LAB REPORT CPE622: PID TUNING
Wan Nur Izzati Fadhlin Binti Azmi (2017550253), Nik Fadhullah Syafiq Aiman Bin Fauzi (2019794689),
Amiruddin bin Abdullah (2019574141)
Summary
For regulation of speed, temperature, flow, pressure and
other process variables, a PID controller can be used. The
main aim of the experiment is to perform an open loop and
closed loop test to verify the optimal condition for the loop
method for process control. There are two systems used for
the tests: DCS FOXBORO and DCS DELTA-V Emerson.
The flow control loop of FOXBORO and EMERSON both
demonstrate a slightly nonlinear process response
relation and a manipulated variable. A decrease in the gain
of the controller, Kc value, slows down the response of the
process, PV, and shifts the curve of process response to the
right. A rise in the value of PB slows down the response of
the process, PV, and moves the curve of process response to
the right. An increase in I would result in a slower response
to the process, with PV pushing the curve of the process
response to the right. Compared to the Tangent method and
the Reformulated Tangent method, the numerical method
yields the most detailed data corresponding to the tuning
rules.
I. INTRODUCTION
The acronym for Proportional-Integral-Derivative
Controller is PID Controller. A common instrument used in
industrial control applications is a PID controller. For
regulation of speed, temperature, flow, pressure and other
process variables, a PID controller can be used. Field mounted
PID controllers can be placed close to the sensor or the control
monitoring device and be supervised centrally using a
SCADA system (How Do PID Controllers Work: Application
& Theory, 2014). As the difference between a desired fixed
point, SP and a calculated process element, PV, a PID
controller measures an error value continuously, E and applies
a correction based on proportional, integral and derivative
terms. By changing the control variable, CV, such as the
opening of the control valve, to a new value determined by a
weighted sum of the control conditions, the controller attempts
to decrease the error over time. The definition that will be
manipulated in this laboratory is proportional, integral,
derivative and deadtime respectively.
P is a short proportional notation, but PB
(proportional band) is a common word that has a unit
percentage used in most industrial controllers (percent). Term
P is proportional to the present value of the error generating
SP − PV, E. If the error is large and positive, for example, the
control output would be proportionately large and positive,
taking into account the 'Kc' gain factor. There is no correction
answer when there is no mistake. The behavior of P does not
change the process order. P behavior does not remove offset,
which is the difference between setpoint and steady state
value, but the offset is decreased by a higher gain.
I is a short integral notation that has a time unit such as
second(s) or minute (min). Term I accounts for the SP-PV
error's previous values and combines them to generate the I
term over time. For example, if after the application of
proportional control there is a residual SP − PV error, the
integral term seeks to remove the residual error by introducing
a control effect due to the historic cumulative value of the
error. Term I also remove steady-state offset since the gain of
closed-loop transfer functions is 1. The mistake is avoided
when the integral term is increased. As the error decreases,
this will result in the proportional effect decreasing, but this is
compensated for by the increasing integral effect.
D is a short derivative notation that has a time unit such as
second (s) or minute (min). Term D, based on its current rate
of change, is the best approximation of the potential SP-PV
error pattern. It is often referred to as "anticipatory control"
because, by exerting a control influence produced by the rate
of error shift, it effectively seeks to reduce the effect of the
SP-PV error. The more rapid the change, the greater the
controlling or dampening effect.
The controller algorithm is split into two controllers, the
algorithm controller for the analog controller and the
algorithm controller for the digital controller. Both algorithms
are shown as follows:
Analog controller algorithm:

