Process Control Systems - Try Questions and Answers
1. 1. What are the two main types of process control, and how do they differ?
The two main types of process control are open-loop and closed-loop control systems.
Open-loop control does not use feedback to determine if its output has achieved the
desired goal, while closed-loop control continuously monitors the output and adjusts the
input accordingly.
2. 2. Describe the role of sensors in a process control system.
Sensors detect physical parameters such as temperature, pressure, flow, or level in a
process. They convert these measurements into signals that can be interpreted by the
control system.
3. 3. What is a set point, and why is it essential in process control?
A set point is the desired or target value for a process variable. The control system works
to maintain the process at this value by adjusting the inputs.
4. 4. Explain the difference between process variables and manipulated variables.
Process variables are the measured values in a system (e.g., temperature, pressure), while
manipulated variables are the inputs that are adjusted by the control system to maintain or
change the process variable (e.g., valve position, pump speed).
5. 5. Identify and describe the function of three critical components in a process control
system.
Three critical components are:
- Sensor: Measures process variables.
- Controller: Compares measured value to set point and decides on action.
- Actuator: Implements the controller’s decisions by adjusting the process.
6. 6. How does a closed-loop control system respond to changes in process variables?
A closed-loop control system detects deviations from the set point and automatically
adjusts the inputs to bring the process variable back to the desired value.
7. 7. Discuss the application of process control systems in pharmaceutical production.
Process control ensures consistent product quality, safety, and regulatory compliance in
pharmaceutical manufacturing by maintaining optimal conditions for chemical reactions,
mixing, and packaging.
8. 8. Define the term "error" in a control system and write its mathematical formula.
Error is the difference between the set point (desired value) and the process variable
(measured value).
Formula: Error (e) = Set Point (SP) - Process Variable (PV).
9. 9. What safety precautions are necessary when working with hydraulic systems in
process control?
Safety precautions include:
- Wearing protective gear.
- Regularly inspecting for leaks.
- Depressurizing the system before maintenance.
- Avoiding sudden valve movements.
- Following proper lockout/tagout procedures.
10. 10. Discuss the importance of calibration for sensors in maintaining process accuracy.
Calibration ensures that sensors provide accurate and reliable measurements. Regular
calibration reduces errors, enhances product quality, and maintains regulatory standards.
