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EI2352-Process Control B.E-Electronics and Instrumentation Engg

PROCESS CONTROL
QUESTION BANK
UNIT – I (PART A)
1 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.

2 Define degrees of freedom.

The Degree of freedom is defined as the number of independent variable that must be specified
in order to define 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.

3 What are the different mathematical models used in process control?

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.
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.

4 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.

5 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.

6 Distinguish between servo and regulator operation of control system.

Servo problem Regulator problem
The set point is variable and load the load disturbance is variable and set point
disturbance are kept constant. is kept constant
This method is desired by operator. this may happen any time in the system
Tracking of missiles and automatic controlling of temperature and flow rate are
machining are examples of this type. examples of the type.

.
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• Capacity to store material, energy or momentum.

7 Write any two characteristics of first order process

• The resistance associated with the flow of mass, energy or

momentum in reaching the capacity

8 List any four objectives of process control.

i.) Safety
ii.) Product specification.
iii.) Environmental regulations.
iv.) Operational constraints
v.) Economics.

9 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. Example:
Two tank systems connected in series

10 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.
2
Given h = 10 ft. Q = 5 lpm, A = 10 ft . Time
constant T = AR but R = h / q = 10 / 5 = 2
T = 10 x 2 = 20 min.

11 Define non interacting system and give an example

The dynamic behavior one tank is affected by the other, but the reverse isn’t true, then it is
non-interacting system. Here the liquid heads are independent of each other Example: Two
tanks one below the other.

12 What is the need for mathematical model?

• To optimize process design and operating condition
• To design a control strategy
To understand the behavior of a process, mathematical representation of physical and
chemical phenomenon taking place in it is essential

13 What is a second order system? Write its general form of transfer function.
A second order system is one in which output is described by a second order differential
Equation

14 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. It requires closed loop of action and reaction without human intervention.

15 A Self regulatory system doesn’t require a controller. True/False. Justify the answer.
True. It doesn’t need any external intervention for its stabilization

16 What is the significance of "degree of freedom"?

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 By:
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17 What is the need for servo operation?

To make the process follow changes in the set point as closely as possible,servo operation is
necessary. Example: normally in batch process changes in load variables such as temperature and
pressure causes large errors than the set point change, in that case servo operation is necessary.

18 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.

19. 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.
20 Name different sets of test inputs that can be given to a process.
Step, Ramp, Impulse, Parabolic, Sinusoidal input

PART-B

1. 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) .
2. Develop a mathematical model for the system shown in fig below. What are the states for his
system? All the flowrates are volumetric and the cross sectional areas of the tanks are A1, A2 and A3
(ft2), respectively. The flow rate F5 is constant and does not depend on h3, while all other effluent
rates are proportional to corresponding hydrostatic liquid pressures the cause the flow. (NOV/DEC
2012) .

3. Consider the system shown in fig. Develop a mathematical model for the system. Assume that the
effluent stream from a tank is proportional to the hydrostatic liquid pressure that causes the flow of
liquid. Cross-sectional area of tank 1 is A1 (ft2) and of tank 2 is A2 (ft2). The flow rates F1, F2, F3are
in ft2/min. take necessary assumptions. (MAY/JUNE 2012)

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4. (a) Derive a mathematical model of a first order thermal process.

(b) What is the inverse response? Explain the inverse response noticed in the level control of
feed water in the boiler.( MAY/JUNE 2012).

5. (a) Differentiate servo and regulatory operation with the help of suitable example.
(b) Explain with suitable examples, the difference between the interacting and non- interacting
processes.(NOV/DEC 2010).
6. (a) bring out the difference between the continues and batch process with the help of neat diagrams.
(b) List the merits and demerits of the continues and batch process (APR/MAY 2010).
7. (a) derive the mathematical model of a thermal process from fundamentals.
(b) Explain with suitable examples, the difference between the interacting and non- interacting
processes.( APR/MAY 2010).
8. (a) what are the dynamic components of the loop that may exhibit significant time delays In their
response?
(b) How are the effects of dead time compensated? What are the important features of dead time
compensators? (MAY/JUNE 2009).
9. (a) what is the inverse response? Explain its behaviour with dynamic system.
(b) What is the need for mathematical modeling for process control? Explain the mathematical
model for the first order thermal process(MAY/JUNE 2009).
10. (a) distinguish between servo and regulator operation.

(b) explain the self regulation process with an example(NOV/DEC 2013)

11. derive the mathematical model for the given process (NOV/DEC 2013)

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EI2352-Process Control B.E-Electronics and Instrumentation Engg
UNIT 2

PART A

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.

