GATE Process Control Book

PROCESS CONTROL
For
Instrumentation Engineering
By
www.thegateacademy.com
Syllabus
Process Control
Syllabus for Process Control

Feedback principles. Signal flow graphs. Transient Response, steady state-errors. Routh and
Nyquist criteria. Bode plot, root loci. Time delay systems. Phase and gain margin. State space
representation of systems. Mechanical, hydraulic and pneumatic system components. Synchro
pair, servo and step motors. On-off, cascade, P, P-I, P-I-D, feed forward and derivative controller,
Fuzzy controllers.
Analysis of GATE Papers

(Process Control)
Year
Percentage of marks
2013
4.00
2012
0.00
2011
0.00
2010
2.00
2009
5.00
2008
4.00
2007
4.00
2006
3.33
2005
4.66
2004
2.66
2003
6.00
Overall Percentage
3.24%
THE GATE ACADEMY PVT.LTD. H.O.: #74, Keshava Krupa (third Floor), 30th Cross, 10th Main, Jayanagar 4th Block, Bangalore-11
: 080-65700750, info@thegateacademy.com Copyright reserved. Web: www.thegateacademy.com
Contents
Process Control
CONTENTS
Chapters
#1.
#2.
#3.
#4.
Page No.
Introduction, Building Blocks
1 25
12
3 12
12 16
16 19
19 20
21 22
23
23 25
Process Characteristics
Terminology
Dynamics of Simple System
Interacting and Non-Interacting System
Process Degree of Freedom
Assigment
Answer Keys
Explanations
Modes of Controller Operation
26 69
26 27
27
27 - 30
30 58
58 61
62 64
65
65 69
Control Parameter Range

Reverse and Direct Action of Controllers
Modes of Control Actions
Compostie controller modes
Valves
Assignment
Answer Keys
Explanations
Tuning of Controllers
70 83
70 72
73
73 74
74 76
77 79
80
80 83
Process Reaction Curve Method

Quarter Amplitude Criteria
Ziegler-Nicols Tuning Method
Controller Tuning From Routh Array Method
Assignment
Answer Keys
Explanations
Process Control System Configurations
84 92
84
85
86 87
87 88
89 90
91
91 92
Feed forward and Feed Back control

Feed Forward Control
Cascade Control Configuration
Ratio Control Configuration
Assignment
Answer Keys
Explanations
THE GATE ACADEMY PVT.LTD. H.O.: #74, Keshava Krupa (third Floor), 30 th Cross, 10th Main, Jayanagar 4th Block, Bangalore-11
Page 1
Contents
#Module Test
Test Questions
Answer Keys
Explanations
#Reference Books
Process Control
93 117
93 105
106
106 117
118
THE GATE ACADEMY PVT.LTD. H.O.: #74, Keshava Krupa (third Floor), 30 th Cross, 10th Main, Jayanagar 4th Block, Bangalore-11
Page 2
Chapter-1
Process Control
CHAPTER 1
Introduction, Building blocks of Process control
Introduction
Instrumentation may be defined as an art of using instruments to measure the physical and
chemical properties and changes of matter.
Since it is not possible to measure these changes directly, certain variable like temperature,
humidity, level etc are measured which effects these changes of properties of matter.
Thus instrumentation mainly deals with measurement and control of these variables
The team process refers to physical or chemical change of matter or an ensemble of
environment where a particular variable is measured and controlled.
Process Control refers to regulation and manipulation of variables influencing the conduct
of a process in such a way as to obtain a product of desired quality and quantity in an
efficient manner.
Process Characteristics
To understand the characteristics of process control system, consider a simple problem
where the objective is to maintain the level of the liquid in the tank at a height h (as shown
in fig 1.1) irrespective of disturbance that tend to deviate it from desired level.
(Inlet )
Level measuring instrument
h
(Control Value )
Human
operator
(Outlet)
Figure 1.1
Page 1
Chapter-1
Process Control
The tank has inlet flow-rate q and Outlet flow rate q which is controlled by a control value.
To achieve the objective or to convert it into a control system, a human operator is placed
near the control valve as shown.
The operator has desired level in his mind also known as set point. He constantly monitors
the level measuring instrument.
If the level is above the desired level (set point) he performs an operation on control value
by opening it till the level reaches the set point and fixes the control value at this position
which makes outlet flow rate equal to inlet flow rate.
Similarly, if level goes down the desired level, he performs an operation on control value by
closing it.
Thus, the control system shown in fig 1.1 is manual control system.
This can be converted in to an automatic control system by: Replacing human operator
with AUTOMATIC CONTROLLER as shown in fig 1.2.
Automatic Level Control System

Set-Point
(Inlet )
Automatic
LT
Controller
h
Final Control Element
LT level transmitter
Figure 1.2
Block Diagram of A Control System

