Bachelor of Science

(Industrial Automation Engineering)

Unit code BIA108S

Unit name Process Instrumentation and Control

Assessment # 2

Paper # B

Version # 2

Created by Anand Srinivasan Date 9 July 2018

Reviewed by Helmut Schütte Date 24 Feb 2023

Bachelor of Science (Industrial Automation Engineering) 2

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BIA108S_Assessment2_PaperB_v2
Bachelor of Science (Industrial Automation Engineering) 3

Unit code and name: BIA108S: Process Instrumentation and Control

Assessment #: 2B

Assessment type: Short-answer Questions

Weighting: 20%

Total marks: 20 marks

Please complete your answers on the assessment cover page document available on Moodle.
Clearly label your question numbers (there is no need to copy the full question over). Include all working
out.

Question 1: (1 mark)
Given that flow delivered (Q) is usually expressed in cubic meters per second, but that Q can ALSO
be expressed as kW/pa, carfeully consider the following: If the pump discharge pressure during
unloading equals 180 bar and the power disipated across the valve is 430 kW, calculate the pump
flow delivered?

Question 2: (1 mark)
In the counterbalance circuit shown in Fig below, load to be lifted is 2.5 kN, choose a min cylinder
diameter so that the load induced pressure doee not exceed 8.3 bar.
Load
Hint: Load-induced pressure = Area therefore use the given data to calculate the area first, and then
calculate the diameter.
Bachelor of Science (Industrial Automation Engineering) 4

Question 3: (2 marks)
A pressure-relief valve contains a poppet with an area of 2.3 cm2 on which the system pressure
acts. If a spring with a spring constant of 1600 N/cm is installed in the valve to hold the poppet
against its seat and If the spring is initially compressed to 0.35 cm from its free-length condition,
Determine the cracking pressure.
Hint 1: Force is in Neuton, and the spring constant is in N/m. So, start off by calculating the force
required to keep the valve closed.
Hint 2: Cracking pressure x area = force required to keep valve closed

Question 4: (2 marks)
A pressure-relief valve with spring supported poppet is used for fluid control. A spring with a spring
constant of 6400 N/cm is installed in the valve to hold the poppet and spring has 2.1 cm free-length
condition. The full pump flow pressure (pressure-relief valve pressure setting) is 9.5 MPa.
Determine the area of the poppet required for the valve.
Hint 1: Force is in Neuton, and the spring constant is in N/m. So, start off by calculating the force
required to keep the valve closed.
Hint 2: Full flow pressure x area = force required to keep valve closed

Question 5: (2 marks)
When working with Cv, and using flow and pressure values that are not in gallons per minute and
psi, what must be done to the Cv formula?

Question 6: (2 marks)
A level control valve is to be installed on a fluid line going from a storage tank to a settling tank. The
settling tank max pressure at inlet is specified as 2.8 bar and the line restriction between the
control valve and the storage tank is 0.45 bar. The fluid flow-rate is 18 m3/hr and Outlet pressure at
the Storage Tank is 6.5 bar. Calculate the control valve flow coefficient or valve Cv. Assume Fluid
specific Gravity as 0.45

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Bachelor of Science (Industrial Automation Engineering) 5

Hint: When working with cubic meters per hour and bar, the formula will change to Q =
𝑠𝑔
𝐶𝑣 divided by (1.16 × √∆𝑃𝑣)

6.5 bar Storage

Tank

Settling 2.8 bar

Tank

Question 7: (5 marks)
A room heating system provides heat during winter with hot water circulated in set of heating
coils with fins inside the room. The amount of heat provided in the room is controlled by regulating
the amount of water flowing in the pipes by the help of solenoid valve with inputs from the
temperature sensor in the heater panel on actual room temperature. The temperature required for
the occupants of the room can be set to the desired value in the heater panel .
Identify the following process control parameters for the above system with appropriate reasons
• Process variable
• Primary sensing element
• Set point
• Manipulated variable
• Final control element

Question 8: (2 marks)
A diesel engine powering an alternator has a water jacket water circuit which cools the cylinder and
other parts of the engine to keep them at desired operating temperature. The water is pumped
with an engine mounted pump and it absorbs heat from the engine and is then sent to a radiator to
reject the heat to atmosphere and cool water flows back to engine. In order to maintain desired
temperature within the engine jacket – a temperature controlled bypass valve is used to recirculate
water within the engine jacket until the water reaches the threshold temperature and then send
the water to the radiator once the threshold temperature is reached.
Propose an On-Off system, and Modulating System (proportional) for the Water Flow circuit– how
can it be beneficial than on -off system.
Bachelor of Science (Industrial Automation Engineering) 6

Question 9: (2 marks)
An earthmoving machine is used to remove dirt and mud to achieve the desired grade on a road.
The desired grade for the road is provided by a topographic map in the control module of the
machine ( by GPS) , the machine moving at low speeds has a blade in the front which is lowered or
raised to the desired level to ensure correct level of material removal as per the desired grade
map. The blade is controlled by Hydraulic cylinders which are provided pressurized oil by control
valve from a hydraulic system on the machine. A position sensor on one of the hydraulic cylinder
provides the position of the blade with respect to the ground.
Specify the basic configuration of a Feed forward control system for this and identify the main
components
• CO= controller output signal
• D= measured disturbance variable
• e(t) = controller error ( SP – PV)
• FCE = final control element
• PV = measured process variable
• SP = set point

Question 10: (2 marks)

A water pump used for cooling a power generator in the basement of a Commercial Building pumps
water from the generator to the roof of the building to a cooling tower which cools the water and
returns the water to the generator. The pump is equipped with a Variable Frequency Drive (VFD)
controller for the motor which allows for lesser power consumption by running the motor at
reduced speeds when lesser water flow is sufficient to achieve the cooling as measured by the
generator water outlet temperature.
Draw a simple feedback control system for this application

Question 11: (1 mark)

In a process where fluid flow is in the range of 250 -300 units – a PID controller is installed to
monitor and control the fluid flow.
The following data for of a P, I, D feedback are provided to a PID controller

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Bachelor of Science (Industrial Automation Engineering) 7

Proportional constant: 0.87 Integral constant: 0.37 Derivative constant: 1.45

Current error = 12.7 Average change in error ( Integral input) : 0.43
Rate of Change in error (Derivative Input) : 0.14
Calculate the total correction ‘u’ that is to be provided by the controller using the principles of PID
control.

Question 12: (2 marks)

A simple block diagram is given below with various gain functions.

For simplicity the instantaneous transfer function values for the control loop variables are listed
below as:
• Gc(s) = 10.8
• Gv(s) = 5.2
• Gp(s) = 0.254
• Gs(s) = 1.75
• Gd(s) = 2.54

a) Calculate the set point response. (1 mark)

b) Calculate the disturbance response. (1 mark)

END OF ASSESSMENT