ABSTRACT

The experiment was conducted to study about the open loop test and closed loop test
proceeding with load disturbance test and set point test to determine the optimum condition
for the process control loop system. There are two system used for the tests which are DCS
FOXBORO and DCS DELTA – V Emerson. While the three types analysis are Control
Process (LIC11), Flow Control (FIC 21) and Liquid Flow Process (FIC31). One of the
conventional method is tangent analysis where it used to analyse an open loop step response
curve which is done by drawing a tangent line at the steepest point of the step response curve.
The values of response rate (RR), dead time (Td) and time constant (Tc) can be calculated
using either tangent method, reformulated tangent method or numerical technique. Therefore,
the optimum values which is P and I is then calculated by using Ziegler-Nichols or Cohen-
Coon depending on their specification for closed loop test with load disturbance and set point
test. Furthermore, an increase in PB slows down the process response (PV) which indicated
by shifting the process response curve to the right. An increase in I also slows down the
process response (PV) which indicated by shifting the process response curve to the right
while an increase in D increase the process response (PV) which indicated by shifting the
process response curve to the left. The value of Kc, I and PB can be divided or time by 2 or 4
to stabilize the process in case oscillations occurred. Finally, the data could be obtained one
the process is determined.
OBJECTIVES

1. To carry out open loop test using both DCS Delta A-V Emerson and DCS
FOXBORO.
2. To carry out closed loop test using both DCS Delta A-V Emerson and DCS
FOXBORO.
3. To observe the behaviour of the P and I mode towards the process response curve for
the flow control system.
4. To calculate the Td, Tc and RR value by using tangent method, reformulated tangent
method and numerical tangent method.
5. To determine the value of PB and I value using Ziegler Nichol’s and Cohen-Coon’s
method.
6.  To calculate and analyse either the response curve is linear, slightly non-linear or
roughly non-linear.
7. To undergo the correct method to do open loop test and closed loop test proceeding
with load disturbance test and set point test.
THEORY

Process Linearity

Process linearity is a study of process behaviour on changing manipulated variable

and to determine the relationship between dependent variable and independent variable is
linear or not. Process linearity can be either linear on non-linear. An independent variable
(MV) is the variable that is changed or controlled in a scientific experiment to test the effects
on the dependent variable while a dependent variable (PV) is the variable being experienced
and calculated in a scientific experiment. The MV steps must change gradually from 0 to
10% until 100%. A linear process changes proportionally with changing manipulated
variable. However, for a nonlinear process the change in process is not proportional and not
easily predictable. PV should change with MV where PV should have reach the desired set
point (SP) once MV reached 100%. The process lack in efficiency PV does not reach the SP.
The process linearity behaviour can be observed graphically by plotting a graph of MV
against PV to identify if it is linear or nonlinear. The figure below shows the process linear
identification:

Figure 1: Process Linearity Identification.

The process linearity behaviour can also be observed mathematically.

 For a linear process behaviour
∆ PV 1−2 ∆ PV 2−3
=
∆ MV 1−2 ∆ MV 2−3
 PV 2−PV 1 PV 3 −PV 2
=
MV 2−MV 1 MV 3 −MV 2

 For a nonlinear process behaviour

∆ PV 1−2 ∆ PV 2−3
≠
∆ MV 1−2 ∆ MV 2−3
PV 2−PV 1 PV 3−PV 2
≠
MV 2−MV 1 MV 3−MV 2

1. If the percent change value is equal to 0 then the relationship between the dependent
variable and independent variable is linear (% change=0%).
2. If the percent change value is higher than 50 % then the relationship between the
dependent variable and independent variable is highly non-linear (50<% change).
3. If the percent change value is smaller than 50 then the relationship between the
dependent variable and independent variable is slightly nonlinear (50≥% change>0).

Open Loop Test

Open loop systems tend to be simple and act solely on the basis of the input. In other
words, open loop systems do not use feedback from the output to self-correct while the test is
running. The open loop test is significant as it enables the plant to define the process by
knowing the process dead time (Td), time constant (Tc) and response rate (RR). There are
few ways on how to get these values which are by using tangent method, reformulated
tangent method and numerical method. These values are important as it leads to better overall
control of the process.