An output value which is proportional to the current
error value is provided by the proportional term, P. By
multiplying the error with a constant (Kc), called the
proportional gain constant, the proportional response can be
modified. For a given change in the error, a high proportional
gain results in a large change in the output. The system can
become unstable if the proportional gain is too high. A small
gain, by comparison, results in a small output response to a
large input error and a controller that is less responsive or less
sensitive. If the proportional gain is too low, when responding
to device disturbances, the control action can be too little. The
rise in P makes the control operation slower since P is
inversely proportional to the variables manipulated (MV). As
MV is directly proportional to PV, a slower action of MV
would result in a slower process response (PV). By moving
the process response curve to the right, a slower process
response is indicated (Abdul Aziz Ishak, 2018). It can be
assumed that the greater the P value, the lower the overshoot
and the lower the oscillation, resulting in a shorter time to
settle. When the controller doesn’t have the overshoot, it
means that the process variable had achieve the set point
target.
I is proportional to both the magnitude of the
error and the length of the error by the contribution from the
integral term. In a PID controller, the integral is the sum of the
instantaneous error over time and the cumulative offset that
should have been previously corrected. The accumulated error
is then multiplied (Ki) by the integral gain and applied to the
output of the controller. The integral term speeds up the
process movement to the set point and removes the remaining
steady-state error with a pure proportional controller.
However, since the integral term responds to past cumulative
errors, it may cause the present value to overshoot the value of
the set point. An increase in I makes the controller action
slower since I is inversely proportional to manipulated
variables (MV). As MV is directly proportional to PV, a
slower action of MV would result in a slower process response
(PV). By moving the process response curve to the right, a
slower process response is indicated (Abdul Aziz Ishak,
2018). The higher the value of I, the lower the overshoot and
less oscillation, can be inferred, resulting in shorter settlement
time.
The process error derivative, D, is determined
by calculating the error slope over time and multiplying this
change rate by the derivative gain (Kd). The amount of the
derivative term's contribution to the overall control operation
is termed as the derivative gain, Kd. Derivative behavior
predicts system conduct and therefore increases the system's
settling period and stability. An ideal derivative is not causal,
so that implementations of PID controllers include an
additional low-pass filtering for the derivative term to limit the
high-frequency gain and noise. Derivative action is seldom
used in practice though because of its variable impact on
system stability in real-world
applications. An increase in D makes the controller action
faster since D is directly proportional to manipulated variables
(MV). A rise in D makes the control action quicker since D is
directly proportional to the variables that are controlled (MV).
As MV is directly proportional to PV, a quicker action of MV
would result in a faster process response (PV). By moving the
process response curve to the left, a quicker process response
is indicated (Abdul Aziz Ishak, 2018). It can be assumed that
the greater the value of D, the greater the oscillation and the
greater the overshoot, resulting in a longer settling time.
In the temperature application, one of the PID controller
applications is A standard application of the PID temperature
controller could be used to continuously vary a regulator that
can modify a process temperature. For electrical heaters or by
opening and closing a gas valve, this could be a pulsed
switching system. A reverse output operation, where more
power is applied when the temperature is below the set point
and less power when above, is used by a heat only PID
temperature controller. PID control also utilizes additional
cooling control outputs for injection and extrusion applications
and typically includes several controllers. A PID controller
reads the sensor signal, typically from a thermocouple or
RTD, and converts the measurement to Degrees C engineering
units. To determine an error, it subtracts the measurement
from the desired set point (How Do PID Controllers Work:
Application & Theory, 2014). …
II. THEORY
A. Linearity
The linearity test attempts to determine whether
or not the relationship between the dependent variable
and the independent variable is linear. The linear
relationship between the dependent variable and the
independent variable should be a successful regression
model. The variable that is changed or monitored in a
scientific experiment to assess the impact on the
dependent variable is an independent variable (MV). In a
scientific experiment, a dependent variable (PV) is the
variable being evaluated and measured. We adjust the
MV steps progressively from 0 to 10 percent until 100
percent to perform this test. Answer to PV is observed.
Pv should shift with MV; if MV is already approaching
100 percent PV, the optimal set point (SP) should have
been achieved if the method is not lacking in efficiency.
Then, to observe the graph where you can see a straight
line with no curves, one simply has to plot a graph of
MV against PV for this experiment with full range
availability. We may deduce, upon confirmation, that
MV is directly proportional to PV.
Figure 1 - Example of linear (left) and non-
linear graph (right).
However, in a case with limited range, use percentage
change to determine linearity of a process:
PV1−PV2
MV1−MV2
1) If the value shows significant deviation from
linearity = 0 then the relationship between the
independent variable and dependent variable is linear.
2) If the value shows significant deviation from
linearity > 50 % then the relationship between the
independent variable and dependent variable is highly
non-linear.
3) If the value shows significant deviation from
linearity <50 % then the relationship between the
independent variable and dependent variable is slightly
non-linear.
B. Open Loop Test
Open-loop systems are simple systems since
they operate solely on the basis of the input (MV) and do
not use self-correct feedback from the output. A manual
process, also referred to as a non-feedback system, is the
open loop test. The open-loop response test is very
important and beneficial, enabling plant or refinery
workers to define the process by determining:
1) Process dead time (Td)
2) The process time constant (Tc)
3) Response rate (RR)
New controller settings can be measured and
implemented using these values. Tc is the lag time or
time taken for the process to be constant, more precisely
reflecting the time required for the PV to reach 63.2% of
its total, In the meantime, RR is the response rate and the
faster the better, and Td Dead time is the delay from
when the output of a controller (CO) signal is given until
the first response of the calculated process variable (PV).
Such values are essential parameters that lead to
improvements in loop efficiency, better overall process
control and improved productivity.
There are many methods that can be used to find the
values such as tangent method,
Reformulated tangent method and numerical method
Figure 2 - Example of a graph
Tangent Method
A tangent line should be drawn at the steepest point
of a process response curve as shown in figure 2. Using
tangent method we can determine the response rate(RR)
and dead time (Td) of a process. The process response
rate(RR) is the process change (ΔPV) per change in time
(Δt) as shown below:
Meanwhile, Dead time Td (s) = td × b

