QUESTIONS AND ANSWERS
reduce the error that is constant over time.
3. What are the differences between
feed-forward and feed-backward
control?
Feedback control Feedforward
control
closed loop open loop
compensate every compensate only
disturbance measured
disturbance
Can be unstable always stable
less exact math Very precise and
necessary exact math needed
4. Why is good P, PI, PID, PD
controllers?
P controller : Proportional controller
The proportional controller helps in
reducing the steady-state error, thus
makes the system more stable.
The slow response of the overdamped
system can be made faster.
PI: Proportional integral controller
PI control stops the system from
fluctuating, and it is also able to
return the system to its set point.
This helps in the situation where
proportional control is necessary to speed
up the settling and integral control to
reduce the error that is constant over time.
PID: proportional integral derivative
controller
can be used to control the magnitude and
lead/ lag phase problems. (Changes the
magnitude and can add positive or
negative phase to the output as per the
requirements.)
PID control is used when the process
requires no offset and a fast response
time.
PD: Proportional Derivative controller
This helps in the situation where
proportional control is necessary to speed
up the settling and integral control to
Reduces rise time and transient errors
such as overshoot, oscillations in
output.(Changes both the magnitude as
well as adds a leading phase to the
output.)
5. Definition of the measurement.
A method of determining the numerical
value of a physical quantity by comparing
the quantity to be measured with a
conventional unit value of the same
quantities.
6. Carnap criteria.
1.Define the unit
2.Define the zero point
3.Define the scale
4.Define the equality
5.Define the smaller greater relation
7. Basic and derived units definitions.
Basic quantities are physical quantities
that we arbitrarily select that we can’t
determine from other physical quantities
because they would be self-referenced.
Derived quantities: the quantities that can
be expressed from the basic quantities.
8. The SI units.
are the standard units of measurement
defined by the International System of
Units (SI)
There are 7 basic SI units:
time: second (s)
length: meter (m)
weight: kilogram (kg)
temperature: kelvin (k)
electric current: ampere (A)
brightness(luminous intensity):
candela (Cd)
amount of substance: mole
9. Definition of the dimension.
dimension of a physical quantity: power
product of the basic quantities where the
exponents are positive or negative integers
or zero.
it gives the relation between the basic units DoF=D-R=(φ+φ’)*(k+2)- φ’*(k+2)=
and quantities. φ*(k+2)
10. Type of dimensionless numbers. D=Describer parameters
● Simplexes: the map ratio R= Restrictions
● Complexes: Re number
φ= input flow
● Quantities of efficient
φ’= output flow
nature: Pr number
11. Analyze the next P&ID markings.
k= number of components
P&ID: Piping and Instrumentation diagram 17. Example how to use DoF on a
P&IDs are a schematic illustration of the unit (you choose one unit)!
functional relationship of piping,
Flash with a throttle valve
instrumentation and system equipment
D=3*4=12 (feed parameters)
components used in the field of
R=4 balance equation + 4 equilibrium
instrumentation and control or automation
equation =8
P&ID markings: usually a unified design
DoF=4
and markings system is used
Control target: xBD be constant
Disturbances: xBF can change (it cause,
12. Why do we measure?
the outlet flows changing butthe xBD not
We have three targets when we measure:
(isobar phasediagram)
1. Monitoring
2.Control
3.Engineering experimental measurement 18. What are the instrument
13. List 5 extensive parameters! properties?
• Amount of material - Scale
- Indes
• Volume
- Signaling range
• Internal energy
- Measuring range
• Entropy - Lower limit
• Enthalpy - Upper limit
• Free enthalpy - Sensitivity= Slope = (X2-X1)/(Y2-
• Free energy Y1)
14. List 5 intensive parameters! - Reproductive ability
• Temperature - accuracy
• Pressure - Linearity
• Chemical potential - Hysteresis
• Specific quantities - temperature error
• Density - Nullpoint shift
• Viscosity
• Refractive index 19. What means grade of accuracy?
15. Gibbs degree of freedom It is the measure of how far the results are
equation and the characters in contrast with the real value. In other
meaning! words it is defined as the closeness of
DoF=k+2-φ measured value with respect to a specific
value or accepted value.
