ABSTRACT

Process control can involve in many sector from the smaller to the bigger process plant.
In the chemical industries, process control refers to the methods that are used to control process
variables when manufacturing a product. A typical control loop in a process is made up of four
basic control blocks namely the sensor, process, controller and final control element. An open
control loop is where controller is set to manual and closed loop is when controller is in auto
mode. PID controller is one of the most common forms of closed loop control. The term PID
stands for proportional, integral and derivative. The objective of the lab work is to perform open
loop test, closed loop test, load disturbance test and set point test using Foxboro controllers
systems. The process which these test is conducted on flow control. The open loop data from the
time of change of the MV is collected for further calculations and the values of P,I and D are
calculated using Ziegler Nichols tuning rules. The P, I and D values are then used for closed loop
test, load disturbance and set point test. It is found that there still oscillations occur and the value
of P needs to be change to prevent oscillations. For set point and load disturbance test, the
process is not oscillatory and move towards set point.

INTRODUCTION
Control in process industries refers to the regulation of all aspects of the process. Precise control
of level, temperature, pressure and flow is important in many process applications. Process
control refers to the methods that are used to control process variables when manufacturing a
product. For example, factors such as the proportion of one ingredient to another, the temperature
of the materials, how well the ingredients are mixed, and the pressure under which the materials
are held can significantly impact the quality of an end product
The importance of process control are refining, combining, handling, and otherwise
manipulating fluids to profitably produce end products can be a precise, demanding, and
potentially hazardous process. Small changes in a process can have a large impact on the end
result. Variations in proportions, temperature, flow, turbulence, and many other factors must be
carefully and consistently controlled to produce the desired end product with a minimum of raw

materials and energy. Process control technology is the tool that enables manufacturers to keep
their operations running within specified limits and to set more precise limits to maximize
profitability, ensure quality and safety.
Some basic terminologies related to process control are controlled variable or process
variable PV, manipulated variable (MV), set point (SP) and also disturbance or load variable.
Controlled variable is the parameters that indicate product quality or the operating condition of
the process. Manipulated variable is a process being adjusted (controlled) by a final control
element (such as control valve, damper, motor speed). Set point refers to the desired value of
process variable. Load variable is defined all other affecting variable, other than the one being
manipulated. A process control loop consists of four blocks. The four blocks are controller, final
control element, process and sensor. The controller acts as a brain of the control loop. It performs
decision in the control system. Sensor acts by transmitting signals obtained from process to the
controller. Final control element such as control valve implements the decision performed by the
controller.
It is control system in which a control action is applied on the output of the system. Such
system are simply command by the input, an open loop control system is shown in the below
figure. The process is controlled by providing the input to the control of the open loop system to
keep the output at desired level. The set point of the open loop system is also called command.
It is necessary to achieve the ideal operating point for the process and observe the result at the
output manually. The open loop control system are cheaper and less complex.

Figure 1.1: Open Loop System

The closed loop system is one of the control system in which the feedback taken from the output
and then this feedback is feed is applied to the comparator for the comparing with the set point
and the error is then apply to the further circuit. The operation and block diagram of the closed
loop system is shown in the below figure.

Figure 1.2: Closed Loop System

Feedback control involves a process in which the outcome of an action is fed back to the
controller for corrective measures. Feedforward control is anticipate and correct for errors before
they happen. Ratio control is connect two flows to maintain a constant ratio while the cascade
control is sensors which control the set points of other sensors to integrate information. Cascade
control is mainly used to eliminate effect of disturbance. Ratio control does not require a
complex model. Feedback control is simple to design and no process model required.
PID controller is one of the most common forms of closed loop control. The term PID
stands for proportional, integral and derivative. The proportional mode is used to set the basic
gain value of the controller. For open loop analysis, the purpose of integral action is to return the
PV to SP. This is accomplished by repeating the action of the proportional mode as long as an
error exists. With the exception of some electronic controllers, the integral or reset mode is
always used with the proportional mode. For closed loop analysis, adding reset to the controller
adds one more gain component to the loop. The faster the reset action, the greater the gain. Some
large and/or slow process do not respond well to small changes in controller output. To improve
response, a large initial change in controller output may be applied. This action is the role of the
derivative mode. The difference between the measured value and the set point or also known as

error signal is then used to adjust the input to the process so that the measured value will be at
the desired set point. Outputs of process can be adjusted based on history and rate of change of
error signal by using PID.

OBJECTIVE

The objective of the lab work is to perform open loop test, closed loop test, load

disturbance test and set point test using Foxboro controllers systems.
To study the working principle of process control for chemical engineering.