• Cycling: when control variable does not remain at set point(SP) value it keeps oscillating around
5 Identify two parameters of ON-OFF controller
SP.
• Differential gap: to overcome cycling
6 Draw the open loop response of an inverse response process when excited with unit step input

7. What is meant by neutral zone in ON-OFF controller?

It is known as differential gap. A small range of value through which control variable must pass in
order to change from maximum to minimum or vice verse
8. Sketch the input, output characteristics of single speed floating controller

9. Define integral windup and Anti reset windup.

Windup occurs when PID system has constant error. The difference between set point and control
variable never gets to zero; the integral term grows to a very large number. This is called integral
windup.
Anti- reset windup is a system to stop the I term from growing without bound
Reset windup is to set the reset interval to a very large number

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10 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.

11 What is meant by single speed floating control?

The output will not change but remains (floats) at whatever previous 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

12 Derivative controls 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 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.

14 Define ¼ decay ratio.

The decay ratio is expressed as, Decay ratio: C/A= exp ( -2ζπ / √ 1 – ζ ). If C/A=1 then it is called ¼
The ratio of the amounts above the ultimate value of two successive peaks is called as decay ratio.
2

decay ratio.

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

Advantages: Easy to design, Low cost
Disadvantages: Cycling behavior of the control valve, FCE is subjected to high frequency of
oscillation if neutral zone is not used

16. 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
process variable(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.

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17. 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

18. 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.
19. 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

20. What are the advantages and disadvantages of PID control actions?
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 noisy processes.
PART B

1. With neat schematic diagram explain the single speed floating control.(nov13)

2. With neat sketch explain the of P+I pneumatic controller.(nov13)

3. Explain with neat diagram the working of electronic PID controller.(nov13)

4. When an on-off controller is recommended? How its performance affected by process dead
time.(may12)

5. A pi controller has 20% and integral time of 10sec.for a constant error of 5%.determine the controller
output after 10sec.the controller offset is 25%.(may12)

6. Compare the features of ON & OFF,P,I,D control modes and draw their characteristics.(nov10)

7. Explain the procedure for tuning pi controller using zielger Nicholas method.(nov10)

8. What is cycling in the process output in which control mode it occurs.(may10)

9. A second order process with the transfer function of g(s)=5/(10s+1)(3s+1) is controlled by a

proportional controller. Find the value of kp required offset due to unit step change in set point is 5% of
steady state value of controlled variable.(may10)

10. Various steps involved in process reaction curve method of tuning off controllers.(may09)
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11. Explain the various time integral performance criteria with closed loop response.(may09)
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EI2352-Process Control B.E-Electronics and Instrumentation Engg
UNIT 3

PART A

1. How tuning is done 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 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.

3 State the relation between maximum overshoot and decay ratio.

2
The relation between maximum overshoot and decay ratio is, decay ratio = (overshoot)

4 What do you meant by controller tuning?

A procedure of finding the optimum controller setting by conducting a simple experimental test. It
means adjusting the controller parameters.

5 Give an example for Discontinuous and Continuous mode of controller.

Discontinuous-ON-OFF controller.
Continuous – Proportional Controller

6 How to choose evaluation criteria for an application

ISE- to suppress large errors
IAE- to suppress small errors
ITAE- to suppress long time errors
7 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.

8 Write Ziegler Nichols tuning formulae.

Kc τI ( min) τD ( 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

9 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. The stability of the system is decided by the
appropriate gain and phase margins

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10 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.

11 Write the Cohen – Coon controller settings PID controller.

Kc = τ / K td ( 4/3 + td / 4 τ)
For the PID controllers the parameters are,

τI = td ( ( 32 + 6td )/ τ / (13 + 8td/τ) τD = 4td /

( 11 + 2td / τ)
where τ ratio of steady state output and slope of the sigmoidal response K = ratio of steady state output to
the steady state in td – time elapsed until the system responded.

12 When do you go Process reaction curve method for controller tuning.

o For the multi capacity processes whose response is sigmoid
o Process with very short time delay
o The process whose response is over damped
o

13 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.

14 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

• For a response with constant non zero error it gives no control action as the
15 Write two limitations of derivative controller?

• For a noisy response with almost zero error it can compute large derivatives and
controller output goes to zero

thus yield large control action, although it is not needed

16 Explain the function of a controller

Controller is the most important part of the process control which generates a
control signal to the final control element based on the deviation of set point
variable and process variable.

• Keep the maximum errors as small as possible.

17 What are the parameters required to design a best controller?

• Achieve short settling time.

• Minimize integral of errors until the process has settled to set point value

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18 Define time constant of a process

It is a measure of the time necessary for the process to adjust to a change in its input

19 Write any two significance of gain margin

If gain is slightly greater than 1 at 180 shift system becomes unstable
When the phase lag is 180 and if gain is slightly less than 1 system is stable.

