THEORY

a) Graphical Tangent Method

This method is used in the calculation to find RR and graphically find Td. RR and Td is
found on a process curve graph.

PVf

Tangent Line

PV

PVi

Td t
Time

MVf
MV
MVi
Time

Figure (a): Graphical Tangent Method

Dead time (Td) is the time between the beginnings of the open loop test to the foot of the
triangle. The dead time is measured directly on the graph (using ruler).

For Tangent Method, t is equal to Tc which is the time constant of the process. It is from
the front foot of the triangle (after the end of Td) towards the end of the triangle as shown
on Figure (a). Like Td, Tc is measured the same way on the graph.
The response rate, RR is calculated by:
/
RR =

/
=

Where,
PV = PVf PVi
MV = MVf MVi

b) Reformulated Tangent Method

PVf

Tangent Line

a PV

PVi

Td t
Time
b

MVf
MV
MVi
Time

Figure (b): Reformulated Tangent Method

Reformulated Tangent Method is an alternative to tangent method and is quite similar. Instead
of calculating the RR using distance by a ruler, reformulated tangent method allows the
calculation in forms of trigonometric functions.

Based on figure (b), there are angles and and on the both of the axis there are b (scaling
factor for x-axis) and a (scaling factor for y-axis). b and a are scaling factors to be used in the
calculation of RR.

The response rate, RR is,

tan
RR=

Dead time, Td is calculated by,

Td (time) = Td (length by ruler) x b

Where,

increment of time on the axis scale

b=
length of each interval

Time constant, Tc is calculate by,

Tc (time) = Tc (length) x b
c) Discrete Tangent Method

(Td , PVi)

PVf

PV1

Tangent
PVo
Line

PV-1

(Td , PVi)

h
PVi

Time
t-1 t-o t1
Figure (c): Discrete Tangent Method

Some data are in the forms of numerical and tables. 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. Figure 2.3 shows what the graph looks like
if plotted from the data tables.

To calculate response rate, RR

1 1
RR =
2

The dead time, Td

Td (s) = 1 (2)( 1 )
1 1

The time constant, Tc

Tc = (2)( )
1 1
d) PID tuning rule
i) Zigler Nichols tuning rule:
Settling criteria QAD; Performance tests Set point & Disturbance in load variable

Mode P I D
P 100 (RR) (Td)
PI 111.1 (RR) (Td) 3.33 (Td)
PID 83.3 (RR) (Td) 2 (Td) 0.5 (Td)

ii) Cohen-Coons tuning rule:

Settling criteria QAD; Performance tests Disturbance in load variable

Mode P I D
P 100
(RR) (Td)
1+
3

PI 100
(RR) (Td) 1+
11
1+
11
3.33 [ 11() ](Td)
1+
5

PID 100
(RR) (Td) 1+

5
0.37 (Td )
1.35(1+ ) 2.5 [ ] (Td)
5
1+
3() ()
5 1+
5

Where =

iii) Takahashi tuning rule:

Settling criteria minimum control area; Performance test Disturbance in load
variable

Mode P I D
P 110 (RR) (Td)
PI 110 (RR) (Td) 3.3 (Td)
PID 77 (RR) (Td) 2.2 (Td) 0.45 (Td)
PROCEDURE
ii) DCS: Foxboro
a) Open loop test
1. Water Flow and Level Control Plant (WLF922) was selected.
2. The selected control loop which is level control (LIC31) was activated.
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,
Cohen-Coons and Takahashis tuning method.
b) Closed loop test

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 process
span value which is 800mm.
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.
9. The procedure were repeated for Cohen-Coons and Takahashis tuning method.
RESULT
ii. DCS: Foxboro
a) Open loop test
Time (s) Process Variable, PV Process Variable, PV Response Rate, RR
(mm) (%)
0 400.92 50.115

1 400.92 50.115 0.0022

2 401.27 50.159 0.0030

3 401.41 50.176 0.0053

4 402.13 50.266 0.0144

5 403.73 50.466 0.0250

6 406.14 50.768 0.0270

7 408.09 51.011 0.0230

8 409.86 51.232 0.0200

9 411.31 51.414 0.0250

10 413.84 51.730 0.0220

11 414.91 51.864

Dead time (Td) and Time Constant (Tc) for maximum response rate (RR max)
RR max Dead Time ,Td (s) Time Constant, Tc (s)
0.0270 3.29 6.42
b) Closed loop test
Zigler Nichols Cohen-Coon Takahashi

Tuning P= 9.87 P= 8.49 P= 9.77

I= 10.96s @ I= 5.39s @ 0.089min I= 10.857s @

0.183min 0.181min
Set point test SPinitial= 400mm SPinitial= 400mm SPinitial= 400mm

SPfinal= 500mm SPfinal= 480mm SPfinal= 480mm

Load disturbance MVinitial= 32.7% MVinitial= 32.7% MVinitial= 32.7%
test
MVfinal= 42.78% MVfinal= 42.78% MVfinal= 42.78%
SAMPLE OF CALCULATION
a) Open loop test
Process span = 800mm
Initial manipulating variable, MVi = 33.5280%
Final manipulating variable, MVf = 43.5300%
Manipulating variable different, MV = MVf MVi
= (43.5300 33.5280) %
= 10.002%
Step size, h =1
Before calculate the value of response rate, the value of process variable that are in unit
mm should be convert into percentage (%).