THEORY
Discrete Tangent Method

Figure 1.3: Discrete Tangent Method

Discrete Tangent Method is a current advancement in computing technology allows data
to be collected and recorded numerically. As for the open loop process response, numerical data
can be collected using distributed control system (DCS), supervisory control and data acquisition
(SCADA) and paperless recorder. In discrete tangent method, calculation of response rate RR,
dead time Td and time constant Tc to be calculated for numerical data. This numerical method

requires no measuring on graphs but requires numerical calculation from the data tables obtained
from the process. The equations used to calculate the response rate, dead time and time constant:
Response Rate,
RR =

( P V 1)(PV 1)
2 h MV
Dead time,

PV 1PV i
2

h[
]
Td = t1 P V 1P V 1
Time constant,
P V f PV i
Tc = 2 h[ P V 1P V 1 ]
Where, h= Step size

Tuning Rules for Open Loop Method

1) Ziegler- Nichols
In Ziegler-Nichols tuning rules, only requires values of RR and Td, the ones calculated from
Discrete Tangent Method. Performance tests are in terms of set point and load disturbance.
Below is a table for calculating respective values of P,I and D.
Mode
P
PI
PID

2) Cohen Coon

P
I
3.33RRTd
111.1RRTd
3.33Td
83.3RRTd
2Td
Table 1.1: PID Tunes

D
0.5Td

For this tuning rules require values of RR, Td and Tc. Performance test is in terms of load
disturbance variable. Below is a table for calculating respective values of P,I and D.
Mode
P
PI

P
[100/(1+/3)]RRTd
[100/(1+/11)]RRTd

PID

[100/1.35(1+/5)]RRT

3.33[(1+/11)/
(1+11/5)]Td
2.5[(1+/5)/(1+3/5)]Td

0.37Td/(1+/5)

d
Table 1.2: PID Tunes
Where, = Td/Tc
3) Chien, Hrones & Reswick (CHR)
The settling criteria is no overshoot and minimum response time
Table
Performance
test = Set point
Performance

Mode
P
PI
PID
P

P
3.33RRTd
286RRTd
167RRTd
3.33RRTd

1.2Td
Td

0.5Td

PI

167RRTd

4Td

PID

105RRTd

2.4Td

test =
Disturbance in
load

0.4Td

Table 1.3: PID Tunes

The settling criteria is 20% overshoot and minimum response time
Table
Performance
test = Set point
Performance
test=
Disturbance in

Mode
P
PI
PID
P
PI
PID

P
143 RRTd
167RRTd
105RRTd
3.33RRTd
167RRTd
105RRTd

load
Table 1.4: PID Tunes

Td
1.35Td

0.47Td

4Td
2.4Td

0.4Td

4) Takahashi
Performance test is in terms of disturbance in load variable. Below is a table for calculating
respective values of P,I and D.
Mode
P
PI
PID

P
110RRTd
110RRTd
77RRTd

PROCEDURE
DCS: FOXBORO

I
3.3Td
2.2Td
Table 1.5: PID Tunes

D
0.45Td

a) Open Loop Test for FIC31

1. The Level Control Plant, (WLF922) was selected.
2. FIC31 was selected for the control loops.
3. For viewing the trending, the step are by clicking the File>Additional
FoxView>Change Env (The environment was change to operator).
4. Double clicked at the controller at the new windows of WLF922, then trend button
was clicked.
5. The process response was stabilized by setting the process in Auto mode.
6. The initial value of MV was recorded.
7. The process was changed to manual mode and step change of 10% of MV from the
initial was done.
8. After the slope can be calculated, the process was changed to Auto mode again.
9. The data for the process was printed by selecting the AIM Historian Data Display and
desired data was tagged which are SP, PV and MV.
10. Numerical analysis was done to obtain the data of RR, td and tc.
11. The determination of PI controller setting was calculated using the Ziegler-Nichols
method.
b) Closed Loop Test for FIC31

1. After the calculated value of PI was done, the value then were inserted into the
controller setting of PB and I.
2. After the response has reached the steady state, the optimum controller setting were
recorded.
3. The load disturbance test was done by changing the process response into Manual
mode and change 10% of the current value was done for three seconds and set to Auto
again.
4. The response was observed until it stabilized.
5. The set point test was done by adding the previous value set point with 10% of total
value.
6. The response was observed until it stabilized.
7. The

process

response

than

was

printed

by

following

the

step

START>Program>HyperSnap-DX>HyperSnap-DX>Capture>Active Window.
8. The trending active window was selected and then the image was inverted to black
and white. The process response than was printed.

