Foxboro

Time (s)

MV (%)

PV (m3/h)

PV (%)

72.85

2.2961

76.54

72.85

2.2961

76.54

72.85

2.2961

76.54

87.85

2.2961

76.54

0.0357

87.85

2.3283

77.61

0.1063

87.85

2.3920

79.73

0.1080

87.85

2.4256

80.85

0.0587

87.85

2.4448

81.49

0.0340

87.85

2.4562

81.87

0.0127

87.85

2.4562

81.87

10

87.85

2.4562

81.87

Flow (fic31)

Calculation
Process span = 3 m3/h
MVi

= 72.85%

MVf

= 87.85 %

MV

= 15.00 %

=1s

PVi

=76.54 %

PVf

= 81.87 %

PV

= 5.33 %

Response rate
(s-1)

PV (%)

RR

PV (m 3 / h)
3m 3 / h

PV1 PV1
2 h MV

From the table, notice that RR increases until time = 5 s, then it keeps
decreasing. Response rate for this process is taken at maximum RR.
RRmax = RR5 = 0.108 s-1
Dead time, Td:
Td T1 2 h

PV1 PVi
PV1 PV1

80.85 76.54

Td 6 2 1

80.85 77.61

Td 3.34s

Time constant, Tc:

Tc 2 h
Tc 2 1
Tc 3.29 s

PV f PVi
PV1 PV1

81.87 76.54
80.85 77.61

Optimum controller setting ( Ziegler-Nichols method)

P 111.1 RR Td
P 111.1 0.108 3.34
P 40.076

I 3.33 Td
I 3.33 3.34
I 11.122 s
I 0.185 min

1 min
60 s

DISCUSSION
Open loop test
In an open loop system, a process can be either a self-regulating or a nonself-regulating process. For this experiment using Foxboro, FIC31 was chose
for the open loop test. Flow is a self regulating process whereby the system
stabilizes the process on its own without have to change to MAN mode. Once
the process stabilized, MV should be changed and in our case the MV is
changed from 30 % to 50 %. 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: 5 seconds. This means that after 5
seconds the process slope move downwards for the first time after moving
upwards. From RR, Td, and Tc, by using Ziegler-Nichols method is being used
to calculate PI controller setting values. All the data and calculation can be
seen in the calculation part.

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. From open loop test, value of
proportional, P = 40.076 and integral, I = 0.185 min. After the value of P and
I have been inserted, the process show oscillations. This means the value of
P and I are not accurate for the process and further adjustments needed. The
suitable value of proportional will not produce any error that will cause the
oscillation. For set point and load disturbance test, the process is not
oscillatory and move towards set point.

PROCEDURE
DCS FOXBORO
Open Loop Test for FIC31
1. The Flow Control Plant 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.

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 which is 80m3/h.
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.

OBJECTIVE
The objective of the lab is to perform an open loop test, closed loop test, load
disturbance test and set point test using Emerson and Foxboro controller
systems.

t Td

Time

Tangent Line

THEORY
1. Graphical Tangent Method
MVf

MV

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

Figure 1: 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 2.1. Like Td, Tc is measured the
same way on the graph.

Time

The response rate, RR is calculated by:

PV
RR t
MV

Where,
PV = PVf PVi
MV = MVf MVi

2. Reformulated Tangent Method

Figure 2: 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 2.2, there are angles and and on the both of the axis
there are b and a. b and a are scaling factors to be used in the calculation of
RR.
Dead time, Td is calculated by,
Td (time) = Td (length by ruler) x b
Where,
b = (increment of time on the axis scale)/(length of each interval)
The response rate, RR is,
tan
MV

RR

Time constant, Tc is,

Tc(time) = Tc(length) x b

2.1.3 Discrete Tangent Method

(Td , PVi)
PVf
PV1
Tangent Line

PVo
PV-1
(Td , PVi)
h
PVi
t-1

t-o

t1

Time

Figure 2.3 : 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

PV1 PV1
2 h MV

The time constant, Tc,

Tc 2 h

PV f PVi
PV1 PV1

The dead time Td,

Td T1 2 h

PV1 PVi
PV1 PV1

2.1.4 Ziegler-Nichols Tuning rules

In Ziegler-Nichols tuning rules, only requires values of RR and Td. These
values are the ones calculated from tangent, reformulated tangent or
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

P
3.33RRTd
111.1RRTd
83.3RRTd
Table 2.1

3.33Td
2Td
: PID tunes

0.5Td

2.1.5 Cohen-Coon Tuning Rules

Another Tuning rule is Cohen-Coon Tuning rules. For this tuning rules require
values of RR, Td and Tc. Performance test is in terms of load disturbance
variable.
Mode
P
PI
PID

P
[100/
(1+/3)]RRTd
[100/
(1+/11)]RRTd
[100/1.35(1+/5)
]RRTd
Table

3.33[(1+/11)/
(1+11/5)]Td
2.5[(1+/5)/
(1+3/5)]Td
2.2 : PID tunes

0.37Td/(1+/5)