurs in a valve when the pressure drop across the orifice first results in the pressure being lowered to below the
liquid’s vapour pressure and then recovering to above vapour pressure. This pressure recovery causes on implosion
or collapse of the vapour bubbles formed at the venacontracta. This Phenomena is called Cavitation
19. Why is equal % valve mostly used in process industries?

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.
20. What is meant by cavitation and flashing in a control valve?

Flashing: In a control valve when the pressure at venacontracta goes below the liquid vapour pressure the
fluid enters the port as a liquid & comes out as a vapour.
Cavitation: It occurs in a valve when the pressure drop across the orifice first results in the pressure is being
lowered to below the liquid’s vapour pressure and then recovering to above vapour pressure. This
pressure recovery causes on implosion or collapse of the vapour bubbles formed at the venacontracta.
21. What is self regulation?

It is the ability of a control valve to reach a specific value for nominal changes in the load variable without any
controller.
22. What are the different types of actuators used in control valve?
Different types of actuators used in control valve are pneumatic actuators, hydraulic actuators, electro-pneumatic
actuators, and electric motor actuators.
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.
26. The upstream pressure of control value is 4kg/cm² and the downstream pressure varies 51kg/cm². The port
diameter of the control value is 5 cm. Find the actuator force required?
. Given : pı =4kg/cm² , p2= .51 kg/cm² ,d= 5cm , a= π/4*d^2 ,

Ans: F=(4-.51)*π/4*8^2= 68.5kn
27 . What is the function of valve positioner in the actuator? (May/Jun 2013)
For many applications, the 0.2 to 1 bar pressure in the diaphragm chamber may not be enough to cope with friction
and high differential pressures. A higher control pressure and stronger springs could be used, but the practical
solution is to use a positioner.
UNIT-I
PART-B
1. Explain with examples batch process and continuous process.

2. Develop the transfer function relating to the liquid level to the inflow for a simple tank system with an inlet
and an outlet.
3. Obtain the transfer function of two vessels of liquid level systems which are connected in series.
4. Obtain the mathematical model of the following process.
5. Sketch the response of processes with several equal time constants in series.
6. Define thermal time constant. Give two examples for thermal process and explain.
7. (a) A tank operating at 10ft head and 5gpm outflow through a valve has a cross section area of
10sqft.Calculate the time constant.
(b) Derive the transfer function for the following liquid level systems.
8. Explain the dynamic behavior of a process that shows inverse response with proper diagram and give the
conditions for inverse response
9. What is meant by mathematical modeling? Derive an expression for the differential level of an U tube
manometer under an applied differential pressure.
8. With an example, explain self – regulation of a process
9. In a stirred tank heater, the flow rate of the effluent system is proportional to the square root of the liquid level
in the tank. Obtain the relation between change outflow temperatures for change in inflow temperature.
Assuming the inflow outflow and steam temperature are constants.
10. Obtain the transfer function h2(s) / q1(s) for the following liquid process.
11. i) Bring out the difference between continuous and batch process with the help of neat diagrams.
ii )list the merits and demerits of continuous and batch process.(8+8)
12. For the level process shown in figure, derive the transfer function H2(s)/Q(s). Determine the value of time
constants involved, when h1=2.5m; h2=2.0m; q=40 liters/min; A1= 1.5 m2 and A2= 1.2 m2.
13. Derive the mathematical model of first order level,pressure and thermal processec. (16)
14. i) Distinguish between continuous and batch process (8)
ii) Describe briefly about the servo and regulator operation (8)
15. i) Derive the mathematical model of a thermal process from fundamentals.(8)
ii) Explain the suitable examples, the difference between interacting and non-interacting processes.(8)
16. Find the transfer function for the three tank system below
17. A tank with a capacity of0.2.5m3 has a inflow of water at the rate of 20 litres/min. The inlet temperature is
20deg C. An electrical heater supplies a constant heat input of 10kW. At t=0,the inlet temperature starts
varying at the rate of 0.5degC/min. Determine the temperature of outlet water at t=20 min.
18. Determine the transfer function H3(s)/Q(s) for the liquid level system shown below. The flow rate from tank 3 is
maintained constant at b by means of a pump.
19. Derive the transfer function H(s)/Q(s) for the liquid level system shown below when
i. The tank level operates about the steady state value of 1 feet and
ii. The tank level operates about the steady state value of 3 feet.
20. Describe a simple thermal system in which incoming liquid is heated by the heater in the tank and going out
with higher temperature. Develop first order transfer function of the thermal process. (Nov/ Dec 2012)
21. (i) Illustrate servo and regulatory operation with an example for each.(8)
(ii) Explain continuous and batch process with an example.(8)(May/June2013)
UNIT II - CONTROL ACTIONS AND CONTROLLERS

