Advanced Process Control - Practice
Worksheet
[Link] Chemical Engineering
Instructions: Answer all questions. Marks are indicated for each question.
1 MARK QUESTIONS (Remember)
Q1. Define a dynamic process model. (1 mark)
Q2. What is a transfer function? (1 mark)
Q3. State the time constant of a first-order system. (1 mark)
Q4. Write the Laplace transform of f(t) = e^(-at). (1 mark)
Q5. State the Initial Value Theorem. (1 mark)
Q6. Name two controller tuning methods. (1 mark)
Q7. List three types of controllers used in process control. (1 mark)
Q8. What is the Routh-Hurwitz stability criterion? (1 mark)
Q9. Define offset in controller response. (1 mark)
Q10. What is cascade control? (1 mark)
2 MARKS QUESTIONS (Remember & Understand)
Q11. Distinguish between lumped and distributed parameter systems. (2 marks)
Q12. Explain the significance of poles and zeros in a transfer function. (2 marks)
Q13. A first-order system has τ = 5 minutes. What percentage of the final value is reached in 5
minutes for a step input? (2 marks)
Q14. State and write the mathematical expression for the Final Value Theorem. (2 marks)
Q15. What is the purpose of derivative action in a PID controller? (2 marks)
Q16. Differentiate between P and PI controllers in terms of steady-state error. (2 marks)
Q17. What are the necessary and sufficient conditions for stability of a control system? (2 marks)
Q18. Explain the basic principle of inferential control. (2 marks)
Q19. What is the purpose of ratio control in process industries? (2 marks)
Q20. Define split-range control with an example application. (2 marks)
3 MARKS QUESTIONS (Understand & Analyze)
Q21. Derive the transfer function for a stirred tank heater system considering energy balance.
State your assumptions. (3 marks)
Q22. For the transfer function G(s) = 5/(2s+1), determine the system gain and time constant.
Sketch the step response. (3 marks)
Q23. Find the Laplace transform of f(t) = t²e^(-3t) using properties of Laplace transforms. (3
marks)
Q24. Apply the Initial and Final Value Theorems to find the initial and final values of the time
function whose Laplace transform is F(s) = (10s + 5)/(s²(s + 2)). (3 marks)
Q25. A process has transfer function G(s) = 2/(5s+1) with a time delay of 2 seconds. Using
Ziegler-Nichols tuning rules, calculate PI controller parameters. (3 marks)
Q26. Compare the performance of P, PI, and PID controllers for a first-order plus dead time
(FOPDT) process. (3 marks)
Q27. Construct the Routh array for the characteristic equation s⁴ + 2s³ + 3s² + 4s + 5 = 0 and
determine the number of roots in the right half plane. (3 marks)
Q28. Explain why cascade control provides better disturbance rejection than single-loop control.
Draw a block diagram. (3 marks)
Q29. A distillation column requires ratio control for reflux to feed. Sketch the control scheme
and explain its operation. (3 marks)
Q30. Describe the implementation of split-range control for a reactor temperature control system
using both heating and cooling. (3 marks)
4 MARKS QUESTIONS (Analyze & Evaluate)
Q31. Develop a dynamic model for a liquid level system in a cylindrical tank with inlet and
outlet flows. Derive the transfer function H(s)/Q_in(s). Linearize if necessary. (4 marks)
Q32. A second-order system has the transfer function G(s) = 4/(s² + 3s + 2). Determine: (a)
Natural frequency, (b) Damping ratio, (c) Type of response, (d) Peak time. (4 marks)
Q33. Using partial fraction expansion, find the inverse Laplace transform of F(s) = (s + 3)/(s(s +
1)(s + 2)). Verify using Initial and Final Value Theorems. (4 marks)
Q34. A process has the open-loop transfer function G(s) = K/((s+1)(s+2)(s+3)). Using Routh-
Hurwitz criterion, determine the range of K for stability. Analyze the stability margins. (4 marks)
Q35. Design a cascade control system for a chemical reactor where temperature is the primary
variable and coolant flow is the secondary variable. Draw the block diagram, identify transfer
functions, and discuss tuning sequence. (4 marks)
Q36. Analyze the advantages and disadvantages of using inferential control for product
composition in a distillation column. When would you prefer inferential control over direct
composition measurement? (4 marks)
5 MARKS QUESTIONS (Analyze & Evaluate)
Q37. A CSTR (Continuous Stirred Tank Reactor) has the following parameters: Volume = 2 m³,
Flow rate = 0.4 m³/min, Reaction: A → B (first order), Rate constant k = 0.3 min⁻¹. Develop the
dynamic model for reactant concentration. Derive the transfer function C_A(s)/C_Ain(s) and
determine the process time constant. (5 marks)
Q38. For a unity feedback control system with open-loop transfer function G(s)H(s) =
K(s+2)/(s(s+1)(s+4)), perform complete stability analysis using: (a) Routh-Hurwitz criterion, (b)
Root locus concepts to find critical gain K_c, (c) Frequency at which system becomes marginally
stable. (5 marks)
Q39. A temperature control system has process transfer function G_p(s) = 2e^(-s)/(5s+1) and is
controlled by a PID controller. (a) Determine controller parameters using Ziegler-Nichols closed-
loop tuning method, (b) Cohen-Coon tuning method, (c) Compare the two methods and
recommend which is better for this application with justification. (5 marks)
Q40. Design a complete cascade control scheme for controlling the top product composition in a
distillation column by manipulating reflux flow rate. The secondary loop should control reflux
drum level. Include: (a) Detailed block diagram with all transfer functions, (b) Selection and
tuning of primary and secondary controllers, (c) Analysis of disturbance rejection capability
compared to single-loop control, (d) Potential problems and solutions. (5 marks)
Q41. A fired heater in a refinery requires split-range control where fuel gas and fuel oil are used
based on availability and cost. Design the split-range control system including: (a) Control
scheme with valve characteristics, (b) Signal splitting logic, (c) Transition region management
between fuels, (d) Safety considerations, (e) Performance evaluation criteria. (5 marks)
End of Practice Worksheet