Conversion process variable, PV (mm) to process variable, PV (%) = 100%
400.92
= 100%
800

= 50.115
1 1
Response rate, RR=
2
50.15950.115
=
2110.002

= 0.0022
Time delay, Td and time constant, Tc are calculated for the maximum response rate.
The maximum response rate, RRmax = 0.0270

Time delay, Td (s) = 1 (2)( 1 )
1 1

51.01150.115
= 7 (21)(51.01150.466)

= 3.29s

Time constant, Tc (s) = (2)( )
1 1

51.86450.115
= (21)(51.01150.466)

= 6.42s
b) Closed loop test
The process control used for DCS: Foxboro was level control, so the PID tuning controller
for the level process control is PI controller:
i) Zigler Nichols tuning rule
P = 111.1 (RR) (Td)
= 111.1 (0.027) (3.29)
= 9.87
I = 3.33 (Td)
= 3.33 (3.29)
= 0.183s
ii) Cohen- Coons tuning rule
100
P= (RR) (Td) where =
1+
11

100 3.29
= 0.512 (0.027) (3.29) =
1+ 6.42
11

= 8.49 = 0.512

1+
11
I = 3.33 [ 11() ] (Td)
1+
5

0.512
1+
11
= 3.33 [ 11(0.512) ] (3.29)
1+
5

= 5.39s @ 0.089min
iii) Takahashis tuning rule
P = 110 (RR) (Td)
= 110 (0.027) (3.29)
= 9.77
I = 3.3 (Td)
= 3.3 (3.29)
= 10.857s @ 0.181min
DISCUSSION
ii) DCS: Foxboro
a) Open loop test
For DCS: Foxboro equipment, the process used is level control process. Level
control process is non self-regulating process. A non self-regulating process is one where
the process does not tend towards self-regulation. These process have no self-regulating
feedback characteristics and will tend towards being unstable if not controlled externally.
When the Manipulating Variable (MV) in open loop test are change it will cause the Process
Variable (PV) to start increasing or decreasing and it keeps moving in that direction in a
mostly linear mode. To stabilize the process, it must be changed to AUTO mode. Once the
process is stabled, the initial MV which is 33.5280% are change to the final MV which is
43.5300%. It is a 10% step changes of the MV. In order to change the MV, it must be change
to MAN mode first it is because when in AUTO mode the MV cannot be change, it set the
MV automatically. The set of data are collected from the time of change of the MV for the
further calculations. From the numerical data collected, response rate (RR), dead time (Td)
and time constant (Tc) are calculated. The method used for calculate all these characteristics
is numerical analysis or discrete tangent method. Dead time and time constant for numerical
analysis are calculated based on the maximum response rate. The maximum response rate
is obtained at 7s, which is 0.027/s. Dead time and time constant calculated are 3.29 s and6.42
s respectively.

b) Closed loop test

The closed loop test is done by using Ziegler Nichols, Cohen-Coons and
Takahashis tuning rule. All these tuning rule are used to calculated the value of P and I.
The value of P and I only are calculated because level process is a fast response and it only
used P and I value for tuning. The calculated value of P and I for every tuning rule show
slightly different. The value for the P and I for Ziegler Nichols tuning rule are 9.87% and
10.96s respectively, for Cohen-Coons tuning rule are 8.49s and 5.39s and for Takahashis
tuning rule are 9.77% and 10.857s. After the value of P and I have been inserted for tuning,
no oscillations occur to the process variable and directly stabled for each tuning rule. This
means all the value of P and I are optimum for the process and there is no need for further
adjustment or tuning. Then, the load disturbance test are done. The purpose of doing the
load disturbance test is to give a disturbance to the process and to check whether the set
 point of the process can be reached or not. The process are disturbed for a while the move
back towards the set point.

REFERENCES

1) Ishak, A. A; Abdullah. Z. (2016), PID Tuning Fundamental concepts and application. UiTM
Press, Kuala Lumpur

2) Process Control Fundamental. Retrieved at June 7th, 2017 from

https://www.techtransfer.com/blog/process-control-fundamentals/

3) The PID Tuning Blueprint. Retrieved at June 7th, 2017 from

https://www.pidtuning.net/article1-PID-Types.php