Reformulated Tangent Method
This method is simpler compared to tangent method.
This method uses angle.
RR = tanθΔMV×ab
Dead time Td (s) = td × b
There are three ways used to calculate time constant.
1) Tangent:
a. Tc = tc x b
2) Two point:
a. Tc = 1.5 x (T63.2 – T28.3) x b
3) Tangent and a point:
a. Tc = ( T63.2 – Td) x b
C. PID Setting and Closed Loop
The alphabet of PID, controllers refers to the modes of
proportional, integral and derivative power they provide.
They are commonly used in industrial automated process
control applications. To regulate flow, temperature,
pressure, level, and many other variables of the
industrial process, PID controllers can be used. For
almost every operation, proportional control can be used.
For processes such as flow, pressure and level, PI
control is suitable. Meanwhile, when dealing with a slow
response process such as temperature, the PID controller
that mixes the benefit of proportional, derivative and
integral control action is ideal for use. The job of a PID
controller is to force feedback to match a set point in a
closed loop system.
Closed loop description. : An automatic control
system in which input is used as a mechanism, process,
or operation. It is commonly used in industrial systems
and a range of other applications that require
continuously automatic modulated control. Close loop
uses the controller's PID environment, a process
control's PID value can be calculated based on their
settling requirements using the tuning rule.
Some of the tuning rule that we uses in this experiment
is Ziegler Nichols and Cohen-Coon.
1) Ziegler Nichols :
2) Cohen-Coon :
D. Process Stability
Process reliability refers to the process's consistency, so we
can assume that the process is stable or in control whether the
process behaves consistently over time. There is less error,
less oscillation, less damping and more smooth running. An
error between feedback and set point is often triggered by a
change in set point and load change, so performance
monitoring is key to enhancing process reliability. The
performance test is a test that intentionally introduces
disturbance to the process. In this experiment, the output test
is set point and disturbance of load, we adjust the set point and
load of the process to observe the response. If the response is
not consistent, we can change the PID values of the controller
to enhance loop efficiency and lead to better overall process
control and improved productivity. Some of the theories of
tuning:
•When the value of PB is decreases, the process response
becomes faster.
•When the value of I is decreases, the process response
becomes faster.
•When the value of D is increases, the process response
becomes faster.
This is because MV, though directly proportional to D, is
inversely proportional to PB and I. MV is also directly
proportional to the process response at the same time (PV).
 E. Description of
1) PID CONTROLLER
\
A control loop mechanism typically used in industrial
control systems and other applications requiring continuously
modulated control is a proportional-integral-derivative (PID)
controller. The PID controller, as indicated by its name,
combines proportional control with additional integral and
derivative modifications, allowing the device to compensate
for system changes automatically.
PID controllers are commonly used in a variety of
industrial applications and account for approximately 95% of
the industrial automation industry's closed-loop operations. Feedback Control
They can be found for location control and temperature
regulation of mass quantities of fluid in anything that can take The operator's control task is called feedback control,
days to adjust by a single degree. because the operator changes the firing rate based on feedback
through the temperature gauge that he gets from the process.
PID controller basics As described here, feedback control can be done manually, but
it is usually done automatically, as will be explained in the
next section.
A control loop is formed by the operator, valve, process,
and temperature gauge. The temperature that is fed back to the
operator, thus closing the loop, is affected by any change the
operator makes to the gas valve.

The main function of the PID controller as a feedback
controller is to force feedback to meet a fixed point, such as a
climate control device that forces a heating or cooling unit to
turn on or off depending on a set ambient temperature. Other
process variables, such as velocity, pressure, and flow, are also
governed.
It is safe to assume that PID control operates just the
same as the cruise control system on a vehicle, where external
factors such as steep hills will reduce speed. A PID framework
will use an algorithm in this application to return the vehicle to
its setpoint speed by monitoring the vehicle's engine's power
output as it moves up and over the hill. Before the invention of
microprocessors, PID control was achieved by analog
electronic components. Today, however, all PID controllers
are handled by microprocessors.
Manual Control
Automatic Control
The control feature can be automated with a PID controller to
relieve the operator from the boring task of manual control.
They need the following:
 Install an electronic temperature measurement device
 Automate the valve by adding an actuator (and
perhaps a positioner) to it so that it can be driven
electronically
 Controller, and connect it to the electronic
temperature measurement and the automated control
valve
A PID controller has a fixed point (SP) which can be set to the
desired temperature by the operator. The Output (CO) of the
Controller sets the location of the control valve. And the
temperature calculation, called the Process Variable (PV),
provides the much-needed input to the controller. Present,
voltage or digital signals are transmitted to the process
variable and controller output (Figure 2).

