APPENDIX I

QUESTIONS
LEARNING UNIT I: AUTOMATIC CONTROL APPLICATIONS & DISTRIBUTED
CONTROL SYSTEMS

1.1 List the equations for the estimated settings for a one -term, two-term,
and three-term controller.
1.2 Name the following symbols that are used in the “ULTIMATE TUNING
METHOD OF CONTROLLERS”:
(a) Ku
(b) Pu
(c) Pbu
(d) PB
(e) Ti
(f) Td
(g) Kc
1.3 How many loops are normally only found per central processing unit in a
Distributed Control System (DCS)?
1.4 Draw a diagram of a typical distributed network instrumentation control
system. Also list the abbreviated components within the diagram.
1.5 Sketch and describe the working principles of a cascade control system.
1.6 Sketch and describe the working principles of a typical cascade control
loop of a stirred tank reactor.
1.7 Flow controllers in a cascade loop must have (a) ______, but never (b)
______, with a (c) ______ proportional band of the primary controller, and a
(d) ______ proportional band of the secondary controller.
1.8 What should the secondary controller not have in a temperature cascade
control system?
1.9 What type of cable is used for communication between local control
stations and the central operator stations?
1.10 Name the requirements that are necessary for the communication
network in the distributed control system.
1.11 List the reasons why provision is made for a supervisory computer in the
distributed control system.
1.12 From where can the configuration of distributed control systems be
done?
1.13 Name the three basic steps that entail the configuration process of a
distributed control system.
1.14 List all the functions executed by the central operator station.
1.15 The local control unit contains the (a) _____ which measures the process
variables, and generates the (b) _____ signals to final control elements such as
control valves. In the local control unit, the (c) _____ input signals from field
equipment are converted to (d) _____ signals which are needed by the
computer. The (e) _____ signals are also converted from digital to analogue by
the local control unit. (f) _____ for field equipment such as transmitters can
also be supplied by the local control unit. The local control unit is self
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supporting and has its own (g) _____, which supplies the required (h) _____ to
the different elements in the unit.
1.16 Draw a detailed block diagram of the Internal Structure of a Local
Control Unit.
1.17 The development in the field of micro-processors had a major influence
on the development of the process control industry. Name two of the new
conversions that have been made in distributed control systems.
1.18 Make a detailed sketch that represents a Feed-forward Control System of
a Heat Exchanger.
1.19 Draw a block diagram of a Feed-forward Control System.
1.20 Draw a detailed diagram of a typical Feedback Control System of a Heat
Exchanger. Also indicate the associated signals on the sketch (load, set-point,
etc.).
1.21 Explain the basic operating principle of a feed-forward and feedback
combination control system.
1.22 Draw a detailed diagram of a Feed-forward and Feedback Control
combination with Dynamic Compensation of a heat exchanger.
1.23 When a feed-forward and feedback control combination is applied to a
heat exchanger, the feed-forward system can control the steam flow within (a)
_____ of what is required by the load. The feedback system is therefore
required to control only the (b) _____ of the steam flow that the feed-forward
system fails to correct.
1.24 Explain the basic operating principle of an override control system.
1.25 Sketch and describe the operating principle of an override control
system of a pump.
1.26 Explain the basic operating principle of a ratio control system.
1.27 Draw a detailed diagram of a typical ratio control system.
1.28 Explain by means of an equation how “FlowB”, also known as the
controlled flow, of a ratio control system can be determined.
1.29 When one considers a ratio control system, what advantages could one
obtain from the ratio station and the controller?
1.30 Sketch and describe the operating principle of th e “Relation Control of
Pressure & Flow to Prevent Compressor Surge”.
1.31 Describe in short how relation control is achieved.
1.32 Sketch and describe the operating principle of a typical signal selector.
1.33 Sketch and describe the operating principle of the “Split-Range Control
of a Dearating Feedwater Tank”.
1.34 Show by means of a table, the relationship between the feedwater tank
level, controller output, valve A and valve B of the “Split-Range Control of a
Dearating Feedwater Tank”.
1.35 Show by means of an equation how the output of the controller can be
determined and label the vari ables within the equation as well.
1.36 Sketch and describe the basic operating principle of a “Time Cycle
Controller”.
1.37 Sketch and describe the basic operating principle of a “Time-Schedule
Controller of a Batch Reactor”.

