Process Control System

Ms. Afroj M Dange

Assistant Professor
Department of Electronic Science
Annasaheb Awate College Manchar Pune
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Rayat Shikshan Sanstha's

Annasaheb Awate Arts, Commerce & Hutatma Babu Genu Science College
Manchar, Pune
Department of Electronic Science
Class: TYBSc: SEM 5
EL365: Paper V: Process Control System
Question Bank
Unit 1: Process Measurements

Sr. No Questions Remark

1. What is meant by measurement? 1M
Measurement is an act or the result of comparison between the
quantity and a predefined standard.
2. Define instrument. 1M
Instrument is defined as a device for determining the value or
magnitude of a quantity or variable.
3. List the functional elements of the measurement systems. 2M
The three main functional elements of the measurement
systems are:
i. Primary sensing element
ii. Variable conversion element
iii. Data presentation element
iv. Data Storage

4. Describe the functional elements of an instrument with its block 4M

diagram.

1. Primary Sensing Element

The measurement first comes into contact with primary sensing element
where the conversion takes
place. This is done by a transducer which converts the measurement (or)
measured quantity into a usable
electrical output. The transduction may be from mechanical, electrical (or)
optical to any related form.

2. Variable Conversion Element

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The output of the primary sensing element is in the electrical form suitable
for control, recording and
display. For, the instrument to perform the desired function, it may be
necessary to convert this output to
some other suitable for preserving the original information. This function is
performed by the variable
conversion element. A system may require one (or) more variable
conversion suitable to it.
(a) Variable Manipulation Element
The signal gets manipulated here preserving the original nature of it. For
example, an amplifier accepts a
small voltage signal as input and produces a voltage, of greater magnitude.
The output is the same
voltage but of higher value, acting as a voltage amplifier. Here the voltage
amplifier acts as a variable
manipulation element since it amplifies the voltage. The element that
follows the primary sensing
element in a measurement system is called signal conditioning element.
Here the variable conversion
element and variable manipulation element are collectively called as Data
conditioning element (or)
signal conditioning element.
(b) Data Transmission Element
The transmission of data from one another is done by the data transmission
element. In case of
spacecrafts, the control signals are sent from the control stations by using
radio signals.
The stage that follows the signal conditioning element and data
transmission element collectively is
called the intermediate stage.
(c).Data Presentation Element
The display (or) readout devices which display the required information
about the measurement, forms
the data presentation element. Here the information of the measurand has to
be conveyed for,
monitoring, Control (or) analysis purposes.
(a). 1t case of data to be monitored, visual display devices are needed like
ammeters; voltmeters and so
on are used.
(b)In case of data to be recorded, recorders like magnetic tapes, T.V
equipment, and storage type C.R T,
printers and so on are used.
Or

PRIMARY SENSING ELEMENT: The quantity under

measurement makes its first contact with the primary sensing
element of a measurement system.
VARIABLE CONVERSION ELEMENT: It converts the
output of the primary sensing element into suitable form to

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preserve the information content of the original signal.

TRANSDUCER ELEMENT: Normally ,a transducer sense the
desired input in one physical form and converts it to an output in
another physical form. For example, the input variable to the
transducer could be pressure, acceleration or temperature and the
output of the transducer may be displacement, voltage or
resistance change depending on the type of transducer element.
Sometimes the dimensional units of the input and output signals
may be same. In such cases the functional element is termed a
transformer.
Depending on the transducer signal the signal
conditioning may be any one of the following,
[Link] amplifying elements such as levers , gears or a
combination of the two, designed to have a multiplying effect on
the input transducer signal.
[Link]/Pneumatic amplifying elements employing
various types of valves or constrictions ,such as
venturimeter/orificemeter,to get significant variation in pressure
with small variation in the input parameters.
[Link] amplifying elements in which lenses, mirrors and
combinations of lenses and mirrors or lamp and scale
arrangement are employed to convert the small input
displacement into an output of sizeable magnitude for a
convenient display of the same.
[Link] amplifying elements employing transistor circuits,
integrated circuits, etc, for boosting the amplitude of the
transducer signal. In such amplifiers we have either of the
following

voltage amplification= output voltage = Vo

input voltage Vi
Current amplification= Output current = Io
Input current Ii
or

Gain= Output power = VoIo

Input power ViI i

Signal filtration: The term signal filtration means the removal

of unwanted noise signals that tend to obscure the transducer
signal. The signal filtration element could be any of the
following depending on the type of situation, nature of
signal ,etc..
[Link] Filters that consist of mechanical
elements to protect the transducer element from various
interfering extraneous signals. For ex: the reference
junction of a thermocouple is kept in a thermos flask
containing ice. This protects the system from the ambient
temperature changes.
[Link] filters consisting of a small orifice
or venturi to filter out fluctuations in a pressure signal.

