COURSE FILE

BEE050 PROCESS CONTROL ENGINEERING

Page 1 of 27
 COURSE OBJECTIVE
To enlight the student in the field of energy engineering concern with energy efficiency, energy
service and facility management. This course to develop a strong foundation in energy engineering and
conservation.

LEARNING OUTCOME
.

Learn the basic control actions and. Compute the Mathematical Model for different
process
Analyse the characteristics of different types of Controllers and selection of
controller
Select ,design and tune a controller to suit a particular process

Identify the basic components of a final control element and distinguish the
different Characteristics of control valve
Understand and analyze the concept of multi loop control techniques

Page 2 of 27
 SYLLABUS
UNIT I MATHEMATICAL MODELLING OF PROCESS 9

Process control introduction – Need for process control –Hardware elements of a process control system –
Need of Mathematical modelling –Mathematical model of level, pressure ,thermal processes and interacting
and non-interacting systems– Servo and Regulator Operation – Batch & Continuous Process – Concept of
self regulation– x.

UNIT II VARIOUS CONTROLLERS AND ITS CHARACTERSTICS 9

Characteristics of ON- OFF, Single speed floating and PID controllers – Response of P,PI and PID
controllers to various type of error signals – Analysis of Servo and Regulatory response of P and PI and PID
controllers for first order and second order process – Reset Wind-up and prevention – Derivative and
Proportional kick –Bumpless transfer – Selection of a controller for a particular process

UNIT III CONTROLLER DESIGN 9

Need for controller tuning –Evaluation criteria - Quarter Decay Ratio, IAE, ISE and ITAE– Optimum
controller tuning using Evaluation criteria–Tuning of PID controllers using Process reaction curve method,
Damped oscillation method and Z-N tuning method.

UNIT IV FINAL CONTROL ELEMENTS 9

I/P, P/I converters – Final control elements - Pneumatic and electric actuators -Types of control valves -
Valve positioner and its importance - Inherent and Installed characteristics of control valve - Control valve
sizing - Cavitation and flashing.

UNIT V MULTILOOP CONTROL 9

Feed-forward control – Ratio control – Cascade control – Inferential control – Split-range and introduction to
multivariable control – Examples from distillation column and boiler systems – IMC– Model Predictive
Control – Adaptive control – P&ID diagram.

Text book(s) and/or required materials

1. Stephanopoulos. G, “Chemical Process Control - An Introduction to Theory and Practice”, Prentice Hall
of India, 2005.
2. Johnson .C.D, “Process Control Instrument Technology”, Prentice Hall Inc., 2004.

Page 3 of 27
 Academic Course Description

BHARATH UNIVERSITY
Faculty of Engineering and Technology
Department of Electrical and Electronics Engineering

BEE050 Process Control Engineering

Eighth Semester, (even Semester)
Course (catalog) description
To enable the students to learn the basic concepts of process control and to develop sufficient
knowledge of the various control actions and design of controllers used to control any process

Compulsory/Elective Course : Elective for EEE students

Credit & Contact hours :3 and 45 hours
Course Coordinator : Mr.K.S.S.PRASAD
Instructors : Mr.K.S.S.PRASAD

Name of the Class Office Office Email (domain:@ Consultation

instructor handling location phone bharathuniv.ac.in
Mr.K.S.S.PRASAD Second KS 101 04422290125 Hod.eee@bharathuniv.ac.in 9.00-9.50 AM
year EEE

Relationship to other courses:

Pre –requisites :BEE501- Control System

Assumed knowledge :To get basic knowledge of process control and design.

Syllabus Contents
UNIT I MATHEMATICAL MODELLING OF PROCESS 9

Process control introduction – Need for process control –Hardware elements of a process control system –
Need of Mathematical modelling –Mathematical model of level, pressure ,thermal processes and interacting
and non-interacting systems– Servo and Regulator Operation – Batch & Continuous Process – Concept of
self regulation– x.

UNIT II VARIOUS CONTROLLERS AND ITS CHARACTERSTICS 9

Characteristics of ON- OFF, Single speed floating and PID controllers – Response of P,PI and PID
controllers to various type of error signals – Analysis of Servo and Regulatory response of P and PI and PID

Page 4 of 27
controllers for first order and second order process – Reset Wind-up and prevention – Derivative and
Proportional kick –Bumpless transfer – Selection of a controller for a particular process

UNIT III CONTROLLER DESIGN 9

Need for controller tuning –Evaluation criteria - Quarter Decay Ratio, IAE, ISE and ITAE– Optimum
controller tuning using Evaluation criteria–Tuning of PID controllers using Process reaction curve method,
Damped oscillation method and Z-N tuning method.