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1.38 Briefly explain the ultimate tuning method for controllers.

1.39 Who developed the ultimate tuning method for controllers?
1.40 List the steps to determine the ultimate gain and the ultimate period
when one makes use of the ultimate tuning method for controllers.
1.41 Describe the procedure to determine whether the proportional band
must be increased or decreased.
1.42 Describe in short how adaptive control is achieved.
1.43 When one considers adaptive control, the factors that affect the
response of a process are independent of the controller’s input and output.
Name the factors on which the compensating adjustments are based on.
1.44 A system which adapts on the basis of measurement of the disturbing
factor is said to be a...?
1.45 A system which adapts on the basis of the loop response, in other words,
one which uses a measurement of its own performance, is called a...?
1.46 Describe the architecture of distributed control systems.
1.47 Name two advantages of Cascade Control.
1.48 Name the one very important factor in designing a cascade system.
1.49 Describe the major features of a central operating station.
1.50 List the functions executed by the central operating station.
1.51 If one refers to distributed control systems, name at least 4 of the
normal field equipment found on any plant.
1.52 Explain in short the purpose of the local control unit.
1.53 Describe the operating principles of the local control unit.
1.54 Explain what led to the conversion process in the process control
instrumentation industry with respect to distributed control systems.
1.55 What are the load components that normally affect the load in a feed
forward system, where the product composition is to be controlled?
1.56 What are the load components that normally affect the load in a feed
forward system, where the temperature of the product is to be controlled?
1.57 Describe the operating principles of feedback control.
1.58 Sketch and describe the operating principles of a block diagram of a
feedback control system.
1.59 What is the main disadvantage of a feedback control system?
1.60 What type of control will be better, if the disturbances in a control
system are frequent and the time delay substantial (dependant on the type of
process) ?
1.61 Draw a typical feedback control system of a heat exchanger and also
include the signal legend on the diagram.
1.62 Make a sketch of a heat exchanger where feed-forward and feedback
combination control with dynamic compensation is applicable and describe the
control principles of the steam flow (Heating Medium) with respect to figure.
1.63 Describe the operating principles of override control.
1.64 Sketch and describe the override control of a pump.
1.65 Make a sketch of a batch reactor where time-schedule control is applied
and briefly explain the control principles of time-schedule control.
1.66 Describe the operating principles of feed-forward control.

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1.67 List the equations for the estimated settings for a Proportional
Controller.
1.68 List the equations for the estimated settings for a Proportional + Integral
Controller.
1.69 List the equations for the estimated settings for a Proportional
+ Derivative Controller.
1.70 List the equations for the estimated settings for a Proportional + Integral
+ Derivative Controller.
1.71 If the level of a tank is 50%, the PB = 80%, and the SP = 56. Determine
what the output of the controller will be if a normal acting controller is used.
1.72 If the level of a tank is 50%, the PB = 80%, and the SP = 56. Determine
what the output of the controller will be if a reverse acting controller is used.
1.73 State whether the following statements are True or False.
(a) A system which adapts on the basis of measurement of the disturbing
factor is said to be self adaptive system.
(b) A system which adapts on the basis of the loop response, in other
words, one which uses a measurement of its own performance, is called a
programmed adaptive system.
(c) In the Distributed Control System (DCS), there are normally only 6
loops found per central processing unit. If the central processing unit should
go faulty, only the 6 loops are affected. In most cases, provision is made for
a backup processing unit, so that there is no interruption in the process
control.
(d) Two important things can be accomplished with Cascade control:
i. It reduces the effect of load changes near their source.
ii. It improves the control system by reducing the effect of time lags.
(e) For Cascade Control, any disturbances that would affect the secondary
variable can be corrected by the primary controller before the influence is
felt by the primary variable.
(f) The proportional band of the primary controller must also be smaller
that it would be without a secondary loop, because a cascade control system
results in a higher dynamic gain.
(g) In some distributed control systems, a redundant cable is used for
communication purposes. If anything should go wrong in the one cable, the
process is automatically switched off and the redundant cable can be
switched with the faulty one.
(h) Locks are normally supplied, to prevent unauthorised persons from
changing the configuration data.
(i) The local control unit still has control over the process, in the case of
an interruption of communication with the central operator station.
(j) In the case of an interruption, the operator can in some circumstances
control the process from a terminal at the local control unit.
(k) The Wild Flow of a Ratio Control System can be calculated as shown
by the equation below where R can be set manually for the required ratio.
FlowB(Wild Flow) = R X FlowA(Controlled Flow)