PART B
1 Give the electronic configuration of a PI and PD control modes.

2 Explain the basic principle of operation of PID electronic controller.
3 Give the pneumatic configuration of a PI and PD control modes.
4 Explain with neat sketch the basic principle of operation of PID pneumatic controller.
5 For measuring flow in a process, the derivative action is not recommended. Give your comments on this
result.
6 Derive the values for Kp, Ki and Kd for electronic PID controller by using 3 operational amplifier
7 Derive the transfer function for PI, PD and PID control modes.
8 Briefly explain the following controller modes. ON-OFF mode, PI mode.
9 A PD controller has 0.4 to 2.0 V input measurement range, 0 to 5V output, Kp= 5% per
%and Kd= 0.08 per (% per min). The period of the fastest signal change is 1.5 sec. Implement the controller
using OPAMP.
10 Explain why offset occurs in a process with a proportional controller. Draw the sketch of pneumatic
proportional controller and explain its operation?
11 Obtain the response of P, PI, PID controllers with KP = 2, TR = 1 sec, TD = 0.1 sec for the following error
signal shown in Fig
12 Can we use pure integral or pure derivative control mode for any process? Give reasons for your answer.
Explain P+I+D control action by means of an example.
13 A process has two time-constants of 10 sec and 25 sec and a steady – state gain of 1.3. Find the gain of the
proportional controller required to give a damping ratio of 0.5 in the closed loop response.
14. (i) Explain the effect of differential gap of ON-OFF controller on the response
of the same. (4)

