Lalu Seban, Assistant Professor, Dept.

of E&IE, NIT Silchar

Industrial Process Engineering Laboratory
Laboratory questions for 28/03/2014
1. Design P, PI and PID controller for the control of a heating process which is found to have the following
dynamics
1
( )
0.5 1
f
G s
s

2.2
0.236
( )
(7 1)(5 1)
s
p
G s e
s s

( ) 1
m
G s

I. Use Cohen Coon (CC) open loop method (Process reaction curve method) for finding the parameters
(tuning)
II. In P-only controller, change the value of
P
K by 25% from the tuned value and analyse the effect on rise
time (
r
t ), % overshoot (%OS ), peak time (
p
t ), oscillations, settling time (
s
t ), steady state error (
ss
e ), ISE,
IAE, ITSE, ITAE for closed loop performance with unit step change in set point.
III. In PI controller, change the value of
I
T by 25% from the tuned value and analyse the effect on rise time (
r
t ), % overshoot (%OS ), peak time (
p
t ), oscillations, settling time (
s
t ), steady state error (
ss
e ), ISE, IAE,
ITSE, ITAE for closed loop performance with unit step change in set point. (Keep the value of
P
K unchanged
as the CC value)
IV. In PID controller, change the value of
D
T by 25% from the tuned value and analyse the effect on rise time
(
r
t ), % overshoot (%OS ), peak time (
p
t ), oscillations, settling time (
s
t ), steady state error (
ss
e ), ISE, IAE,
ITSE, ITAE for closed loop performance with unit step change in set point. (Keep
P
K and
I
T values
unchanged as the CC value)
V. Analyse the effect of ,
P I
K T and
D
T on output dynamics:
Controller
Parameter
r
t
p
t
s
t
%OS Oscillation
s
ss
e
I
n
c
r
e
a
s
e
s

P
K

I
T

D
T


2. Test the ability of designed PID controller for disturbance rejection. Give disturbance in the form of pulse with
magnitude = -0.5, Time period = 200s and duty cycle = 5% to the process (add with the real process output, Note:
summation should be before the feedback). And analyse the closed loop performance.
3. If the FCE is subjected to constraint that it will get saturated at -4 and +4. Analyse the closed loop performance.
Note:
1. Simulation time should be high enough to understand the dynamics properly.
2. In all closed loop analysis, use two scopes. (Scope 1: Process output and Set point; Scope 2: Controller
output and Final control element output).
3. See Appendix -1, for some guidelines for Cohen Coon tuning method.


Lalu Seban, Assistant Professor, Dept. of E&IE, NIT Silchar
Appendix - 1
The Cohen-Coon (C-C) Process reaction curve method is a PID tuning technique which uses the open loop step analysis
for finding the parameters of PID controller for the closed loop system. The steps to follow are given below.
i. Detach the controller from the closed loop system. The input is given as the manipulated variable (to the final
control element). The output is taken from the process (in reality the sensor circuit output). So C-C method checks
the dynamics of final control element, process (and sensor) in the test for finding the tuning parameters.
ii. Make sure the process is at an initial steady state.
iii. Introduce a step change in the manipulated variable.
iv. Wait until the process settles at a new steady state.
v. From the reaction curve (output response) to the step change at input, find its approximate FOPTD (First Order Plus
Transport Delay) model. (Identify gain K , time constant , transport/time delay )
vi. Identify the PID parameters from the table provided by Cohen Coon.