UNIT IV FINAL CONTROL ELEMENTS 9

I/P, P/I converters – Final control elements - Pneumatic and electric actuators -Types of control valves -
Valve positioner and its importance - Inherent and Installed characteristics of control valve - Control valve
sizing - Cavitation and flashing.

UNIT V MULTILOOP CONTROL 9

Feed-forward control – Ratio control – Cascade control – Inferential control – Split-range and introduction to
multivariable control – Examples from distillation column and boiler systems – IMC– Model Predictive
Control – Adaptive control – P&ID diagram.

Text book(s) and/or required materials

1. Stephanopoulos. G, “Chemical Process Control - An Introduction to Theory and Practice”, Prentice Hall
of India, 2005.

2. Johnson .C.D, “Process Control Instrument Technology”, Prentice Hall Inc., 2004.

Computer usage:

Professional component

General - 0%

Basic Sciences - 0%

Engineering sciences & Technical arts - 0%

Professional subject - 0%

Non major elective - 100%

Broad area :

Page 5 of 27
Test Schedule

S. No. Test Tentative Date Portions Duration

1 Cycle Test-1 February 1st week Session 1 to 14 2 Periods

2 Cycle Test-2 March 2nd week Session 15 to 28 2 Periods

3 Model Test April 2nd week Session 1 to 45 3 Hrs
University
4 Examination TBA All sessions / Units 3 Hrs.

Mapping of Instructional Objectives with Program Outcome

To enable the students to learn the basic concepts of process control and to develop Correlates to
sufficient knowledge of the various control actions and design of controllers used to program
control any process
outcome
H M L
1. Learn the basic control actions and. Compute the Mathematical Model for a, l c,e
different process b,i
2. Analyse the characteristics of different types of Controllers and selection of b a,c,i,l e
controller
3. Select ,design and tune a controller to suit a particular process b, a,e,l
c,i
a b,c,i,l e
4.Identify the basic components of a final control element and distinguish the
different Characteristics of control valve
5.Understand and analyze the concept of multi loop control techniques a,b,e,i,l c

H: high correlation, M: medium correlation, L: low correlation

Page 6 of 27
Draft Lecture Schedule

S.NO Topics Problem solving Text / Chapter

(Yes/No)

UNIT I

1. Process control introduction NO

2. Need for process control NO

3. Hardware elements of a process control system NO

4. Need of Mathematical modelling NO

5. Mathematical model of level, pressure ,thermal YES

processes and interacting and non-interacting
systems

6. Servo and Regulator Operation NO

7. Batch & Continuous Process NO T1

8. Concept of self regulation NO

9. Dead time,Degrees of freedom ,Linearization NO

UNIT II

10. Characteristics of ON- OFF, Single speed floating NO

and PID controllers

11. Response of P,PI and PID controllers to various YES

type of error signals

12. Analysis of Servo and Regulatory response of P NO

and PI and PID controllers for first order process

Page 7 of 27
 13. Analysis of Servo and Regulatory response of P NO
and PI and PID controllers for second order
process

14. Derivative and Proportional kick NO T1

15. Bumpless transfer NO

16. Selection of a controller for a particular process NO

17. Reset Wind-up and prevention No

18. Revision No

UNIT III

19. Need for controller tuning NO

20. Evaluation criteria NO

21. IAE, ISE and ITAE– Optimum controller tuning NO

using Evaluation criteria

22. Tuning of PID controllers using Process reaction NO

curve method, and Z-N tuning method.

23. Tuning of PID controllers using Damped No

oscillation method

24. Tuning of PID controllers using Damped No

oscillation method

25. Tuning of PID controllers using Z-N tuning No

method.
T1
26. Tuning of PID controllers using Z-N tuning No
method.