All regulation tasks have to be done manually without

automatic controllers. For example, an operator must monitor
a temperature gauge and adjust a fuel gas valve accordingly to
keep the temperature of water discharged from an industrial
gas-fired heater constant (Figure 1). If, for some reason, the
water temperature becomes too high, the operator must close
the gas valve a bit, just enough to return the temperature to the
desired value. He has to open the gas valve if the water gets
too cold.

The PID controller receives the process variable signal when
all is up and running, compares it to the set point and measures
the discrepancy between the two signals, also known as the
Error (E). The controller then determines an effective
controller output based on the error and the tuning constants of
the PID controller, which sets the control valve to the correct
position to preserve the temperature at the set point. If the
temperature should rise above its set point, the controller will
reduce the valve position and vice versa.
PID Control
PID controllers have three control modes:
 Proportional Control
 Integral Control
 Derivative Control
Each of the three modes reacts differently to the error. The
amount of response produced by each control mode is
adjustable by changing the controller’s tuning settings.
2) P, I & D ACTIONS
P, PI and PID control
If devices have a PID (proportional-integral-derivative)
control function, this means that three forms of control can be
realized: P, PI, and PID.
P Control
The power of output is directly proportional to the error of
control. The higher the coefficient of proportion, the lower the
power of output at the same control error. For fast-response
systems with a high transmission coefficient, proportional
control can be suggested. You can first set the maximum
proportion coefficient where the output power decreases to
zero in order to change the propotional regulation.
Set a defined value when the calculated value is stabilized
and progressively reduce the proportion coefficient and the
control error will decrease. If there are periodic oscillations in
the device, the coefficient of proportion should be increased so
that the control error decreases to the limit with minimal
periodic oscillations.
PI Control
Output power equals the sum of the coefficients of proportion
and integration. The higher the coefficient of proportion, the
lower the power of output at the same control error. The
greater the coefficient of integration, the slower the coefficient
of integration that is accumulated. PI control provides zero
error in control and is immune to measurement channel
interference.
Slow response to disruptions is the PI control
disadvantage. You can first set the integration time equal to
zero and the maximum relative time to change the PI
controller. Then, by decreasing the proportionality coefficient,
the system achieves periodic oscillations.
Near to the optimum value, the proportionality coefficient is
twice the value of any hesitation, and close to the optimum
value of the integration time constant, which is 20% less than
the oscillation period.
PID Control.
The output power is equal to the number of three proportional,
integral and differential coefficients. The higher the
coefficient of proportion, the lower the power of output at the
same control error. The greater the coefficient of integration,
the slower the coefficient of integration that is accumulated.
The higher the coefficient of differentiation, the greater the
system's response to the disturbance.
The PID controller is used in inertial systems where the
measuring channel has a relatively low noise level. The
benefit of PID is rapid warm-up time, precise temperature
regulation of the setpoint and quick reaction to disturbances.
PID manual tuning is incredibly complex, so using the
autotune function is recommended.
F. Proportional, Integral, Derivatives (PID)
Tuning Effect on Process Output
The process of setting the optimal gains for P, I and D to get
an ideal response from a control system is called tuning.
Before the working of the PID controller takes place, it must
be tuned to suit with dynamics of the process to be controlled.
Designers give the default values for P, I, and D terms, and
these values couldn’t give the desired performance and
sometimes leads to instability and slow control performances.
In this method, the controller of I and D terms are set to zero
first and the proportional gain is increased until the output of
the loop oscillates. As one increases the proportional gain, the
system becomes faster, but care must be taken not make the
system unstable. Once P has been set to obtain a desired fast
response, the integral term is increased to stop the oscillations.
The integral term reduces the steady state error, but increases
overshoot. Some amount of overshoot is always necessary for
a fast system so that it could respond to changes immediately.
The integral term is tweaked to achieve a minimal steady state
error. Once the P and I have been set to get the desired fast
control system with minimal steady state error, the derivative IV. To undergo fine tuning to achieve the optimum PI
term is increased until the loop is acceptably quick to its set controller setting.\
point. Increasing derivative term decreases overshoot and V. To calculate either the response curve is linear,
yields higher gain with stability but would cause the system to slightly non-linear or roughly non-linear.
be highly sensitive to noise. VI. To find the Td, Tc and RR value using tangent
method, reformulated tangent method and numerical
The desired closed-loop system performance can be achieved tangent method
with an appropriate adjustment of controller settings. VII. To calculate the PB and I value using Ziegler
Hundreds of tools, methods and theories are available for Nichol’s and Cohen-Coon’s method.
tuning the PID controller. However, finding optimal
parameters for the PID controller is still a tricky task, in
practice still the trial and error method is used for tuning IV. PROCEDURES
process by the control engineers. The controller can
provide optimized control action, and minimized error
performance with optimum tuning of the three parameters in The methodology of this experiment is discussed below:
the PID controller algorithm.
DCS: DELTA-V EMERSON
G. Example of PID Application in Real Life Open Loop Test
Process
1. Select the control loops:

At present, there are various kinds of PID controllers are a) Gas Pressure Control Plant
available in the market. These controllers are used for i. PIC91
industrial control requirements like pressure, temperature,
level, and flow. The standalone type PID controllers provide ii. PIC92
several fixed-point configurations to produce the autonomous b) Gas Flow Temperature Plant
several alarms. These standalone controllers mainly comprise i. FIC91
PID controllers from Honeywell, temperature controllers from
Yokogawa, autotune controllers from OMEGA, Siemens, and c) Boiler Drum Heat Exchanger Plant
i. FIC12
ABB controllers.
ii. LIC11
Electronic analogue PID control loops were often found
d) Liquid Flow Plant
within more complex electronic systems. For example, the
i. FIC21.
head positioning of a disk drive, the power conditioning of a
power supply, or even the movement-detection circuit of a
modern seismometer. Discrete electronic analogue controllers
have been largely replaced by digital controllers using
microcontrollers or FPGAs to implement PID algorithms.
However, discrete analogue PID controllers are still used in
niche applications requiring high-bandwidth and low-noise
performance, such as laser-diode controllers.

Other than that, the best PID controller application is

Figure 1
temperature control where the controller uses an input of a
temperature sensor & its output can be allied to a control 2. Double click at Controller to open the Faceplate. E.G:
element like a fan or heater. Generally, this controller is PIC92.
simply one element in a temperature control system

III. I. OBJECTIVES

I. To perform open loop test using DCS Delta A-V

Emerson and DCS FOXBORO. Figure 2
II. To perform closed loop test using DCS Delta A-V
Emerson and DCS FOXBORO.
III. To perform the correct method in order to do open
loop test and closed loop test.

Figure 3
3. Click at Process History View to view the trend/graph.
4. Stabilize the process either in manual (MAN) or Automatic
(AUTO) mode.
5. Record the initial value of manipulated variable (MV in %).
6. Once the process stabilized, if it is in AUTO mode, switch
it to MAN mode. (Remember: open loop test must be
carried out in MAN mode).
7. Make a step change between 5 – 20% to the manipulated
variable.
8. a) For self-regulating system: wait until the new steady
state reached.
b) For non-self-regulating system: wait until slope can be
calculated from process response. Then, set the system to
AUTO mode.
9. Print the response curve.
10. Use Tangent Method or Reformulated Tangent Method to
determine response rate (RR), time delay (Td) and time
constant (Tc).
(Remember: Value of PV and MV MUST be in %)
11. Determine the PI controller setting using Ziegler Nichol’s
or Cohen Coon’s method.
Closed Loop Test
1. Set the controller in AUTO mode
Figure 4
3. Insert the PI controller setting (Kc and I) value at Gain and
Reset Section.
4. 4. If the response oscillates, do fine tuning to achieve stable
condition.
5. 5. If the response oscillates:
a) Reduce the Kc -an excessively large proportional gain
will lead to process instability and oscillation.
OR
b) Increase the I – an excessively small integral term can
cause the present value to overshoot the setpoint value.
6. Record the optimum PI controller setting.
Load Disturbance Test
1. Set the controller in manual mode
2. Make change to MV of about 10% of current MV value
3. Wait for 3 s.
4. Then set the controller to automatic mode.
5. Wait until the response become stable.
Set point test
1. From load disturbance test, continue with set point test.
2. System must be in automatic mode
3. Make a change in set point about ±10% of current
operating process value
4. Wait until the response become stable.
5. Combine both response curves and print the graph.