DoF= Degree of freedom
k= number of components
20. What can be a regular error?
φ=phases
Regular error can be: parallaxis,
16. How calculate the degree of interpolation, scale shift, self energy using
freedom (not Gibbs)? error

21. What can be a random error?
Random error can be from the
environment or personal error
22. What mean and what is the
difference between calibration and
verification?
Calibration of an instruments it is when an
instrument is compared with an
instruments of known accuracy under static
behavior.
Verification is when an instrument is
measured by a certificated-official person
with an official instrument.
Main difference is that calibration is a non
official measure that can be done in a
domestic way and verification is an official
measure done by official instrument and an
official person.
23. Describe 3 flow meters!
Differential Pressure Meters: The basic
operating principle is based on the premise that
the pressure drop across the meter is
proportional to the square of the flow rate. The
flow rate is obtained by measuring the pressure
differential and extracting the square root.
Venturi tubes have the advantage of being
able to handle large flow volumes at low
pressure drops. A venturi tube is essentially a
section of pipe with a tapered entrance and a
straight throat. As liquid passes through the
throat, its velocity increases, causing a
pressure differential between the inlet and
outlet regions.
Elbow tap meters operate on the principle that
when liquid travels in a circular path, centrifugal
force is exerted along the outer edges. Thus,
when liquid flows through a pipe elbow, the
force on the elbow's interior surface is
proportional to the density of the liquid times the
square of its velocity. In addition, the force is
inversely proportional to the elbow's radius.
24. Describe 3 thermometers
Liquid or gas-filled thermometers: use a gas
or liquid as the temperature-sensing element.
The liquid expands as the temperature rises in
the tube and indicates the temperature.
Typically, the liquid is mercury or alcohol. As
heat is transferred into the substance, it expands
and pushes the column of liquid or gas higher
up the capillary, which indicates the
temperature. The typical temperature ranges are
-60°C to 200°C.
Bimetal Thermometer: The biggest strength
of bimetal thermometers is that the change in
the ambient temperature does not affect the
measurement result through an offset or jitter
pointer. Bimetal thermometers have to wait for
the metal inside to expand to measure the
temperature, so the response time is slower.
Stainless steel is suitable for use outdoors and
in other places. The typical temperature range
is -70°C to 600°C
Thermocouple thermometers have high
accuracy and a large measurement range. The
output signal is stable, so they are often used in
industrial automation. However, signal
conditioning in the reading range takes a lot of
time and complexity, so they are not suitable for
measuring small temperature changes. They are
more prone to corrosion and abrasion, so they
need protective equipment to extend their life.
The typical temperature range is -200°C to
2500°C
25. Describe 3 pressure sensors
Manometer Sensors: A manometer is a fluid
pressure sensor that provides a relatively simple
design structure with an accuracy level greater.
The most common form of the manometer is
the U-shaped model in which pressure is
applied to one side of a tube, displacing liquid
and causing a drop in fluid level at one end and
a correlating rise at the other
Bourdon Tube Pressure Sensors: employ a
helical or C-shaped sensing element. The
pressure of the measuring medium acts on the
inside of the tube and produces a motion in the
non-clamped end of the tube. This motion is the
measure of the pressure and is indicated via the
movement. Bourdon tube pressure gauges are
used for the measurement of gauge pressures
from 0.6 to 7,000 bar.
The diaphragm pressure sensor uses the
elastic deformation of a diaphragm to measure
the difference between an unknown pressure
and a reference pressure. Diaphragm is a thin
circular elastic membrane generally made of
silicon. As pressure changes, the diaphragm
moves, and this motion is the measure of
differential pressure.
26. How to build a thermometer in a pipe?
27. How to measure level?
Sensors for continuous level measurement
detect steplessly filling levels in tanks or
containers. According to the filling level,
measured value output is a percentage in
length or volume units. for example:
Ultrasonic sensors utilize the measured
propagation time of ultrasonic signals. They
transmit high-frequency sound waves which
reflect on the surface of the medium to be
detected. The medium may be liquid or in grain
or powder form.