(ii) Obtain the response of P, I, D, PI, PD, PID controllers for the following
ramp input r(t) =0.5t (12)
Kp =2 %/%, KI = 1% /% sec-1, KD = 0.1 %/% sec.
15 Design an electronic PID controller with the following specifications
Proportional Band – 25%
Derivative gain(KD) – 20
Integral gain(KI) – 2.5
16 For the system shown in Fig. 1., find the offset that results due to unit step change in U when the process
transfer function is
i. 1 / ( 1+12s),
ii. 1 / s(1+12s)
17. Draw the plot of PID controller output for the following error pattern.
(KP=5, τI=1 sec, , τD=0.5 sec and PI(0)=10%)
18. Sketch the PID controller output for the given error signal shown in the following figure. Given that Kp =
5, KI = 0.7 s-1, KD= 0.5 sec and PI (0) =20%. (16)
19. The differential gap in an ON – OFF is 1% of set point value. When set point is 300 oC duration of
valve open is equal to 2 minutes duration of valve closed is 2 minutes. Find the period of oscillation of
controlled variable when set point is 250oC. Design an electronic PID controller with the following
specifications:
i.Proportional band – 25%
ii.Derivative gain ( KD) – 20
iii. Integral gain ( KI ) – 2.5
20. Compare the features of various control schemes listed in the table given.
SI.NO Controller Controller output m(t) of Advantages Disadvantages
u(t)
1. ON-OFF
2. P
3. I
4. D
5. PI
6. PID
21. i) With a neat sketch, explain the characteristics of on-off and proportional controller. (10)
ii) Write a short note on single- speed floating. (6)
22. A temperature control scheme inputs the controlled variable as arrange from 0 to 4V. The output is a heater
requiring 0 tot 8V. A PID controller is to be used with KP =2.4%/%, KI=9%/(%-min), KD=0.7%(%/min). The
period of the fastest expected change is estimated to be 8 seconds. Develop the PID circuit.
23. Draw and explain the electronic circuit that realizes the on-off controller.
24. A P+I+D controller has a proportional band of 40%, reset time of 25 sec and derivative time of 10 sec. At
steady state the controller output is 50%. When the controller is subjected to a ramp error of 1.5%/min, how
long does it take for the controller to saturate?
25. i) Define the term „Differential Gap‟ of a on-off controller? Discuss its effect on the performance of the
controller.(8)
ii) What do you understand by floating control? Bring out the difference between single speed and
proportional speed floating control? Mention the applications of these two control modes. (8)
26. i) What is meant by bumpless transfer?
ii) Discuss about the factors to be considered while selecting the type of controller for various process.
27. i) What are the situations under which an ON/OFF controller satisfactory response? (4)
ii) A 5m diameter cylindrical tank is emptied by a constant outflow of 1.0m3/min. A two position controller is
used to open and close a fill valve with an open flow of 2.0 m3/min. For level control the neutral zone is 1.0m
[or hysteresis ] and the set point is 12.0m. Sketch the level versus time and calculate the cycling period.
(12)
28. i ) What is „cycling‟ in the process output? In which control mode it occurs?(2)
ii) A second order process with a transfer function is to be controlled by a
proportional controller. Find the value of „kp‟ required, so that the offset value off-set due to unit step change
in set point is 5% of steady state value of the controlled variable. (10)
iii) A proportional controller in a flow loop has a chart scale of 20 to 170lpm. If the controller output
is14mA at 100lpm, find the proportional band (in%) (4)
29. For the block diagram shown below obtain the offset with P and P+I controller for step change in the load
variable.
30.(i) Obtain the response of P,I,D controller for a step change in input.(6)
(ii) Illustrate the need and benefit of each component of composite PID controller. (10)(May/June 2013)
31.(i) Design an electronic PI controller with proportional gain =10& integral gain=0.1S-1.(8) (May/June 2013)
(ii) With a neat block diagram, explain the functioning of a pneumatic PID controller.(8) (May/June 2013)
32. Draw and explain the electronic circuit for realizing the P,PI, PID, PD controller modes.(16) (Nov/Dec2012)
UNIT III – OPTIMUM CONTROLLER SETTINGS
PART B
1. How can you get the optimum control settings for a closed loop system?
2. Suggest a method which is more accurate than continuous cycling method.
3. Explain process reaction curve method.
4. Sketch the reaction curve for a process with one time constant and one time delay.
5. Write a note on Zeigler- Nichols tuning. (May/June‟13)
6. Describe the continuous cycling method of tuning the controllers.
7. In an application of the Zeigler - Nicholas method, a process begins oscillation with a 30% proportional
band in an 11.5 min period. Find the nominal three mode controller settings.
8. A closed loop system has time constant of 1min. and 10 min. and a proportional
controller. Obtain the response to a step change in set point at a controller gain that gives a
damping ratio of 0.3.
9. Explain any one time response method of tuning controller.
10. i)Describe the evaluation criteria of integrals of the square, absolute value and time-
weighted absolute errors of the controller settings.(10)
ii) Give the optimum controller settings for the model G(s) = e-0.5s / (4s + 1) obtained by
Reaction Curve method. (6)
11. Write brief note on ¼ decay ratio.
12. Why both gain margin and phase margin should be considered for tuning of a controller.
13. i) What do you mean by optimum controller setting?(6)
ii) Given the transfer function of the system. (10)
with 5secs transportation lag. Find the optimum setting using Process reaction curve for:
a. P controller
b. PI controller
c. PID controller
14. Explain the damped oscillation method of tuning the controllers. What is the advantage of this method over
continuous cycling method? (10+6)
15. i) Compare IAE, ISE, and ITAE. (8)
ii) Explain ¼ decay ratio and optimum settings. (8) (May/June‟13)
16. (i) Using the Nyquist stability criterion, show that feedback systems with first and second order open loop
response are always stable. (8))
(ii) Describe the Ziegler-Nichols tuning methodology. This procedure is often called the continuous cycling
tuning method. Why? (8)
17. (i) Explain Zeigler Nichols Reaction Curve method. (6)
(ii) How to tune controller for higher order system? (10)
18. Discuss the Procedure for setting controller parameters by using frequency response method.(Nov/Dec‟13)
19. Explain the method of Process reaction curve and damped oscillation method for tuning the controllers.
. (Nov/Dec‟13)
20. Explain frequency response method of controller tuning.(8)(May/June‟13)
UNIT IV – MULTILOOP CONTROL
PART B
1. With a neat block diagram explain Ratio control.
2. What is meant by feed forward control? Why it is preferred along with feedback control? (8)
Explain the feed forward control strategy for a typical process. (8)
3. Describe the control loops in an exothermic reactor.
4. Explain the role of induced draft fan and forced draft fan in the combustion of fuel in a boiler.
5. Explain the cascade control strategy for a typical process with an example.
6. Explain Inferential control with neat diagram.
7. (i) Justify that cascade control can give better performance than feedback controller. (10)
(ii) Describe an application which needs cascade control. (6)
8. (i) Explain feed forward control with an example from distillation column. (8)
(ii) Describe split range control. Under what circumstances it is recommended? (8)
9. With neat block diagram explain Gain scheduling method and programmed adaptive control
method.
10. Explain with a neat diagram a method of directly controlling the overhead composition in a binary
distillation column.
11. Explain how the composition of top and bottom product is controlled in distillation column.
12. Draw a complete instrument diagram for boiler drum level control.
13. Draw and explain the three types of pressure control schemes in distillation.
14. Explain the operation of a distillation column. List the important control loops in distillation
Column and explain one of them in detail.
15. i) Explain the process of Binary distillation. (8)
ii) Describe the feedback control schemes for top tproducts, inlet fluid and reflux with a neat block
diagram. (8)
16. Explain how parameters are adjusted in Self-Tuning regulator (STR) and Model reference
Adaptive Control (MRAC) with a neat sketch. (8+8)
17. i) When do you prefer cascade control mode?
ii) Explain the design of cascade control scheme for a system of your choice, from fundamentals.(10)
iii) What are the precautions to be taken during the tuning of cascade control loop?
18. Explain in detail the various control schemes used for binary distillation column.
19. Describe in detail with necessary diagrams the multivariable control process using distillation column.
20. Explain the principle, mechanism and applications of
i. Inferential control and
ii. Split range control
21. i)List any four advantages and disadvantages of a feed forward control scheme(8)
ii) Explain the adaptive control scheme with the help of neat diagram (8)
22.(i) Explain control of a heat exchanger , using feed forward control.(8)
(ii) What is split range control? Expalin with a simple example.(8) (may/June 2013).
23. (i)Explain issues involved in multivariable control.(8)
(ii)Explain control of boiler , using three element method.(8) (may/June 2013).
UNIT V – FINAL CONTROL ELEMENT
PART B
1. With a neat sketch explain the principle of