DCS: FOXBORO
Open Loop Test.
1. Select the Plant -Water Flow and Level Control Plant
(WLF922)
2. Click Detail icon at Faceplate to set the controller setting. 2. Activate the selected control loops
i. FIC31
ii. LIC31

Set Point (SP)

MV(%)
Figure 5 Control loops
AUTO and MAN
mode
Figure 6 Controller
3. To view trending
a) select File > Additional FoxView Closed Loop Test
b) Click at Change Env
c) Change the Environment to Operator 1. Set the controller in AUTO mode.
d) At new FoxView select Plant WLF922. 2. Insert the PI controller setting (PB and I) value at
e) Double click at Controller. Click at TREND. PBAND and INT Section.
4. To enlarge the trending 3. If the response oscillates, do fine tuning to achieve
stable condition.
a) Click at Change Env
b) Change the Environment to Process_Eng 4. If the response oscillates:
c) Then, right click at the trend and select a) Reduce the Kc -an excessively large proportional
moveable. gain will lead to process instability and
d) Maximize the trend oscillation.
5. To perform open loop test, stabilize the process either OR
in manual (MAN) or Automatic (AUTO) mode. b) Increase the I – an excessively small integral term
6. Record the initial value of manipulated variable (MV can cause the present value to overshoot the
in %). setpoint value.
7. Once the process stabilized, if it is in AUTO mode, 5. Record the optimum PI controller setting.
switch it to MAN mode. (Remember: open loop test Load Disturbance Test
must be carried out in MAN mode)
1. Set the controller in manual mode
8. Make a step change between 5 – 20% to the
manipulated variable. 2. Make change to MV of about 10% of current MV
value.
9. For self-regulating system: wait until the new steady
state reached. For non-self-regulating system: wait 3. Wait for 3 s.Then set the controller to automatic mode.
until slope can be calculated from process response. 4. Wait until the response become stable.
Then, set the system to AUTO mode.
Set point test
10. Collect the data from AIM Historian Data Display at 1. From load disturbance test, continue with set point test.
Desktop 2. System must be in automatic mode.
a) Tag the desired data
b) Set the desired Date/Time 3. Make a change in set point about ±10% of current
c) Click at View Data operating process value.
4. Wait until the response become stable.
5. Combine both response curves.
6. Use HyperSnap-DX program to print the graph:
a) START > Program > HyperSnap-DX
>HyperSnap- DX
b) In HyperSnap-DX Pro select Capture > Active
window and click at the trending
c) Once the trending appear in HyperSnap –DX
program, go to Image >Invert Black and White
d) Print the inverted graph.

Figure 7
11. Use Numerical Analysis to determine response rate
(RR), time delay (Td) and time constant (Tc).
(Remember: Value of PV and MV MUST be in %)
12. Determine the PI controller setting using Ziegler
Nichol’s or Cohen Coon’s method.
 V. RESULTS
according to the video and data given in Microsoft Team, data
were obtained and tabulated as following below:

Figure 8 –Flow control process (F1C21)

Table 2 – numerical method open loop (F1C31)

VI. CALCULATION
Figure 9- Level flow control (L1C11)
Open Loop: Tangent Method (FIC21)

Figure 1 shows an open loop process response of water

flowrate control when a change in manipulation variable was
made from 45% to 55% at clock time = “09:57”. The plot is
obtained from a SCADA system. The process dead time (Td)
and response rate (RR) are calculated by using tangent
Table 1 – Process Span method. The process span is 6m3/h

Figure 10 – Open Loop Process Response when the

Manipulated Variable was changed from 45% to 55%

MVi = 45% ; MVf = 55%

ΔMV = MVf – MVi = 55% - 45% = 10%
Based on the graph
 Open Loop: Time Constant (FIC21)
Tangent-and-point method
Figure 3 shows an open loop process response of a self-
regulating process when a change in manipulated variable was
Δy = 23mm made from 45% to 55%. The time constant (TC) is calculated
using tangent-and-point method.
Δx = 3mm
Td (length) = 79 mm
Td (time) = 79 mm × 0.0204 s/mm = 1.6116s

Open Loop: Reformulated Tangent Method (LIC11)

Figure 2 shows an open loop process response of a self-
regulating process after a change in manipulated variable was
made from 70.2% to 80.2% at clock time = “10:34”. This plot
is obtained from a SCADA system. The dead time (Td) and
response rate (RR) are calculated by using reformulated Figure 12: Time Constant Calculation based on Tangent-and-
tangent method. The process span is 1000mm. Point Method
Based on the graph,
b = 1s/(49 mm)=0.0204 s/mm
Δy = 23 mm
Td (length) = 79 mm
PV63.2% (length) = 0.632 × 23 mm = 14.5360 mm
T63.2% (length) = 82 mm
Tc (time) = [T63.2% (length) - Td (length)] × b
= [82 -79]mm × 0.0204 s/mm = 0.0612s

