MEO Class IV - GEK

Controls
Control Media Exam Guide

This exam guide contains model questions similar to the ones you would answer in the written
examination. Our aim is to equip you on important subject areas. Answers provided are in the
form of cues and bulleted list to enable easy recollection.

Qu e st ion s

1. a. What are the different types of control system based on the media used for automation?
b. Why automation is preferred? Give the advantages of different types of control systems.

2. Sketch a nozzle relay valve.

3. Suggest with reasons the effect of following faults in a pneumatic control system.
a. A punctured diaphragm in the nozzle relay valve.
b. Grit on the seat of the nozzle relay valve.
c. Leaking proportional bellows in valve controller.
d. Leaking measurement bellows in valve controller.

4. a. Sketch and describe a valve positioner and briefly explain the fail safe concept.
b. Under what circumstances the positioner would be used?

5. Explain in detail data logger system with a detailed sketch.

 MEO Class IV - GEK
Controls
Control Media Exam Guide

Q 1.a.
What are the different types of control system based on the media used for
automation?

A Different types of control system based on the media used are:

z Pneumatic

z Electronic

z Hydraulic

Q 1.b.
Why automation is preferred? Give the advantages of different types of
control systems.

A Automation is preferred for the following reasons:

z Accurate monitoring and operation

z Human operator is relieved of repetitive and tiring task

z Automatic control gives consistent result

z Saves fuel and maintenance cost

z Complex machinery operations are easily coordinated

Advantages of p n e u m a t ic sy st e m

z Less expensive than electronic and hydraulic systems

z Leakages are not dangerous

z No heat generation, hence no ventilation is required

z Not very susceptible to variations in power supply in ships

z Simple and safe

Advantages of e le ct r o n ic sy st e m
 MEO Class IV - GEK
Controls
Control Media Exam Guide

z Fewer moving parts and hence less lubrication and wear

z Power consumption is low

z Adaptable

z Quick response

Advantages of h y d r a u lic sy st e m

z Gives instant response as fluid is virtually incompressible

z Can provide reciprocating and rotary motion

z Position control is accurate

z Amplification factor is high

Q 2.
Sketch a nozzle relay valve.

Output
C

E Valve
From
controller

D B
Leakage to Operating air
atmosphere
 MEO Class IV - GEK
Controls
Control Media Exam Guide

Q 3.a.
Suggest with reasons the effect of punctured diaphragm in nozzle relay
valve in a pneumatic control system.

A A punctured diaphragm will result in insufficient closure of the valve.

Q 3.b.
Suggest with reasons the effect of grit on the seat of nozzle relay valve in
a pneumatic control system.
A Grit on the valve seat causes continuous leakage of air into the atmosphere. The control
valve will be partially shut.

Q 3.c.
Suggest with reasons the effect of leaking proportional bellows in a valve
controller.

A Leaky proportional bellows in valve controller will reduce the ability of the bellows to
introduce a negative feed back. The gain of the controller is increased. Therefore, the
control valve will move to extreme positions making the controller unstable.

Q 3.d.
Suggest with reasons the effect of leaking measurement bellows in a valve
controller.

A Leaking measurement bellows in valve controller will hinder the flapper from moving
towards the nozzle. Hence the control valve will shift from its equilibrium position causing
the system to hunt.
 MEO Class IV - GEK
Controls
Control Media Exam Guide

Q 4.a.
Sketch and describe a valve positioner and briefly explain the fail safe
concept.

Hand jack

Hand jack
packing

Diaphragm

Air

Positioner

Spindle
packing

Fuel oil flow Fuel oil flow

Diaphragm valve

The valve positioner has three parts. They are motor, valve and positioner.

M o t o r e le m e n t :

Air pressure acts on top of synthetic rubber diaphragm and is opposed by upward spring
force, oil flow is from right to left. Hand regulation is also possible. The pressure stroke
characteristic is based on linear relationship. Diaphragm has a large constant area.
Diaphragm and spring have a linear force deflection characteristic.

V a lv e :

Valve is a correcting element. It can be single seated reverse action or double seated.
Double seated valves are preferred due to balanced valve forces and less operating
 MEO Class IV - GEK
Controls
Control Media Exam Guide

energy. Materials for all components depend on the medium being controlled.
Mitre valves with wings are best suited to on–off operation.

Vee port high lift valves are more suited for proportional control. Valve positioners are
used for controlling valves where accurate and rapid control is required without error or

Diaphragm
pressure

Opening
Without positioner

With positioner
Closing

Valve position

hysteresis. They can cope with large variations in forces acting on the plug. Valve
positioners also remove sticking and friction effects of gland. They are
preferred were the distance between the controller and valve is large.

Co n st r u ct io n

A valve positioner consists of a:

Diaphragm

Changeover cock

Spring Nozzle

Flapper

Cam linkage Bellows

Valve
Seat

Input from
controller
 MEO Class IV - GEK
Controls
Control Media Exam Guide

z High gain amplifier - It may be pneumatic, electro pneumatic etc.

z Feed back link - It detects the actual position of the valve.

The flapper is fastened to the valve stem via a feedback cam linkage. The output air
pressure from the nozzle acts on top of diaphragm. The control air signal acts in between
the two extremities of flapper, via bellows and spring. A set value of pressure Ps is
established in the bellow. The measured value Pm is the spring setting. When the pressure
to the bellows decreases, the bellow moves down. This results in flapper moving away
from the nozzle. The pressure at the orifice falls. This results in drop in output
pressure which is exerted on the top of the diaphragm. Since the pressure acting on top
of diaphragm decreases, the valve begins to close. The movement of the valve causes the
valve stem to move and rotates the cam clockwise. This raises the flapper against the
spring. The flapper moves closer to the nozzle. This increases the output pressure until
equilibrium is reached.

The changeover cock allows the signal from the controller to be placed directly on the
diaphragm.

Fa il sa f e

On failure of air supply control to valve, the valve may be adjusted to a position that
allows the plant to continue to operate safely, either in fully open or shut position. This
phenomenon is known as fail safe.

Q 4.b.
Under what circumstances the positioner would be used?

A A positioner would be used if:

z the valve is remote from the controller

z there is a high pressure difference across the valve

z the medium under control is viscous

z the pressure on the gland is high

Q 5.
Explain in detail data logger system with a detailed sketch.
 MEO Class IV - GEK
Controls
Control Media Exam Guide

Analog process transducer

Multiplexer

Analog to digital
converter

Digital signal Keyboard

input
Output to Digital
on/off System set points
computer
switches Visual
display unit
Digital to analog Data recorder
converter
Multiplexer

Output to control devices

(Valves, switches etc.)
A The term data logger is nothing but a broad range of electronic systems that automatically
collects and processes the data. Some data loggers control and supervise the plant.

The function of various elements in this system is as follows:

z Sensors are the detecting elements which measure the pressure, temperature, flow
level and convert the received signal into proportional voltage signals.

z Scanner receives the dc output from sensors which are analogous in nature.

z Analog to digital converter converts the received signal into digital signal.

z The analog transducers of pressure and temperature sensors produce a voltage signal
proportional to the measured parameters.

z Multiplexer receives the transducer signals and linearises them.

z Analog to digital converter converts this linearised signal into digital signal.

z A computer then compares this digital signal with the reference signal.

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