27. Quarter Decay Ratio No

UNIT IV

28. I/P, P/I converters NO

29. Final control elements NO

30. Pneumatic and electric actuators NO

Page 8 of 27
 31. Valve positioner and its importance NO

32. Inherent and Installed characteristics of control NO T2

valve

33. Inherent and Installed characteristics of control NO

valve

34. Control valve sizing NO

35. Control valve sizing NO

36. Cavitation and flashing. NO

UNIT V

37. Feed-forward control NO

38. Ratio control ,Cascade control NO

39. Inferential control NO

40. Split-range and introduction to multivariable NO

control

41. Examples from distillation column and boiler NO [T1]

systems

42. IMC– Model Predictive Control NO

43. IMC– Model Predictive Control NO

44. Adaptive control,P&ID diagram NO

45. Adaptive control,P&ID diagram NO

Teaching Strategies

The teaching in this course aims at establishing a good fundamental understanding of the areas covered
using:

 Formal face-to-face lectures

Page 9 of 27
  Tutorials, which allow for exercises in problem solving and allow time for students to resolve
problems in understanding of lecture material.

 Laboratory sessions, which support the formal lecture material and also provide the student with
practical construction, measurement and debugging skills.

 Small periodic quizzes, to enable you to assess your understanding of the concepts.

Evaluation Strategies
Cycle Test – I - 5%
Cycle Test – II - 5%
Model Test - 10%
Assignment - 5%
Attendance - 5%
Final exam - 70%

Prepared by: Dated :

Mr.K.S.S.PRASAD

Page 10 of 27
Addendum

ABET Outcomes expected of graduates of B.Tech / EEE / program by the time that they graduate:

a) An ability to apply knowledge of mathematics, science, and engineering fundamentals.

b) An ability to identify, formulate, and solve engineering problems.
c) An ability to design a system, component, or process to meet the desired needs within realistic constraints such
as economic, environmental, social, political, ethical, health and safety, manufacturability, and sustainability.
d) An ability to design and conduct experiments, as well as to analyze and interpret data.
e) An ability to use the techniques, skills, and modern engineering tools necessary for engineering practice.
f) An ability to apply reasoning informed by the knowledge of contemporary issues.
g) An ability to broaden the education necessary to understand the impact of engineering solutions in a global,
economic, environmental, and societal context.
h) An ability to understand professional and ethical responsibility and apply them in engineering practices.
i) An ability to function on multidisciplinary teams.
j) An ability to communicate effectively with the engineering community and with society at large.
k) An ability in understanding of the engineering and management principles and apply them in project and finance
management as a leader and a member in a team.
l) An ability to recognize the need for,and an ability to engage in life-long learning.
Program Educational Objectives

PEO1: PREPARATION

Electrical Engineering Graduates are in position with the knowledge of Basic Sciences in general and Electrical
Engineering in particular so as to impart the necessary skill to analyze and synthesize electrical circuits, algorithms and
complex apparatus.

PEO2: CORE COMPETENCE

Electrical Engineering Graduates have competence to provide technical knowledge, skill and also to identify,
comprehend and solve problems in industry, research and academics related to power, information and electronics
hardware.

PEO3: PROFESSIONALISM

Electrical Engineering Graduates are successfully work in various Industrial and Government organizations, both at the
National and International level, with professional competence and ethical administrative acumen so as to be able to
handle critical situations and meet deadlines.

PEO4: SKILL

Electrical Engineering Graduates have better opportunity to become a future researchers/ scientists with good
communication skills so that they may be both good team-members and leaders with innovative ideas for a sustainable
development.
Page 11 of 27
PEO5: ETHICS

Electrical Engineering Graduates are framed to improve their technical and intellectual capabilities through life-long
learning process with ethical feeling so as to become good teachers, either in a class or to juniors in industry.

Course Teacher Signature

Mr.K.S.S.PRASAD

Course Coordinator HOD/EEE

(Mr.K.S.S.PRASAD) ()

Page 12 of 27
 COURSE EXECUTION PLAN
BEE050 PROCESS CONTROL ENGINEERING
To enable the students to learn the basic concepts of process control and to develop
sufficient knowledge of the various control actions and design of controllers used to control any
process

Portions to be
S. No. completed Tentative Date Remarks

1 Unit – 1 & Unit -2 Before February 1st week Students are asked to submit one
assignment after completing the
portions of Unit-1 and Unit-2.

2 Unit -3 & Unit – 4 Before March 2nd week Students are asked to submit one
assignment after completing the
portions of f Unit-3 and Unit-4.

3 Unit -5 April 1st week They should be ready to undergo

Model Examination after
completing all the portions in the
prescribed course, following
University Board Examinations.

Course Co-ordinator Course Instructor

Page 13 of 27
 GROUP DETAILS FOR ASSIGNMENT / ACTIVITY
 Individual Assignments are given to the students with innovative questions. Such that they have to
think and answer for the questions, which they cannot simply take from books/materials ..etc.
 Total of 2 Assignments are given to the students per course.