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[Link] filters are employed to get rid of

stray pick-ups due to electrical and magnetic fields. They
may be simple R-C circuits or any other suitable
electrical filters compatible with the transduced signal.
DATA PRESENTATION ELEMENT:
The information about the quantity under
measurement has to be conveyed to the personnel
handling the instrument or the system for monitoring,
control or analysis purpose
This system gathers the output of the signal
conditioning element and presents the same to be read or
seen by the experimenter. This element should:
[Link] as fast a response as possible
[Link] as little drag on the system as possible,
and
[Link] very small inertia, friction, stiction, etc..
(hence using light rays and electron beam is
advantageous).
This element may be either of the visual display
type, graphic recording type or a magnetic tape. In the
visual display type element, devices such as pointer and
scale/panel meter, multi-channel CRO, storage CRO,
etc.., may be employed. The graphic recording type of
element gives a permanent record of the input data. The
device in this element may be pen recorders using heated
stylus, ink recorders on paper charts, optical recording
systems such as mirror galvanometer recorders or
ultraviolet recorders on special photosensitive paper.
Further , a magnetic tape may be used to acquire input
data which could be reproduced at a later date for
analysis.
In case the output of the signal conditioning
element is in digital form, then the same may be
displayed visually on a digital display device.
Alternatively, it may be suitably recorded either on
punched cards, perforated paper tape, magnetic type,
typewritten page or a combination of these systems for
further processing
5. Explain about the performance characteristics of the 4M
instruments.
It consists of two characteristics as follows:
[Link] CHARACTERISTICS:
The static characteristics of an instrument are considered
for instruments which are used to measure an unvarying
process condition, performance characteristics mostly
obtained by calibration.
a)Accuracy: It is the measure of closeness with an instrument
measures the true value of a quantity.
b)Precision: It is the measure of the consistency or repeatability
of a series of measurements. Although accuracy implies
precision, precision does not necessarily imply accuracy. It is
given by
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Precision = 1- | |
xi− X
Xi
Where xi is the value of the ith measurement
X is the average value of n measurements.
c)Sensitivity: It is a measure of the change in reading of an
instrument for a given change in the measured quantity
d)Resolution: It is the smallest change in the measured quantity
that will produce a deductable change in the instrument reading.
e)Error: It is the deviation from the true value of the measured
quantity. Absolute error is defined as the difference between the
expected value of a quantity and the measured value.
Absolute error = Xe - Xm
where Xe is the expected value, Xm is the measured value

% error = | |
X e− X m
Xe
f)Range: The range of an instrument describes the limits of
magnitude over which a quantity may be measured .It is
normally specified by stating its lower and upper limits.
g)Span: The span of an instrument is the algebraic difference
between the upper and lower limits of the instrument range.
h)Drift: It is the variation of the measured value with time.
Perfect reproducibility means that the instrument has no drift.
There are 3 types of drifts: Zero, span and zonal drift.
i)Dead zone : It is defined as the largest change of input
quantity for which there is no output of the instrument.
The factors which produce dead zone are hysteresis and
backlash in the instrument.
j)Threshold: It is clear that if the input into the
instrument is increased very gradually from 0, there will
be some minimum value below which no output change
can be detected.
k)Significant figure: In stating the numerical results of a
measurement, only those figures that are meaningful
should be recorded.
i)Retaining digits: While recording values of
known precision, the convention is to retain the last digit
that is not uncertain by more than ten units.
ii)Rounding off:
Significant figures: After the number of
figures to be retained is determined, the last retained
figure is increased by one unit, if the first dropped figure
is greater than 5, or is a 5 followed by any other number
other than zero.
Significant Zeros: To avoid giving indication of
a higher degree of precision that is warranted, zeros that
are not significant, but which serve only to indicate the
position of the point, should not be used in writing a
value.
2. DYNAMIC CHARACTERISTICS:
Speed Of Response: It is defined as the rapidity with
which a measurement system responds to changes in
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measured quantity. It is one of the dynamic

characteristics of a measurement system
Fidelity: It is defined as the degree to which a
measurement system indicates changes in the measured
quantity without any dynamic error.
Dynamic Error :It is the difference between the true
value of the quantity changing with time and the value
indicated by the measurement system if no static error is
assumed. It is also called measurement error. It is one the
dynamic characteristics
Measuring Lag :It is the retardation delay in the
response of a measurement system to changes in the
measured quantity. It is of 2 types:

(a)Response with dead time

(b)Dead time and dead zone

Retardation type: The response begins immediately

after a change in measured quantity has occurred.
Time delay: The response of the measurement system
begins after a dead zone after the application of the input.

