Process Two Mark Questions & Answers

UNIT-I

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.

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
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 the load disturbance is variable and set point
disturbance are kept constant. is kept 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 This is quantity to be measured in the
and it is constant. process.
2. This is supplied by external world.
3. This has definite value ( set point, This is developed in the process itself.
Controller parameters ) This does not have definite value

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

UNIT III

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 / Kp.

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?

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

1. 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.

2. 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.

3. 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.
 4. 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)

5. 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 = Pu / 8
By C – C method,
Kc =  / K td ( 4/3 + td / 4 )
I = td ( ( 32 + 6td )/  / (13 + 8td/)
D = 4td / ( 11 + 2td / )
 6. 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.

7. 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

8. 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.

9. What are the advantages, disadvantages and applications of PD controller?

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.

15. 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.

16. 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.

17. 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.

18. 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.

19. 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

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.
20. 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.

21. 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

22. 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

UNIT II

1. What is meant by tuning in process control?

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

1. 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

2. 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.

3. 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.
4. 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.

5. Write Ziegler Nichols tuning formulae.

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

6. Why is it necessary to choose controller settings that satisfy both gain margin and phase
margin?
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

7. 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.

8. 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.

5. 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/)

6. 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

7. 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.

8. 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.

9. 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.

10. 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)

11. 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.

12. 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 V

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 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.

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.

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
29. Write down the principle of distillation.
The distillation columns is use to separate different distillate and bottom products with
different temperature and different concentration.

30. Name the different types of distillation.

The types of distillation are Binary distillation column and Multi compound distillation
column.

31. 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.

32. 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.

33. List some of the variables which can be manipulated when controlling a distillation
column.
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

34. 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.
 UNIT IV
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?
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
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.