20 Write the Cohen – Coon controller settings PI controller.

Kc = τ / K td ( 0.9 + td / 12τ)
For the PI controllers the parameters are,

τI = td ( (30 + 3td / τ) / (9 + 20td/τ)

PART B

1. What are the principles that arise during the design of feedback controller. Discuss them on the basis
of physical example.(nov04)

2. What is cascade control? Explain need for cascade control with an example. When do you prefer
cascade control mode (may09)

3. What is the need for inferential control? Explain the method finding the estimate for a process needs
interferential control.(may09)

4. Explain the design of cascade scheme for a system of our choice from the fundamental. What are the
precaution taken to tuning of cascade control loop.(may10)

5. Explain the block diagram of cascade control and adaptive control. List the advantages and
disadvantages of feed forward control scheme.(dec10)

6. With the block diagram explain the operation of split range control scheme.(dec10)

7. Explain the feed forward control with an example. Compare this with feedback control. Also bring
out this merits and demerits.(may12)

8. Discuss the procedure for setting controller parameters using frequency response method.(nov12)

9. Explain the method of process reaction curve and damped oscillations for tuning the
controllers.(nov12)

10. Explain how to find the controller settings using process reaction curve.(nov13)

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UNIT 4

PART A

1.Draw the block diagram of inferential control scheme?

Pg-439(stephanopoulous)

2.List the precautions to be taken while tuning the cascade control scheme?

i.determine the settings for the secondary controller using one of the methods(cohen-coon,Ziegler-
Nichols or others employing time integral criteria or phase and gain margin
considerations)

3. 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

4.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.

5.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.

6. 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.

7.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.

8.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.

9.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.

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10. What is meant by auctioneering control?
Such control configurations select among several measurements the onewith the highest value and feed it
to the controller. Thus it is a selective controllerwhich possesses several measured outputs and only one
manipulated input.
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 decouplers?

The special element introduced in a system with two strongly interactingloops to cancel the
interaction effect between the two loops and thus render two non-interacting control loops is called
decoupler.
13.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

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.

14. 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.

15.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.

16..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

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17. 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.

18. 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.

19.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

20. 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).

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PART B
1. What are the main advantages and disadvantage of cascade control for what kind of process
can you employ cascade control.(nov 04)

2. What is split range control? Describe a situation when you could use split range control.(nov
04)

3. Explain feed forward control with an example from distillation column.(apr 06)

4. Justify the cascade control can give better performance then feedback controller(may 06).

5.. Describe an application which needs cascade control.(may 06).

6. Explain the difficulties involved in controlling multivariable system with example from
distillation column.(may 06)

7. Explain the feed forward control with an example .compare feed forward controller with fed
back controller. Also bring out its merits and demerits.(may 12)

8. A cascade control system is shown in fig. Calculate the maximum gain and critical frequency
of the primary controller? Eliminating the inner loop compare these valves the single loop
system. Use bode plot technique.(may 12).

9. Explain the concept of ratio control with an example.(nov 12)

10. Explain the application of feed forward control and cascade control in distillation
column.(nov 12)

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EI2352-Process Control B.E-Electronics and Instrumentation Engg

UNIT 5

PART A

1. Why are the installed characteristics of control valve differ from its inherent characteristics?
Inherent Characteristics (ideal):
The control valve acts like an orifice and the position of the plug decides the area of opening
of the orifice. The flow rate through an orifice can be expressed in terms of the upstream &
downstream static pressure heads as:
Q=k1a (2g(h1-h2))1/2

Q=flow rate in m3/sec

K1=flow coefficient
A=area of the control valve opening in m2
H1=upstream static head of the fluid in m
H2= downstream static head of the fluid in m
Installed Characteristics (Effective):
When valve are installed with pumps,piping and fitting,and other process equipment,the
Pressure drop across valve will vary as the plug moves through its travel.

2.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.

3.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.

4. 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.

5.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.

6. 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

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tendency and the range ability is limited.

7. 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.

8.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.

9.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.

10.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.

11.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 and
Comes out as a vapour. This phenomenon is called Flashing

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.

For control valve the flow rate is given by m = Ka√ 2g(h1 – h2 )

13. Relate valve flow coefficient and liquid flow rate.
3
where m – flw rate ft / sec
K1 – a flow coefficient
2
a – area of control valve port, ft .
2
g = acceleration sue to gravity, ft/ sec .

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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.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

18.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.
19.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.

20.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.
PART B

1. Write the flow equation of a equal percentage valve and sketch its inherent valve
characteristics (may 12)
2. With necessary diagram, explain the characteristics of control valves.(nov 13)
3. Explain the procedure for control valve sizing for a flow control system.(nov 13)
4. Explain the principles of working and construction of I/P converter.(nov 12)

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5. Explain in detail the various control schemes used for binary distillation column(may 10)
6.. With the help of the neat diagram describe the operation of
A. Heat exchanger
B.drying process
7. Draw a neat sketch of pneumatic actuated control valve with positioned and explain its
working.(dec 10)
8. Explain cavitations and flashing effect. (apr 06)
9. Explain the principle of direct and reverse acting pneumatic actuators with a neat sketch.(may
09)
10. Write short notes on the following. (may 10 &dec 10)
a.) valve sizing
b.) cavitations and flashing
c.)I/P converter.

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