RESULT
Time (s)
0
1
2
3
4
5

MV (%)
42.4767
42.4767
52.4800
52.4800
52.4800
52.4800

PV (m3/h)
1.1044
1.1044
1.1175
1.3517
1.4766
1.5385

PV (%)

Response

36.81
36.81
37.25
45.06
49.22
51.28

rate (s-1)
0.0220
0.4125
0.5985
0.3110
0.1535

6
7
8
9
10

52.4800
52.4800
52.4800
52.4800
52.4800

1.5686
1.5831
1.5831
1.5940
1.5940

MVi

: 42.4767 %

PVi

: 36.81 %

MVf

: 52.4800 %

PVf

: 53.13 %

52.29
52.77
52.77
53.13
53.13

0.0745
0.0240
0.0180
0.0180
-

MV : 10 %
h

:1s

To change PV (m3/h) to PV (%)

PV (m 3/h)
100
3 m3 /h

1.1044 m3/h
100 =36.81
3 m3/h

Response rate, RR
RR =

PV 1PV 1
2 ( MV ) ( h)

RR1 =

37.2536.81
2 ( 10 ) (1)

= 0.0220 s-1

From the table, the value RR increase until time = 3 and then it keep
decreasing. Response rate for this process is taken at maximum RR
RRmax = RR3 = 0.5985 s-1

Dead time, Td

Td =

T 12 h

42(1)

PV 1PVi
PV 1PV 1

49.2236.81
49.2237.25

= 1.93 s

Time constant, Tc

Tc =

2 h

2(1)

PVf PVi
PV 1PV 1

53.1336.81
49.2237.25

= 2.73 s

Optimum controller setting ( Ziegler-Nichols method)

P = 111.1 RR Td

= 111.1

0.5985

= 128.33 %
I = 3.33 Td
= 3.33

1.933

= 6.44 s = 0.107 min

1.93

DISCUSSION
Open Loop Test
For level control, the system is a non self regulating. So to stabilize the process, it
must be changed to MAN mode. Once the process stabilized, change the MV and in
our case the MV is changed from 42.48 % to 52.48 %. Short time after that, change
the process back to AUTO mode. The set of data from the time of change of the MV
is collected for further calculations. From the numerical data, dead time (Td),
response rate (RR) and time constant (Tc) can be calculated. The maximum
response rate is obtained at time, T: 3 seconds. This means that after 3 seconds the
process slope move downwards for the first time after moving upwards.

Closed Loop Test

The closed loop test is done by using Ziegler-Nichols method to find the
value of proportional, P and integral, I. The Cohen-Coon method is not used
for closed loop test in Foxboro model. For Foxboro model, the P value can be
directly inserted because Kc value is not used. After the value of P and I have
been inserted, the process shown no oscillations and directly stabilized. This
means the value of P and I are accurate for the process and no further

adjustments needed. For set point and load disturbance test, the process is
not oscillatory and move towards set point.

CONCLUSION
Based on the tests for open loop, non-self regulating system which is the
level controller, the system is left in manual mode until slope can be
calculated from the graph. Basically, Open loop test helps to determine
values P and I for the closed loop test.
After the closed loop tests, it was found that there are still oscillations occur
even after the P and I values are calculated using different tuning rules. The
oscillations can be reduced by manipulating the values of P and I. This is
called fine tuning. The value of P is decreased by dividing by 4 until the
oscillations reduced. The Value of I is increased by multiplying by 4 to further
decrease the oscillations

For Load Disturbance test, level controller process have no oscillations occur
which shows correct values of P and I. From Set point tests, level have no
oscillations

RECOMMENDATION

1. Calculation of RR should be four or more decimal places. This may give more
accurate data and leads to better values of P, I and D.
2. While fine tuning, if process oscillates, adjust the P (by dividing by 4). If
oscillation persists, keep reducing the P
3. It is recommended to adjust P and I values one by one not simultaneously.
Adjusting P and I simultaneously can lead to worst oscillation of the process or
even leads to offset.

REFERENCES
1. Abdul

Aziz

Ishak

&

Zalizawati

Abdullah.

(2014).

PID

TUNING

Fundamental Concepts
and Application. UITM Press.
2. Salgado,

Graham

C.

Goodwin,

Stefan

F.

Graebe,

Mario

E.

(2001). Control System

Design.

Upper

Saddle

River,

N.

J.:

Prentice

Hall.

p. 21. ISBN 0139586539.

3. Blanke, M.; Kinnaert, M.; Lunze, J.; Staroswiecki, M. (2006), Diagnosis
and
Fault-Tolerant Control (2nd ed.), Springer

4. H. Bischoff*, D.Hoffmann*, E.V.Terzi. (1997). Process Control System,

Control of
Temperature, Flow and Filling Level. Festo Didactic GmbH & Co

APPENDICES