Closed Loop Test

Closed loop control system is an automatic control system that utilizes feedback. The
feedback is used to make decisions about changes to the control signal that drives the plant as
the feedback loop continuously sends information from the closed loop controller to the
motor and also from motor to the closed loop controller. It is commonly used in industrial
systems and uses PID setting in the controller where PID value of a process control can be
estimated by using tuning rule based on their specific criteria. The two types of tuning rule
that was used in the experiment is Ziegler-Nichols and Cohen-Coon method.

Tangent Method

The tangent method starts with an open loop test by putting the controller in manual
mode and making a load change (∆MV) of 5 to 20% to the controller’s output. By using tangent
method, the response curve is then analysed for the response rate (RR) and process dead time
(Td) by sketching a tangent line to the steepest point of the response curve. The process dead
time is projected at the cross section between the baseline of the old steady state level and the
tangent line. Response rate, RR is as shown below:

∆ PV /∆ t
RR =
∆ MV

Where, RR is the response rate (1/time), ∆ PV is change in measurement (%), ∆ t is the

change in time (time) while ∆MV is the change in controller’s output (%). Meanwhile, dead
time Td is defined as,
Td(s) = td x b

Figure 1: A step input and the associated step response curve.

Reformulated Tangent Method
The reformulated tangent method is almost the same and simpler compared to tangent
method. However, this method uses angle to proceed with further calculation.

Where,

tan θ a
 RR = ×
∆ MV b
 Dead time Td (s) = td × b
Use either tangent, two-point or tangent and point method to calculated time constant,
Tc.

Tangent Two-Point Tangent and Point

Tc = tc x b Tc = 1.5 x (T 63.2−T 28.3 ¿ x b Tc = (T 63.2-Td) x b

Numerical Method

Numerical method is applied due to a discrete step response data consists of a series
of values of equal time spacing and when Foxboro unit is used. However, only a set of data is
needed to proceed with calculation. There is no need to print the graph. The diagram below
represents a representation of tangent analysis to a plotted step response data.

Figure 2: Numerical analysis of a step response data using 3-point central difference formula

A central difference formula can be applied since the time series is equispacing to
calculate the slope at any given point. There are three numerical techniques that can be
applied to calculate RR, Td and Tc.

1. Tangent method
PV 1−PV −1
RR =
2 ∆ h ∆ MV
PV f −PV i
Tc = 2∆ h
PV 1−PV −1
 Figure 3: Estimation of dead time.

Mathermatically, the dead time can be expressed as:

PV f −PV i
Td = t 1- 2∆ h
PV 1−PV −1

2. Tangent and Point Method

PV 63.2 %= PV i + 0.632 ( PV f −PV i ¿
PV 28.3 %= PV i + 0.238 ( PV f −PV i ¿
Tc=T 63.2 %- Td

3. Two-Point Method
Tc = 1.5 (T 63.2% -T 23.8 % ¿
Optimum Controller Setting

Proportional, Integral and Derivative control also known as PID is broadly used in
automatic process control application applications in industry. To calculate the value of PID,
some of the tuning rule that was used in this experiment is Ziegler-Nichol’s and Cohen
Coon’s. PID controllers can be used to regulate pressure, level, flow, temperature and others
industrial process variable. There are three sections in process variables which are
Proportional control which can be uses for almost all process but processes may not stabilize
at the set point, PI control that is suitable for process such as pressure, flow and liquid level.
The last mode is PID control which suitable for temperature processes.

ZIEGLER-NICHOLS TUNING RULES

A Ziegler-Nichols tuning rule only needs values of RR and Td. Once the value of
RR and Td are acquired, the PB, I and D can be calculated. These values are the ones
calculated from tangent, reformulated tangent or numerical method. Performance tests are
in terms of set point and load disturbance.