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(l) The ratio station and the controller can not be combined into one
unit, for economical reasons and for space saving purposes.
(m) The aim of the Ultimate Tuning Method is to enable one to find the
exact settings for a one-term, two-term, or three-term controller in a
control system.
1.74 State whether the following statements are True or False.
(a) Power supply for field equipment such as transmitters can not be
supplied by the local control unit.
(b) The Local Control Unit also includes a Central Processing Unit (CPU) to
control all activities executed by the local control unit and a form of backup
for the local control unit is also supplied by means of a redundant LCU.
(c) The redundant unit monitors the four LCU units, and if it detects a
malfunction, it will automatically switch over to the redundant unit with a
small interruption in the functioning of the process.
(d) In other local control units provision is made for backup, by including
a Redundant Central Processing Unit (RCPU) in the local processing control
unit. Change over to the backup CPU is by means of a manual switch over in
the case of a malfunction.
(e) The ability of the microprocessor to work at a high speed, the
arithmetical ability to store data at low density, all of these factors led to
the conversion to DCS type of process control instrumentation.
(f) The setpoint is continuously adjusted automatically, in such a way
that the load stays in balance with respect to the manipulated variable.
(g) With feedforward control, theoretically it is possible to achieve
perfect control, although in practice the computing system can’t duplicate
the process exactly.
(h) In most control syste ms, the feed flow is the primary component of
the load, because it can be changed slowly with long time lags.
(i) Most feedforward systems depend on measurement and feedback
control of flow to obtain accurate manipulation of the flow rate.
(j) For a feedforward control system, the major components that can
affect the load are measured, and when one of these components change,
the feedforward system calculates the new manipulated variable re quired to
maintain control at setpoint value.
(k) Relation control maintains a relation between two or more variables,
such as pressure and flow or temperature and pressure.
(l) Selective devices are used to select between two or more inputs,
which may be the highest, medium or lowest of the inputs, and produce a
single output.
(m) The ultimate sensitivity Ku of a controller is the maximum allowable
gain of a controller, with the integral time set to 0 and the derivative time
set to ∞.
1.75 State whether the following statements are True or False.
(a) Feedforward control provides a more direct solution to control
problems than feedback control.
(b) Feedback control is not a perfect type of control.

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(c) If the disturbances in a control system are frequent and the time delay
substantial (dependant on the type of process) feedback control will be an
better option.
(d) In a feedforward control system, there is feedback from the controlled
variable to make sure that the controlled variable is at the desired value.
(e) Feedforward systems are applied mainly to processes that are
sensitive to disturbances and slow to respond, otherwise it is cheaper to use
a feedback system.
(f) The purpose of any form of control is to maintain the load, for
example temp, press flow etc. at a certain predetermined desired value,
known as the set-point value.
(g) The method of control normally applied on a control loop depends on
the application.
(h) As the technology developed in the process instrumentation field,
feed-forward control started to develop as closed-loop control and at a later
stage feedback control developed.
(i) In override control, certain limits are used to protect a process or
product.
(j) In override control, when a primary variable get out of hand the
secondary controller will take over the control permanently.
(k) In a split range control system, the output of a controller is arranged
in such a way, that a certain manipulated variable may have first preference.
(l) The output of a controller can be determined by means of the
following equation:
ControllerOUTPUT = (100/PB) X (Mv -Sp)
1.76 Add new question!?