Process Control Instrumentation Practice Questions

UNIT I Process Dynamics

Process variables – Load variables – Dynamics of simple pressure, flow, level and temperature process –
interacting and non-interacting systems – continuous and batch process – self-regulation – Servo and
Regulator operation - problems.
1. Draw and Explain feedback control system and different variables associated with it
2. The physical system for control of flow through a pipe is shown in Figure. Variation of flow through
an obstruction (the orifice plate) produces a pressure difference variation across the obstruction. This
variation is converted to the standard signal range of 3 to15 psi. The P/I converter changes the pressure
to a 4- to 20-mA electric current, which is sent to the controller. The controller outputs a 4- to 20-mA
control signal to signify the correct valve setting to provide the correct flow. This current is converted
to a 3- to 15-psi pressure signal by the I/P converter and applied to a pneumatic actuator. The actuator
then adjusts the valve setting

Draw the Block Diagram Representation of the Process Control Loop identifying the manipulating
variable, process variable, process, final control element and the feedback measurement element
3. Distinguish between interacting and non – interacting system with suitable example
4. Find the transfer function H2/Q and H3/Q for the three-tank system shown in figure where H2, H3 and
Q are deviation variables. Tank 1 and 2 are interacting. For a unit step change in q, determine the initial
and final heights of Tank – 3(H3)

5. Explain Dynamics of 1st Order and 2nd Order Systems

6. Define Batch Process and Continuous Process. Give a detailed comparison between Batch Process and
Continuous Process.
7. Distinguish between servo and regulator operation with suitable examples and necessary expressions
8. Explain the significance of Servo and Regulator Operation with suitable expressions and examples.

UNIT II Control Actions and Controllers and Types of Controllers

Basic control actions – characteristics of two position, three position, Proportional, Single speed floating,
Integral and Derivative control modes – PI, PD, PID control modes –Problems -types of controllers -
Pneumatic, Hydraulic and Electronic Controllers to realize various control actions.
 1. A liquid-level control system linearly converts a displacement of 2 to 3 m into a 4-
to 20-mA control signal. A relay serves as the two-position controller to open or
close an inlet valve. The relay closes at 12 mA and opens at 10 mA. Find (a) the
relation between displacement level and current, and (b) the neutral zone or
displacement gap in meters.
2. Explain with a suitable example about offset error in Proportional Control action? How it can be
decreased by adding Integral Control action in PI controller?
3. Draw schematics and describe how op amps can be used to implement the proportional, integral and
derivative modes?
4. Describe how the nozzle/flapper system can be used to implement proportional and pi
control using pneumatics
5. Given the error of Figure, plot a graph of a proportional-integral controller output
as a function of time. KP = 5, KI = 1.0 s-1, and pI(0) = 20%

6. Under what conditions are pneumatic controllers preferred over electronic

controllers? Explain how pneumatic PI Controller is implemented?
7. Discuss about the factors to be considered while selecting the type of controller for
various process?
8. List out the characteristics of PI, PD and PID Controller
UNIT III Controller Settings and Tuning of Controllers
Evaluation criteria – 1/4th decay ratio, I AE, ISE, ITSE, ITAE - determination of optimum settings for
mathematically described process using time response and frequency response-tuning of controllers- process
curve reaction method – continuous oscillation method – damped oscillation method – problems.
1. What are the different time integral performance criteria? Write in brief about
them, giving the mathematical representation of each
2. Explain tuning of Controller using Process Reaction Curve method with suitable example and
diagram?
3. Explain tuning of Controller using continuous oscillations with suitable example and diagram?
4. In the Ziegler – Nichols method, the critical gain is found to be 4.0 and the critical
period was 2.0 minutes. Find the standard setting for
i. Proportional Control
ii. PI Control
iii. PID Control
5. An open-loop transient test provides the process-reaction graph given in Figure for a
7.5% disturbance.
a) Find the standard proportional-integral gain settings.
b) Find the three-mode quarter-amplitude settings
UNIT IV Final Control Elements and Control Valves
I/P Converter, P/I converter - pneumatic, electric and hydraulic actuators – valve Positioned - Control valves
– characteristic of control valves – valve body – Globe, Butterfly, diaphragm, Ball valves – Control valve
sizing – Cavitations, flashing - problems.
1. Explain the control valve characteristics? Draw and explain Pneumatic Control Valve?
2. Why is the size of a control valve important? What are the applications of a valve positioner?
3. Explain the construction and working of I/P converter. List few applications
4. Explain P/I converter with suitable diagram. List few applications
5. Describe the working of a pneumatic and hydraulic actuators
6. Explain single and double acting pneumatic actuator with suitable diagrams
7. Explain Butterfly valve and Globe valves with relevant diagrams
8. Explain Cavitations and Flashing in control valves.
UNIT V Multiloop Control System
Feed forward control – Feed Forward Feedback Controller (FFFBC) – Ratio control – Cascade control – Split
range – Multivariable control and examples from distillation column, Boiler system and heat exchanger.
1. What is Cascade control? Explain it with an example? When would you recommend such a
control system?
2. Explain in detail about logic of feed forward control with a suitable example
3. Compare feedback control system with a feedforward control system. Draw and explain feed forward
control system with suitable application
4. Explain working of Cascade Control System with suitable block diagram. Compare Cascade control
system with Feedback control system.
5. Classify different advanced control strategies and explain ratio control system?
6. Discuss in detail the feed forward control strategies used in distillation column control
7. What is split–range control? Describe a situation where you could use split range control?
8. Explain in detail about multivariable control with any example of heat exchanger/ boiler/ distillation
column