Mode PB (%) I (Time) D(Time)

P 100 RR Td
PI 111.1 RR Td 3.33 Td
PID 83.3 RR Td 2 Td 0.5 Td
Table 1: Tuning Rules by Ziegler-Nichols

a) COHEN-COON TUNING RULES

 For this tuning, the value of RR, Td and μ need to be calculated to find the PB, I and
D. Performance test is in terms of disturbance in load variable.

Mode PB (%) I (Time) D (Time)

P 100
RR Td
μ
1+
3
PI 100 μ
RR Td 1+
μ 11
1+ 3.33[ ]Td
11 11 μ
1+
5
PID 100 μ 0.37 Td
RRTd 1+
μ 5 μ
1.35(1+ ) 2.5[ ] Td 1+
5 3μ 5
1+
5
Table 2: Tuning by Chen-Coon Tuning Rule.

PID Tuning

The characteristics of P, I and D are known by studying the change in process

response when one of the tuning parameters (P, I or D) is varied. Process stability is when the
process behaves consistently over time. The relation between MV and PB, KC I and D is as
below:

1
 MV ∝ , where MV is inversely proportional to PB. As PB increases, the action of
PB
MV decreases.
 MV ∝ Kc , where MV is directly proportional to Kc. As Kc increases, the action of
MV also increases.
1
 MV ∝ , where MV is inversely proportional to I. As the value of I increases, the
I
action of MV decreases.
 MV ∝ D , where MV is directly proportional to D. As the value of D increasing, the
action of MV is also increasing.
 MV ∝ e, where MV is directly proportional to e. An increase in e results in faster
action of MV.
 Hence, it can be concluded that when the value of PB is increases, the process
response becomes slower. When the value of I is increases, the process response
becomes slower and when the value of D is increases, the process response becomes
faster.
METHODOLOGY

DCS- Delta A-V Emerson

Open Loop test

1. The control loop that has been selected was:

Liquid Flow Plant

i. FIC21

2. The Controller was double clicked to open the example as below, PIC92.

3. The process history was clicked to view the trends

4. The stabilized the process, the manual or auto mode has been selected.
5. The data of manipulated variables was been recorded for the initial value.
6. Once the process has stabilized, the manual mode has been chosen.
7. The manipulated variables have been changed in the range of 5-20%.
8. For self-regulating system: The new steady state was waited until reached.
For non-self-regulating: The time where slope can be calculated from process
response was waited and then the system was set to AUTO mode.
9. The response curve was printed.
10. Tangent and Reformulated tangent method was used to determine the time delay (Td),
response rate (RR) and time constant (Tc).
11. PI controller setting was determined by using Ziegler Nichol’s and Cohen Coon’s
method.

Closed Loop Test

1. The controller was set into auto mode.

2. Details icon at Faceplate was clicked to set the controller setting.

3. The PI controller setting (Kc and I) value was inserted at Gain and reset Section.
4. Fine tuning was done to reduce the oscillation and achieved stable condition.
5. The optimum value of P and I were recorded.

Load Disturbance Test

1. The controller was set in manual mode.

2. MV was changed about 10% of current MV value.
3. Time taken waited was 3 seconds.
4. The set controller was set to automatic mode.
5. The response was waited until became stable.

Set Point Test

1. Auto mode was selected.
2. The set point has been changed about 10% of the current operating process value.
3. The response was waited until became stable.
4. Both response curves were combined and then the graph was printed.
5. The graph was printed.

DCS: FOXBORO

Open Loop test

1. Water flow and Level Control Plant have been selected.

2. The selected control loops were activated.
 FIC31
 LIC31

3. The open loop test was performed by stabilizing the process either in manual or
automatic mode.
4. The initial value of manipulated variable (MV in %) was recorded.
5. The process was switched to MAN mode once the process stabilized.
6. MV was changed about 10% of current MV value.
7. For self-regulating system: the new steady state was waited until reached.
For non self-regulating system: the slope was waited until can be calculated from
process response. Then, the system was set to AUTO mode.
8. The data was collected from AIM Historian data Display at Desktop.
9. The Numerical Analysis was used to determine response rate (RR), time delay (Td)
and time constant (Tc).
10. The PI controller setting was determined using Ziegler Nichol’s or Cohen Coon’s
method.