Controller Block
Set Point
Automatic
Controller
Final Control
Element
Process
Output
Measurement
Figure 1.3
Page 2
Chapter-1
Process Control
Terminology
1. Process: As defined earlier, it is an environment where a particular variable is measured,
monitored and controlled.
2. Process Variables: They are
(a) Controlled variable (or) dynamic variable.
(b) Manipulating variables
(c) Load variables
(d) flow variables
(e)across variables
2(a). Controlled (or) dynamic variable: It is the variable which is measured, monitored and
controlled.
Ex : Level in the tank is an example of controlled variable.
2(b). Manipulated variable: It is the variable which is manipulated to make the controlled
variable remain at set point value.
Ex: In the above level control system, the output flow-rate is the manipulated variable.
2(c). Load variable: It refers to all the other variables that affect the controlled variable to
deviate from set point value.
Ex: In the above example, changes in inlet flow rate also change the level in the tank, so it
constitutes to load variable.
2(d). Flow Variable: Any variable which is measured along the process loop.
Ex:- Flow in a loop, current in a loop, heat transfer.
2(e). Across Variable: Any variable which is always measured as a differential value or with
reference to some point.
Ex:- Voltage (potential difference), Differential pressure, Temperature, etc.
Process
Flow Variable
Across Variable
Relationship
Electrical N/w
V Voltage
v = i R R = electrical
Resistance
Flow Process
Q Fluid flow
rate
h Pressure
head
h=qR
Current
R = Flow Resistance
Useful Conversations
Pressure 14.7 psi = 1 atm
1 N/
= 1 Pa (=1 Pascal)
Pa = 1 bar
Page 3
Chapter-1
Process Control
1 Psi = 0.07 bar

1 gallon = 3.78 liters
3.8 liters
Process Load
The set of all load variables that cause a change or deviation of controlled variable from set point
are known as process load.
Process Equation
For the example in Fig1.2, process equation can be written, which describes the process
mathematically. Here the liquid level h is a function of changes in inlet flow rate and outlet flow
rate. A simple process equation is
=
Measurement
It is the determination of magnitude of a variable i.e. controlled variable.
Controller
It is an automatic device having an output that varies to regulate the controlled variable. A
controller performs operations such as comparison, evaluation and operation upon the next
stage to meet the demands and control objectives.
Final Control Element

The device that directly controls the value of manipulated variables in a process control loop is
the final control element.
Often the control element is control value.
Elements of Process Control

The different elements with which a mathematical model may be formulated for a process are
A. Resistance element.
B. Capacitance element.
C. Time constant element.
D. Dead time element.
The mathematical model thus obtained is known as Transfer function.
A transfer function is defined as ratio of L T of output to L. T of input under the assumption
that all initial conditions are set to zero. [L.T Laplace Transform]
o p
(
i.e T(s = ( |
T Transfer function
i p
(
Page 4
Chapter-1
Process Control
(A) Resistance Type Element
Resistance may be defined as any obstruction or constriction which can be

incorporated by external means also, (or) the ability to resist the transfer of mass or
energy is called resistance.
Example: Consider the operation of capillary flow system shown in fig 1.4. Two
capillary tubes are inserted at the inlet and outlet sections of the pipeline where the
fluid is flowing.
The difference in the head or height (h) between the rise of fluid in both capillary
tubes is known as Resistance effect.
Capillarly (1)
Capillarly (2)
h
Fluid
flow rate
(q)
Pipeline
Figure 1.4
Resistance =
cross Variable
Flow Variable
The flow-head equation for fig 1.4 may be written as:

(head) h q ( flow-rate)
h=Rq
------------- (
Thus if q = input and h =output (1) represents a linear relation between input and output.
Applying L.T to equation (1)
H(s)=R Q (s)
Q(s)
H(s)
Electrical resistance, thermal resistance, in mechanical or rotational systems, the spring

elements etc are all other resistance elements.
(B) Capacitance Element
Capacitance is the ability to store.

Example is a tank with inlet as show in fig (1.5)
Page 5
Chapter-1
Process Control
Figure 1.5
The flow of fluid into the tank is the input and the level of the liquid in the tank (h) is the
output.
The change in the level of liquid in the tank ( ) is directly propositional to inlet flow rate
dh
i. e
q
dt
c =q
------ (2)
C = capacitance
Applying L.T to equation (2)
CsH(s) = Q (s)
H(s
=
(s
Cs
Q(S)
H(S)
Hence the transfer function representation of capacitance elements is

Response of capacitance elements is obtained by integration of equation (2)
=
= ( )t.
(h)
( )
Page 6

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PROCESS CONTROL

Syllabus for Process Control

Analysis of GATE Papers

Introduction, Building Blocks

Modes of Controller Operation

Control Parameter Range

Process Reaction Curve Method

Process Control System Configurations

Feed forward and Feed Back control

Level measuring instrument

Automatic Level Control System

Block Diagram of A Control System

1 Psi = 0.07 bar

Final Control Element

Elements of Process Control

(A) Resistance Type Element

Resistance may be defined as any obstruction or constriction which can be

The flow-head equation for fig 1.4 may be written as:

Electrical resistance, thermal resistance, in mechanical or rotational systems, the spring

(B) Capacitance Element

Capacitance is the ability to store.

Hence the transfer function representation of capacitance elements is

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