i.Current to Pressure converter.
ii.Pressure to Current converter.
2. Give the characteristics of an equal percentage valve and explain its applications.
3. Explain the operation of spring actuator with positioner and without positioner.
4. What are the classifications of globe valves? Mention their applications.
5. Explain with a neat sketch the working principleof a Electro-Pneumatic converter.
6. What is the need for a valve positioner? Describe the working of an pneumatic actuator
with positioner. (may/June 2013).
7. List the factors that decide the lag in a pneumatic transmission line.
8. Describe the construction of control valves.
9. Explain what is Cavitation and flashing in control valves
10. Discuss the three important flow lift characteristics of control valves.
11. i) Compare pneumatic and electric actuators.(8)
ii) What is meant by valve positioned? Draw the characteristics of control valve and explain it.
12. Explain the flow lift characteristics of control valves.
13. Explain with neat sketches, the construction and salient features of butterfly and ball valves.
14. Explain the working principle of pneumatic actuated control valve with positioner, with the help of neat
diagram
15. i) Write down the flow equation of an equal percentage valve and sketch its inherent valve characteristic.(4)
ii) Explain how you will practically determine the installed valve characteristic of a control valve in an
installation and also the reasons for determining the installed characteristics. (6)
iii) An equal percentage valve has a rangeability of 32. If the maximum flow rate is 100m3/hour. Find the
flow at2/3 open setting.
16. i) Explain briefly about the construction and operating principle of different types of pneumatic valves and
their flow capacity characteristics.
ii) Discuss about the important factors before selecting air-to-close pneumatic control valve.
17. i) The flow through a control valve has to be varied from 300gpm to 1100 gpm. The pressure drop across
the valve varies from 20 to 45 psig. Find the size of the valve required, if the liquid density is 0.9. (10)
ii) What is an equal percentage valve? What is mean by‟ rangeability‟ of a control valve? (6)
18. i) Describe the working of a pneumatic actuator with positioner. Make comparative study on pneumatic and
electric actuators. (8)
ii) Why does the flow-lift characteristic of a control valve change after installation of the valve in a
pipeline? (8)
19. i) What is the need for a valve positioned?(4)
ii) List the factors that decide the lag in a pneumatic transmission line. (4)
ii) Describe the working of a pneumatic actuator with positioner. (8)
20. Write short notes on the following:
i) Valve sizing (6)
ii) Cavitation and flashing (6) (may/June 2013).
iii) I/P converter (4)