Figure 11: Open Loop Process Response of Self-Regulating Open Loop: Time Constant (LIC11)
Process Tangent Method
MVi = 70.2% ; MVf = 80.2% Figure 4 shows an open loop process response of a self-
ΔMV = MVf – MVi = 80.2% - 70.2% = 10% regulating process when a change in manipulated variables
was mad from 70.2% to 80.2%. The time constant (TC) is
Based on the graph, calculated using tangent method.

Ѳ=9
Td (length) = 88 mm
Td (time) = 88 mm × 0.0208 s/mm = 1.8304s
 PV (%) =

=
= 49.1733

RR =

=
= 0.2201
Δh = 1s ; ΔMV = 10% ; PVi = 49.1733% ; PVf = 65.3433%
RRmax = 0.5162/s

Figure 13: Time Constant Calculation based on Tangent

Method Td = t1 - 2Δh = 3 – 2(1) = 1s

Based on the graph, PV63.2%

b = 1s/48mm=0.0208 s/mm =PVi + 0.632 (PVf - PVi) = 49.1733 + 0.632(65.3433-49.1733)

Tc (length) = 52mm = 59.3927%

Tc (time) = 52mm × 0.0208s/mm = 1.0816 s No Time(s) PV(%)

n 2 53.5753
Open Loop 3: Numerical Method (FIC31) T63.2% = unknown PV63.2%= 59.3927
Table 1 shows a discrete open loop process of self-regulating n+1 3 59.4967
process after a change in manipulated variable was made from
Table 4 – interpolation between time and PV to gain PV63.2%
40% to 50%. The response rate (RR), dead time (Td) and time
constant (TC) are calculated based on 2-point method, T63.2%
numerically. The process span is 3m3/h.
Time (s) MV PV (m3/h) PV (%) RR (1/s) = tn + (tn+1 - tn) = 2 + (3 - 2)
(%) = 2.9759s
0 50 1.4752 49.1733
1 60 1.4752 49.1733 0.2201 PV28.3%
2 60 1.6072 53.5753 0.5162 = PVi + 0.28.3 (PVf - PVi)
3 60 1.7849 59.4967 0.4437 = 49.1733+ 0.283 (65.3433- 49.1733)
4 60 1.8735 62.4500 0.2213 = 53.7494%
5 60 1.9177 63.9233 0.1098 No Time(s) PV(%)
6 60 1.9394 64.6467 0.0535 n 2 53.5753
7 60 1.9498 64.9933 0.0173 T63.2% = unknown PV28.3% = 53.7494
8 60 1.9498 64.9933 0 n+1 3 59.4967
9 60 1.9498 64.9933 0.0175 Table 5 – interpolation between time and PV to gain PV28.3%
10 60 1.9603 65.3433 T28.3%
Table 3 - An Open Loop Process Response of Self-Regulating
Process in Discrete Form = tn + (tn+1 - tn)

= 2 + (3 - 2)
= 2.0294s
Tc = 1.5(T63.2% - T28.3%) = 1.5(2.9759s -2.0294s) = 1.4198s
Closed Loop: Optimum Controller Setting
FIC21- Cohen Coon
An open loop test has been performed to a flow control loop.
The process response has been analysed for process
characteristics and summarised as in Table 6.
The optimum controller setting for the flow control is
calculated in which the process will behave like a QAD type
of response when a change in set point is made.
Ziegler-Nichols’s Tuning Rule was selected based on the
settling criteria. The PI mode has been selected based on the
flow process.
PB = 111.1 RR Td
PB = 111.1 × 0.4758 × 1.8304 = 96.76%
I = 3.33 Td
I = 3.33 × 1.8304 = 6.0952s
The PB and I value were then used for close loop test
proceeding with load disturbance test and set point for an open
loop response.