6. STATIC CHARACTERISTICS: 2.5M

The static characteristics of an instrument are considered
for instruments which are used to measure an unvarying
process condition, performance characteristics mostly
obtained by calibration.

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a)Accuracy: It is the measure of closeness with an instrument

measures the true value of a quantity.
b)Precision: It is the measure of the consistency or repeatability
of a series of measurements. Although accuracy implies
precision, precision does not necessarily imply accuracy. It is
given by

Precision = 1- | |
xi− X
Xi
Where xi is the value of the ith measurement
X is the average value of n measurements.
c)Sensitivity: It is a measure of the change in reading of an
instrument for a given change in the measured quantity
d)Resolution: It is the smallest change in the measured quantity
that will produce a deductable change in the instrument reading.
e)Error: It is the deviation from the true value of the measured
quantity. Absolute error is defined as the difference between the
expected value of a quantity and the measured value.
Absolute error = Xe - Xm
where Xe is the expected value, Xm is the measured value

% error = | |
X e− X m
Xe
f)Range: The range of an instrument describes the limits of
magnitude over which a quantity may be measured .It is
normally specified by stating its lower and upper limits.
g)Span: The span of an instrument is the algebraic difference
between the upper and lower limits of the instrument range.

7. State one disadvantages of null method compared to 2M

deflection methods.
Null methods: the pointer is maintained at a fixed position and
measurement is done by balancing.
Deflection type method: the pointer of the electrical measuring
instrument deflects to measure the quantity.
8. What is meant by primary sensing element? 1M
Which receives energy from the measured medium medium and
produces an output depending in some way on the measured
quantity.
9. Mention the basic requirements of measurement. 1M
The standard used for comparison purpose must be accurately defined and
should be commonly accepted.
The apparatus used and the method adopted must be provable.

10. What are the two methods for measurement? 2M

o Direct method

In these methods, the unknown quantity (also called the measurand) is

directly compared against a standard. The result is expressed as a numerical
and a unit. The standard, in fact, is a physical embodiment of a unit. Eg.,
Physical quantities like length, mass and time.
o Indirect method

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Measurement by direct methods is not always possible, feasible and

practicable. These methods in most of the cases, are inaccurate
because they involve human factors. They are also less sensitive.
Hence direct methods are not preferred and are rarely used.
11. Explain the function of measurement system. 1M
The measurement system consists of a transducing element which
converts the quantity to be measured in an analogous form. the
analogous signal is then processed by some intermediate means and
is then fed to the end device which presents the results of the
measurement.
12. Give the applications of measurement systems. 1M
The instruments and measurement systems are used for
 Monitoring of processes and operations.
 Control of processes and operations.
 Experimental engineering analysis.

13. When combined analog/digital systems are used, what are 2M

limitations associated with it?
The digital portions need not limit system accuracy. These
limitations generally are associated with the analog portions and/or
the analog/digital conversion devices.
14. Enlist the methods of correction for interfering and 2.5M
modifying inputs.
1] Method of inherent insensitivity
2] Method of high gain feedback
3] Method of calculating output corrections
4] Method of Signal filtering
5] Method of Opposing inputs
15. What are the two methods for measurement? Explain it 4M
o Direct method

In these methods, the unknown quantity (also called the measurand) is

directly compared against a standard. The result is expressed as a numerical
and a unit. The standard, in fact, is a physical embodiment of a unit. Eg.,
Physical quantities like length, mass and time.
o Indirect method

Measurement by direct methods is not always possible, feasible and

practicable. These methods in most of the cases, are inaccurate
because they involve human factors. They are also less sensitive.
Hence direct methods are not preferred and are rarely used.
16. Write the difference between deflection and null type 4M
method.

Deflection Type Method Null Type Method

Only one source of input Require two input

required measurand and balance
input

Output reading is based It required feedback

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on the deflection from operation that compare

the initial condition. the measurand with
standard value.

Value of the quantity It does not required

depend on calibration of calibration of
instrument. instrument

Less accuracy More accuracy

17. State dynamic characteristics. 2.5M

Class: TYBSc: SEM 5

EL365: Paper V: Process Control System
Question Bank
Unit 2: Process Performance Parameters
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Sr. No Questions Remark

1. What is meant by Data Acquisition System? 1M
The process of digitizing data from the world around so it can be
displayed, analyzed and stored in a computer.
2. What is an order of a system? 1M
The order of a system is the order of the differential equation governing
the system. The order of the system can be obtained from the transfer
function of the given system.
3. Define Dead time Element. 1M
A dead time element or transport lag is defined as a system in which the
output is exactly of the same form as that of the input.
4. Define Multichannel DAS. 1M

It can be time shared by two or more input sources with the main
function of converting the analog signal at the inputs into digital data
that a processing unit can comprehend.