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EI 2352 Process Control Department.

EI 2352 – PROCESS CONTROL

2. Distinguish between batch process and continuous process.

3. Define degrees of freedom.

4. What are the different mathematical models used in process control?

5. What is meant by self-regulation?

6. What is non-self regulation? Give an example.

7. Define the term resistance in liquid level system.

8. Calculate the thermal capacitance of a 30-gal water tank.

9. Distinguish between servo and regulator operation of control system.

10. Enlist the distinguishing features of process control systems.

11. Distinguish between parameters and variables of a process.

12.List any four objectives of process control.

13. Define interacting system and give an example.

17. How the mathematical modeling of higher order process obtained?

b. Processes with dead time

18. What is the need for process automation?

19. Difference between batch process and continuous process?

20.list any four objectives of process control.

21. What is the significance of "degree of freedom"?

24.Define process variable, load variable and manipulated variable.

28.What is a second order system? Write its general form of equation.

UNIT II - CONTROL ACTIONS AND CONTROLLERS

1. What are the basic control actions in process control?

2. Define proportional band.

3. Define reset time

4. Define differential gap. Why is it introduced in a process?

5. What are the applications of on-off control?

7. What is meant by integral wind up?

8. What is anticipatory control? Why is it called?

9. What are the advantages and disadvantages of PI control?

10. What is meant by single speed floating control? (May/Jun 2013)

12. Derivative control cannot be used alone. Justify your answer.

13. Explain the principle of multi-position control.

14. What are the main disadvantages of a proportional controller?

16. Distinguish between Direct and reverse action of a controller.

17. What is dead time?

18. Define decay ratio.

19. Give the optimum settings for PID controller.

20. What do you meant by optimum controller settings?

21. What are the advantages and disadvantages of 2-position control?

23. What are the advantages, disadvantages and applications of PD controller?(Nov/Dec2012)

25. Explain two-position control with a suitable example. Where is it used?

30. Design an electronic p-controller with a proportional gain 5.

UNIT III – OPTIMUM CONTROLLER SETTINGS

1. What is meant by tuning in process control? (May/Jun 2013)

2. What is meant by ultimate period Pu of a controlled process?

3. What is a process reaction curve?

4. State the relation between maximum overshoot and decay ratio.

6. What is ITAE and when to go for it?

7. What is ISE and when to go for it?

8. What is IAE and when to go for it?

9. Write Ziegler Nichols tuning formulae. (Nov/Dec 2012)

12. Write the Cohen – Coon controller settings PID controller.

td – time elapsed until the system responded.

13. Write the Cohen – Coon controller settings PI controller.

15. What is cycling?

16. Briefly explain about Damped oscillation method

18. Explain the continuous cycling method.

21. What is tuning a controller based on quarter – decay ratio?

UNIT IV – MULTILOOP CONTROL

1. What is ratio control? Where is it needed?

3. What are the advantages and disadvantages of cascade control?