Page 14 of 27
 ASSIGNMENT QUESTIONS WITH MARKING SCHEME
ASSIGNMENT - I
1. Derive a mathematical model of a first order thermal process.(10 MARKS)

2. Differentiate servo and regulatory operation with the help of suitable example. (10 MARKS)

3. what is the inverse response? Explain its behaviour with dynamic system. (10 MARKS)

4. With neat schematic diagram explain the single speed floating control. (10 MARKS)

5. Compare the features of ON & OFF,P,I,D control modes and draw their characteristics . (10 MARKS)

ASSIGNMENT – II
1. What is cascade control? Explain need for cascade control with an example. When do you prefer
cascade control mode.(10 MARKS)

2. Explain the block diagram of cascade control and adaptive control. List the advantages and
disadvantages of feed forward control scheme.(10 MARKS)

3. What is split range control? Describe a situation when you could use split range control .(10 MARKS)

4. Describe an application which needs cascade control. (10 MARKS)

5. Explain feed forward control with an example from distillation column. (10 MARKS)

Marking Scheme :

 Introduction (2marks)
 Diagrams (2marks)
 Working(4marks)
 Conclusion(2 Marks)

Page 15 of 27
COURSE MATERIAL

Page 16 of 27
 CYCLE TEST –I
QUESTION PAPER

QN.NO QUESTIONS
1. Distinguish between servo and regulator operation.

2. What is the inverse response? Explain the inverse response noticed in the level
control of feed water in the boiler
3. List the merits and demerits of the continues and batch process
4. With neat sketch explain the of P+I pneumatic controller
5. What is cycling in the process output in which control mode it occurs

CYCLE TEST – II
QUESTION PAPER
Q.NO QUESTIONS
1 What is split range control? Describe a situation when you could use split range
control.
2 Explain how to find the controller settings using process reaction curve.

3 Explain the block diagram of cascade control and adaptive control.

4 Explain the application of feed forward control and cascade control in distillation
column
5 What are the main advantages and disadvantage of cascade control for what kind of
process can you employ cascade control.

BHARATH UNIVERSITY

Page 17 of 27
 DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

BEE026 &Micro Electro Mechanical Systems

MODEL TEST

Time: 3 hrs Maximum: 100 Marks

Part A (10x2=20marks)

1. What is the need for Process Control?

2. Differentiate interacting and non interacting systems.
3. What is meant Proportional Band in Proportional Controller?
4. Compare the effect of PI and PD controllers with respect to (a) order of the closed Loop
system and (b) offset.
5. Define Quarter decay ratio and Integral square error.
6. Write down the procedure for obtaining process reaction curve.
7. List the drawbacks of Feed forward controller.
8. What is ratio control, and why is it useful in process control?
9. Distinguish between continuous and batch process.
10. What do you mean by control value sizing?

Part B (5x6=30marks)
11. Develop the first order transfer function for a liquid level process shown below.
(Or)
Develop a mathematical model for a mercury thermometer
12. Explain about single speed floating control in detail
(Or)
Enumerate the characteristics of ON-OFF control.
13. With neat sketch explain the principle of Current to Pressure converter.
(Or)
Examine the principle and working of flapper nozzle arrangement.
14. What do mean by optimum controller setting? (Or)
How is ITAE criterion different form IAE?.
15. Illustrate Model Predictive control scheme with an example.
(Or)
Explain the model reference adaptive control with neat sketch

Part C (5x10=50marks)

16. Obtain the mathematical model of first order thermal process.

17. Explain about single speed floating control in detail.

18 .Describe the construction and working of a Solenoid..

Page 18 of 27
19. Discuss the procedure for setting controller parameters by using time response method.

20. Explain the operation of adaptive control scheme with the help of a neat block diagram.

Page 19 of 27
CUMULATIVE PERFORMANCE ANALYSIS

Page 20 of 27
CORRECTIVE ACTION PLAN FOR FAILURES AND ABSENTEES

Page 21 of 27
ATTENDANCE REPORT

Page 22 of 27
DETENTION REPORT

Page 23 of 27
MINUTES OF COURSE COMMITTEE MEETING

Page 24 of 27
COURSE FEEDBACK REPORT

Page 25 of 27
STUDENT COURSE FEEDBACK SUMMARY REPORT

Page 26 of 27
Page 27 of 27