5. What is transfer function representation? 1M/2M

The transfer function is defined as the ration of the Laplace

transform of the output quantity to the laplace transform of the input
quantity, when all initial conditions are zero.

6. Write the equation for sinusoidal transfer function. 1M/2.5M

7. Which factors are specifying the dynamic response in control system. 2M

Explain it.

1] Speed of response

2] relative stability

8. What are the elements of data acquisition system? And explain it 1M/2.5M

There are 3 elements of DAS.

1] Sensors

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2] Signal Conditioning

3] ADC

9. What is second order system? Give its one example.

10. Explain Zero order system? Give its one example. 4M

Any instrumentation system that closely obeys a 0 x0 = b0xi over its

range of operation is called as zero order system.

The static sensitivity can be expressed as.

X0 = b0 /a0* xi = K xi

11. Draw and explain generalized data acquisition system. 4M

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12. Write a difference between single channel and multichannel 4M

Data Acquisition System.

13. Draw and explain single channel Data Acquisition System. 4M

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Block diagram
Explanation

14. Explain First order system. 4M

15. Explain signal condition. 2.5M

16. Difference between zero order and first order system 2M/4M

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Class: TYBSc: SEM 5

ELSEC352: Paper XI: Process Control System
Question Bank
Unit 3: Fundamentals of Process Control
Sr. Questions Remark
No
1. What is control system? 1M
A system consists of a number of components connected together to perform a specific
function . In a system when the output quantity is controlled by varying the input quantity then
the system is called control system

2. What are the two major types of control system? 1M

The two major types of control system are open loop and closed loop
3. .Define open loop control system. 1M
The control system in which the output quantity has no effect upon the input
quantity are called open loop control system. This means that the output is not
feedback to the input for correction.
4. Define closed loop control system. 1M
The control system in which the output has an effect upon the input quantity so as to
maintain the desired output value are called closed loop control system.
5. What are the components of feedback control system? 1M
The components of feedback control system are plant , feedback path elements, error
detector and controller
6. What is steady state response? 1M
The steady state response is the response of the system when it approaches infinity
7. Define the following terms 2.5M
1. Plant
2. Compensator
3. Sensor
4. Actuators
5. Feedback Loop
8. 2.5M
Define the following terms
1. Process equation
2. Process load
3. Dead time
4. Process lag
5. Self regulation

9. What are the control system objectives? 2.5M

1] The system should be stable
2] Should provide the best possible steady state regulation
3] The system should provide the best transient regulation
4] should ensuring stability
5] evaluating the response to set point changes.
10. Distinguish between open loop and closed loop system. 4M

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11. Draw and explain process control Block diagram.( Pg no 6) 4M

Block diagram
Explanation
12. Explain process control principle. 4M
The process-Explanation
Human aided control-Explanation
13. Explain Discrete state process control. 4M
14. Write advantages and limitation of automation. 4M
15. Explain error in control system. 4M

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Class: TYBSc: SEM 5

ELSEC352: Paper XI: Process Control System
Question Bank
Unit 4: Process Control Systems
Sr. No Questions Remark
1. Define on/off controller. 1M
Simplest form of feedback control which switches ON when error is positive
and switches OFF when error is zero or negative.
2. What are different types of controllers? 1M
PI= Proportional Integral
PD= Proportional Derivative
PID= Proportional Integral Derivative.
3. Define error and offset. 1M
4. What is proportional controller? 1M
It is a device that produces a control signal which is proportional to the input
error signal.
5. What is need for a controller? 1M
The controller is provided to modify the error signal for better control action
6. 1M
7. Why derivative controller is NOT used in control systems? 2M
The derivative controller produces a control action based on the rate of
change of error signal and it does not produce corrective measures for any
const error.
8. What is the effect of PD and PI controller on the system performance. 2M
PD= to increase the damping ration of the systems and so the peak overshoot
is reduced.
PI= increase the order of the system by one which results in reducing the
steady state error but system becomes less stable than the original system.
9. State the characteristics of the derivative control mode. 2M
Pg no. 501

10. Discuss the Drawbacks with respect to P-Controller, PI-Controller 2.5M

11. Write application of On-Off controller mode. 2.5M

Pg no 485 notes
12. Write applications of Proportional Integral Controller. 2.5M
Pg no 502
13. With a neat graph of error and controller output, discuss working of integral 4M
control mode.
Pg no.497 notes
Explanation= 2m
Graph =2m
14. Explain the PI controller. 4M
15. Write applications of Proportional mode. 4M
16. Explain Derivative control mode. 4M
17. What are the advantages and disadvantages of proportional, proportional 4M
derivative, proportional integral control systems

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18. Compare P, PI and PID controllers. 4M

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