In continuous level measurement, ultrasonic
sensors output the measured distance between
sensor and media surface as voltage. The output
current or voltage is proportional to the distance
or level of the medium surface.
28. Describe how to control a filter
in reality
Framed press filter
-In the first we control the flow (the slurry
is driven by a steam pump)
-When the resistance of the filter cake is
increasing and the inlet pressure reaches
the max limit then the controller control the
flow to keep the pressure near the limit,
that cause lower flow rate
-When the flowrate is small or nothing, it
stops
29. Describe how to control an air
heat exchanger!
Integrating control schemes, such as
feedback, cascade, and feedforward
techniques, can satisfy the control
requirements.
In the feedback control scheme, the
process variable, T1Out, is measured and
applied to a proportional-integral-derivative
(PID)-based feedback temperature
controller (fbTC), which compares the
process variable with the desired
temperature setpoint and in turn calculates
and generates the control action required
to open or close the steam control valve.
30. Describe how to control flash
distillation!
Flash balances:
● L=D+W
● L*xB=D*xD+W*xW (for
product)
● Design equation:
● D/L=(xL-xW)/(xD-xW)
● Two option for solution:
● With throttle or choke
● Heat transfer in the column
31. Mention one type of rectification
column control.
CASE: energy balance control:
• distillation mole fraction by reflux rate,
• bottom product mole fraction by heating,
• condens tank level with distillate flow,
• bottom level with the bottom product flow.
32. How to control a CSTR with
temperature control.
PI controller, which has the obligation of
controlling the temperature of CSTR in
presence of set point changes. The model
structure is offered based on least square
method. The method of least squares is a
standard approach in system identification
for identifying the parameters.
33. How can you use neural-network in
the chemical industry?
ANNs have been successfully applied to
chemistry to correlate spectra of analytical
methods and product properties; in
catalysis, to determine the relationships
between the catalyst structure and its
activity; in process modeling, to predict
product performance and operating
conditions, and particularly in process
control and fault diagnosis.
34. What means DCS and why
is it good?
-A distributed control system (DCS) is a
digital automated industrial control system
(ICS) that uses geographically distributed
control loops throughout a factory, machine
or control area.
A DCS has several local controllers located
throughout the area that are connected by
a high-speed communication network.
While each controller works autonomously,
there is central supervisory control run by
an operator.
-----Reason for why is it good ?
DCS are used to control industrial
processes and increase their safety, cost-
effectivenessand reliability. A DCS
includes both software and hardware
elements. Installation costs are minimized
by the simplicity of local installation with
most controllers. Reliability is improved by
onsite, low-latency automated control;
human oversight is enabled for central
control functions and remote control
options.
35.What is APC and why is it good if
I have it?
---Advanced process control (APC) refers
to a broad range of techniques and
technologies implemented within industrial
process control systems. Advanced
process controls are usually deployed
optionally and in addition to basic process
controls. Advanced process controls are
usually deployed optionally and in addition
to basic process controls.
--reason:
Reduction in energetic consumption.
Equipment downtime minimization.
Increase in the information that flows in the
system. Much Improved quality and
product consistency.
36. What means if the sensor is
active or passive?
An active sensor is a sensing device that
requires an external source of power to
operate; active sensors contrast with
passive sensors, which simply detect and
respond to some type of input from the
physical environment.
Passive sensors detect energy emitted or
reflected from an object, and include
different types of radiometers and
spectrometers. Most passive systems
used in remote sensing applications
37. How can an instrument work
in a view of energy needs?
The instruments can be classified as (i)
mechanical, electrical, and electronic
instruments, (ii) absolute or primary and
secondary instruments, (iii) manual and
automatic instruments, (iv) self operated
and power operated instruments, (v) self
contained and remote indicating
instruments, (vi) contact type and non-
contact type instruments, and (vii) analog
and digital instruments.
Mechanical instruments are simple in
design and application. They are normally
durable and relatively cheaper. No external
power source is needed for their operation.
electronic instruments, the only movement
involved is that of electrons and the inertia
of electrons being very small, the response
time of these instruments is extremely
small
38. What is the difference
between analog and digital signal?
