Inspecting the Trends of PV and SP on a Process

Chart Recorder
Trends of PV and SP
The “wandering” of the process variable (PV) around setpoint may be due to excessive action on the part
of the controller, or it may be due to load fluctuations in the process itself.

Answer

In other words, the instability may be the fault of the controller reacting too aggressively, or it may be
that the controller is not working aggressively enough to counter changes in process load.

Identify a simple method to determine which scenario is true.

Answer:

Place the controller in manual mode and observe the PV trend!

Analytical Process Control Question
In this process, maple syrup is heated as it passes through a steam heat exchanger, and then enters an
evaporator where the water boils off. The purpose of this is to raise the sugar concentration of the syrup,
making it suitable for use as a food topping.

Answer

A level control system maintains constant syrup level inside the evaporator, while an analytical control
system monitors the sugar concentration of the syrup and adjusts steam flow to the heat exchanger
accordingly.
Suppose the syrup analyzer (AT) suffers a sudden calibration problem, causing it to register too low
(telling the analytical controller that the sugar concentration of the syrup is less than it actually is).

Describe in detail the effect this calibration error will have on the performance of the analytical control
system.

Answer

The syrup’s sugar concentration will eventually become excessive as the analytical controller (AC)
attempts to maintain setpoint.
Explain how you would begin troubleshooting this system, and what possible faults could account for the
controller not being able to maintain liquid flow at setpoint.

Question

1. Explain how you could divide this control system into distinct areas or zones which you may then
begin to refer to when “dividing and conquering” the problem.
Answer :

One possible fault has to do with the control valve: perhaps something has happened to make it fail
closed (loss of air supply, signal, etc.). Other possible problems include the following:

 Pump not running (no source of fluid power to motivate flow)

 Very poor controller tuning
 Wrong controller action
 Valve failed closed (loss of air supply, signal, etc.)
 Transmitter failed, showing no flow when in fact there is
A good “first test” for troubleshooting the loop is to check the controller output: is it trying to open up
the valve?
Feedback Control Loop Questions & Answers
Feedback Control Loop Questions & Answers

1. The natural frequency at which a closed-loop system will cycle depends upon:

a. The amplifier gain

b. The attenuation provided by the process
c. The phase shift provided by the resistance-capacitance and dead time networks that exist in the system
d. Resonance

Answer: c

4. All systems may be assumed to be:

a. Linear
b. Nonlinear
c. Linear for the purpose of initial consideration but with full knowledge that this may not be the case
d. Nonlinear for purposes of analysis with the exception that the system may prove to be linear

Answer: c

5. A closed-loop control system that employs a three-mode controller:

a. Can oscillate or cycle at only one frequency
b. Can oscillate or cycle at several frequencies. depending on controller adjustment
c. Will not oscillate because of the stability provided by derivative
d. Will produce only damped oscillations with a 0.25 damping ratio

Answer: b

6. We have a closed-loop control system which is cycling. We should:

[Link] the proportional band

[Link] integral action
[Link] and adjust both
d. Immediately shut it dow

Answer: c

7. A proportional controller is being used to control a process and the offset between set point
and control point must be held to a minimum. This would dictate that the proportional band

a. Be as narrow as possible
b. Be as wide as possible
c. Be of moderate value
d. Does not relate to the problem
Answer: a

16. The integral control mode is:

[Link]-Ieading
[Link]-Iagging
[Link]
d. Phase-reversing

Answer: b

17. The derivative control mode is

[Link]-Ieading
[Link]-Iagging
[Link]
d. Phase-reversing

Answer: a

18. The most common combination of control modes found in the typical process plant is:
[Link]-only
[Link], integral, and derivative
[Link]-plus-integral
d. On/off

Answer: c
 1.
The reason process control is so popular is the increased.

o A.

Safety

o B.

Profitability

o C.

Operability

o D.

All of the above

 2.
Process control can be achieved either in the _____ or closed-loop mode.
 3.
The [Blank]_ is the desired value of the variable being controlled. The setpoint may be set
manually or automatically, or the operator may program it.

 4.
The [Blank]_ (2 words) is a device that manipulates a variable that has a direct influence on
the controlled variable.

 5.
_____________ are varying conditions that cause the controlled variable to differ from the
set point.

 6.
The __________ is an operation or sequence of operations involving a change in the
controlled variable.

 7.
The _______________ (2 words) is a function of the manipulated variable and the
disturbances.
 8.
The _______________ contains a sensing element that measures the actual value of the
controlled variable and generates a proportional signal which is sent back to the controller.

 9.
The disadvantage of the closed-loop mode is that the actual value of the controlled variable
is not taken into account. If disturbances cause the controlled variable to deviate from the set
point, no countermeasure is taken to correct for the deviations.

o A.

True

o B.

False

 10.
When many variables must be controlled simultaneously, this is known as
________________
 11.
The measure of acidity or alkalinity:

 12.
The set of devices used to measure, record, and control industrial processes.

o A.

Primary sensing elements

o B.

Indicators

o C.

Transmitters

o D.

Process Instrumentation

 13.
 Transmitters use _______________________ as analog controller signals

o A.

Voltage

o B.

Resistance

o C.

Hydraulic Pressure

o D.

All of the above

 14.
ISA stands for:

o A.

Industrial Safety Authority

 o B.

Industrial Safety Act

o C.

Industrial Standards Association

o D.

Instrument Society of America

 15.
Indicates the function and nature of a component represented. It is composed of letters and
numbers:

 16.
The primary purpose of process control is to maintain some _______

o A.

Physical Variable
 o B.

Analog Variable

o C.

Input Variable

o D.

Digital Variable

 17.
The controller compares the set point to the measured variable and corrects for any
difference between the two by readjusting the control element until the loop reaches a state
of equilibrium called _______________

 18.
Why do we use a current of 4 to 20 mA for analog controller signals rather than 0 to 20 mA?

o A.

It allows transmitter devices to be powered by the same loop, as we always have at least 4 mA.
o B.

0 mA allows us to detect some failures in the loop.

o C.

Both of the above.

o D.

None of the above

Answer: a

9. A proportional controller will have an offset difference between set point and control point:

a. At all times
b. Equal to the proportional band setting
c. That depends on process load
d. That will eventually vanish

Answer: c

Answer: a

13. All control systems that fit into the usual pattern are:

a. Open-Loop
b. Nonself-regulating
c. Closed-loop
d. On/off
Answer: c

14. If operating properly, automatic control will always:

a. Reduce manpower
b. Reduce costs
c. Make the process operate more uniformly
d. Decrease maintenance

Answer: c
1. There are three kinds of signals that exist for the process industry to transmit the process variable measurement from the instrument
to a centralized control system. Provide the signals of these?
 Pneumatic signal
 Analog signal
 Digital signal

2. NAME AT LEAST 6 CONTROL LOOP COMPONENTS?

3. Describe the Roles of Actuators?

4. What is he main role of recorders and senses in a controls loop?

5. Explain in details the differences of the below variables

Input Variables

Output Variables
Controlled Variable and Manipulated Variable
6 Explain how the control loop is being operated
6. What are the input and output variables of fermentation process?
7. Explain the difference between Accuracy and repeatability

8. Given R2 is 4 ohms and R3 is 5 ohms and R1 is 14 ohms calculate R4?

9.

If R4 is now 5ohms what will be the value ofR3 if all the other parameter are constant/
R 3 resistance is now changed and has a new reading 110 . What reading will appear R4 if parameters of other resistance remain
constent?