Closed Loop Test

6. The controller was set into auto mode.

7. The PI controller setting (PB and I) value at PBAND and INT Section were inserted.

8. Fine tuning was done to reduce the oscillation and achieved stable condition if the
response oscillates.
9. The optimum value of P and I were recorded.

Load Disturbance Test

6. The controller was set in manual mode.

7. MV was changed about 10% of current MV value.
8. Time taken waited was 3 seconds.
9. The set controller was set to automatic mode.
10. The response was waited until became stable.

Set Point Test

6. Auto mode was selected.
7. The set point has been changed about 10% of the current operating process value.
8. The response was waited until became stable.
9. Both response curves were combined.
10. The graph was printed by using HyperSnap-DX.
REFORMULATED TANGENT METHOD LAB

8.1 Level Control (LIC11) – EMERSON

An open loop process response happen when a change in manipulated variable was
made from 45% to 55%. The process dead time (Td), response rate (RR) and time constant
(Tc) is obtained from the Figure 2 using the equation of reformulated tangent method. The
process response stated is 1000 mm.

Data obtained from the graph:

∆ MV =MV f −MV i = 10%

Where,

MV i = 45%

MV f = 55%

100 mm 1
a=( x 100 % ) x = 0.6061%/mm
1000 mm 16.5 mm

1
b = (1 min x 60 s/min) x =1 s/mm
60 mm

θ = 10°
 Figure 1: Steps in determining the data for reformulated Tangent Method

8.1.1 Calculation

Dead Time, T d

T d(length) = 9mm

T d(time) = 9mm x 1s/mm = 9s

Response Rate, RR

tanθ a tan 10 0.6061

RR = ( )= =0.0107/s
∆ MV b 10 1

Time Constant, T c

Since this process is a non-self-regulating process, the time constant for the Level Control
loop cannot be determined. This resulting in the process response cannot reach final steady
state.

Tuning Rule: Ziegler-Nichols

Controller Mode = Proportional – Integral (PI)

PB (%) = 111.1RRT d = 111.1(0.0107/s)(9s) = 10.70%

I (Time) = 3.33T d = 3.33(9s) = 29.97 s

100 100
Emerson system used K c value instead of PB value, K c = = = 9.35
PB 10.70

The value Kc and I will be used for close loop test, load disturbance test and set point test for
an open loop process response.
Figure 2: Process Response for Closed Loop Test, Load Disturbance Test and Set Point Test.

DISCUSSION

Based on the calculation, the value PB and I could be obtained once the value of a, b,
RR, Td have been obtained. The value of the original PB and I are 10.70% and 29.97s,
respectively. These values could be obtained by using reformulated tangent method and
Ziegler-Nichols in controller mode of Proportional–Integral (PI). The mode PI is due to the
level flow. Then, the value of P is then converted to Kc using formula, Kc=100/P. hence, the
value of Kc is 9.35. Once the value of Kc is obtained, we can continue with the close loop
test and performance test to make sure that these values are right for the process. However,
when uploading the data, we found that these values are slightly less accurate. Thus, we
continue with fine tuning process for LIC11 to ensure that the graph can have stable outcome.
The response was waited until became stable. From the result, the oscillation and over
damping occurred due to the values are not quite precise.

Number of trial Controller Gain, Kc Proportional Band, Integral Time, I (s)

PB(%)
0 9.35 10.70 29.97
1 4.68 21.37 29.97
 A few trials are done to get the precise values. The values are obtained by altering the
original values by using formula, Kc/2 and I x 2. The value of Kc should be reduce to adjust
the overdamped while increase the value of I to reduce the oscillation. Thus, the process
response becomes better but still has little oscillates before reaching stability.

Reference

1. Ishak, A. & Ahmad, M. (2000). Reformulation of The Tangent Method For PID
Controller Tuning retrieved from
https://www.researchgate.net/publication/3878248_Reformulation_of_the_tangent_metho
d_for_PID_controller_tuning