Analog and digital signals are the types of
signals carrying information. The major
difference between both signals is that the
analog signals have continuous electrical
signals, while digital signals have non-
continuous electrical signals.
Signal Analog signal is a continuous signal
which represents physical measurements.
Digital signals are discrete time signals
generated by digital modulation
39. How can you control the
flow?
To be able to effectively manage flow
control, flow control valves are used. The
flow control of liquids is regulated as these
respond to signals that are produced by
independent devices like temperature
gauges as well as flow meters.
---In order to maintain proper flow
control, control valves are used,
usually with positioners and
actuators. The most common flow
control valves include:
● Diaphragm valves
● Globe valves
● Butterfly valves
Flow control valves are commonly
present in hydraulic actuators. With
such, automatic flow control valves
are used and the actuator responds to
flow and pressure changes. The
changes cause the valve to open and
close.
40. How can you control the flow in
the case of solid materials?
There are three major design aspects
to consider when designing solids
handling equipment: Hopper angle,
minimum outlet dimension, and
discharge rate….
41. What means if a valve is FC
or FO?
Valves - Fail-Closed (FC) - A control valve
that goes to closed position if control signal
or air fails. Valves - Fail-Last (FL) - A
control valve that should stay put if control
signal or air fails. Valves - Fail-Open (FO)
- A control valve that goes to open
position if control signal or air fails.
42. How can you control the
temperature if the hotter fluid is
steam?
Steam temperature is normally controlled
by spraying water into the steam between
the first and second-stage superheater to
cool it down. Water injection is done in a
device called an attemperator or
desuperheater. The spray water comes
from either an intermediate stage of the
boiler feedwater pump (for reheater spray)
or from the pump discharge (for
superheater spray). Other methods of
steam temperature control include flue gas
recirculation, flue gas bypass, and tilting
the angle at which the burners fire into the
furnace.
43. How can you measure gas
density?.
A dasymeter which allows weighing acts
as a densimeter used to measure the
density of gases.
44. Why measure the noise in the
case of a ball mill grinder?
This sound is caused by the grinding ball
hitting the mill lining and the material in
the mill. A high noise level indicates an
under-loaded mill and a low noise level
indicates an overloaded mill. Both these
conditions result in reduced grinding
efficiency.
45. What is the difference between
flash and batch distillation?
Cyclic flash distillation, the single stage
limit of cyclic distillation without reflux, is
batch distillation with repeated charges of
feed. Continuous flash distillation is
normally a single stage separation
technique, but one variant, column flash
distillation, has multiple stages
46. What means brewer’s window?
47. Draw a diagram how the first
order element will response for a
step and an impulse disturbance.
The first order control systems are stable
with impulse and step inputs because these
responses have bounded output. But, the
impulse response doesn't have steady state
term. So, the step signal is widely used in
the time domain for analyzing the control
systems from their responses.
48. Why do we use FOPDT?
The FOPDT model is a powerful tool as it
provides a consistent and effective means
for tuning a production facility's PID
controllers. If the goal is quick and accurate
results, the FOPDT is the modeling tools
for you and your plant.
49. What can be an integrator element
in practice?
The integrator is the complementary
element to the differentiator. Its output is
the integral of the input signal over time,
multiplied with a proportionality constant.
Typical examples are the capacitor, which
accumulates charges, or a water tank, which
accumulates fluid
50. What can be a first order element in
practice?
51. What is cascade control?
Cascade control involves the use of two
controllers with the output of the first
controller providing the set point for the
second controller, the feedback loop for
one controller nestling inside the other.
Such a system can give an improved
response to disturbances.
52. How can you define the system
stability (one criteria is enough)
A system is said to be stable, if its output
is under control. Otherwise, it is said to be
unstable. A stable system produces a
bounded output for a given bounded input.
The following figure shows the response
of a stable system.
53. Describe a PID tuning method!
PID tuning is the process of finding the
values of proportional, integral, and
derivative gains of a PID controller to
achieve desired performance and meet
design requirements.