Parameters Values
Dead Time (Td), s 1.6116 FIC31- Ziegler Nichols
An open loop test has been performed to a flow control loop.
Time Constant (Tc), s 0.0612
The process response has been analysed for process
Response Rate (RR), 1/s 24.0899 characteristics and summarised as in Table 4.
Table 6: Process Characteristic of Flow Control Loop Table 4: Process Characteristic of Flow Control Loop
The optimum controller setting for the flow control is Parameters Values
calculated based on Cohen-Coon’s Tuning Rule.
Dead Time (Td), s 1
Cohen-Coon’s Tuning Rule was selected based on the settling
criteria. The PI mode has been selected based on the flow Time Constant (Tc), s 1.4198
process. Response Rate (RR), 1/s 0.2201
µ = Td /Tc = 1.6116/0.0612 = 26.3333 The optimum controller setting for the flow control is
PB = 100/ (1+μ/11) RR Td calculated in which the process will behave like a QAD type
of response when a change in set point is made.
PB = 100/ (1+26.3333/11) ×24.0899 ×1.6116=1143.9013%
Ziegler-Nichols’s Tuning Rule was selected based on the
I = 3.33 [(1+μ/11)/(1+11μ/5)] Td settling criteria. The PI mode has been selected based on the
I=3.33[(1+26.3333/11)/(1+(11×(26.3333))/5)]×1.6116 flow process.

I=0.3091s PB = 111.1 RR Td

The PB and I value were then used for close loop test PB = 111.1 × 0.2201 × 1 = 24.4531%
proceeding with load disturbance test and set point for an open I = 3.33 Td
loop response.
I = 3.33 × 1 = 3.33s
The PB and I value were then used for close loop test
LIC11- Ziegler Nichols proceeding with load disturbance test and set point for an open
An open loop test has been performed to a flow control loop. loop response.
The process response has been analysed for process
characteristics and summarised as in Table 7.
Parameters Values
VII. DISCUSSION
Dead Time (Td), s 1.8304
In this experiment, there are several objectives need to be
Time Constant (Tc), s 1.0816 obtained. Firstly, the value of dead time Td, time constant Tc
Response Rate (RR), 1/s 0.4759 and response rate RR were obtained by using 3 methods which
are Tangent Method and Reformulated Tangent Method
Table 7: Process Characteristic of Flow Control Loop (graphical method) and lastly Numerical Tangent Method.
Next, experiment were continued with determining optimum
controller setting based on Ziegler-Nichols / Cohen Coon
method. In this experiment, we focused on one type of
parameter to be controlled which are flow control. Each types
need similar kind of controller mode as according to the
Tuning Rules. As for flow control process, the PI controller
was used as this mode is more suitable for fast and noisy
process. Though P controller mode is suitable for all kind of
processes but it may give a result of off-set and it may cause
the process to be unstable.
For the first experiment, the value of response rate (RR) and
time dead (Td) were obtained by using Tangent Method as
shown in figure 10. By referring to the graph in figure 10, the
value of a and b which are 0.6410 %.mm and 0.0204 s/mm
respectively are calculated by using process span value given
in order to determine the value of Td and RR that are 1.6116 s
and 24.0899 /s respectively. In addition, by referring to figure
11, value of response rate (RR) and time dead (Td) were
obtained by using Reformulated Tangent Method. With the
value of a and b obtained from the graph are 0.6250 %/mm
and 0.0208 s/mm respectively, in this experiment, the value of
Td and RR are 1.83045 s and 0.4759 /s respectively. Next, for
numerical method, under open loop: numerical calculation, the
table 2 were constructed and simplified into table 3. From
table 3, RR value is calculated based on the data tabulated.
Value of RR max which is 0.5162 /s was determined and used
to calculate the value of Td at the end which is 3 s. for the
value of time constant (Tc), the value obtained from Tangent-
Point-Method was 0.0612 s and 1.0816 s from Tangent
Method. In Numerical Method, from 2-point Method, value of
Tc gained was 1.4198 s.
In accordance with the value obtained previously, this can be
concluded that values of Td obtained from the two graphical
method differed insignificantly but both value were very small
compared to the value of Td gained from the numerical
method. In another hand, the value of RR obtained from
reformulated tangent method differed slightly with the RR
value from numerical method and RR value obtained from the
Tangent Method was the greatest among those three. Tangent
method is known as the quickest method to obtained the
optimum P, I, and D as it provides the vital information of
process dynamic which is dead time and response rate. In this
method, the response curve is analyzed for the process dead
time (Td) and the response rate (RR) by drawing a tangent line
to the steepest point of the response curve. By definition, the
process dead time is estimated at the cross section between the
baseline of the old steady-state level and the tangent line. This
lead to inaccurate result. The reformulated tangent in another
hand is proved to alleviate the inadequacy of the conventional
tangent method. Reformulated Tangent Method (RTM)
transforms the process response rate into trigonometric
function to get the optimum PID. This newly reformulated
tangent method simplifies the analysis of process
characteristics of the open loop response curve. It is also
reduce the number of steps in analyzing the response curve
thus improved the speed of data extraction, make it better to
be used compared to tangent method. However, graphical
method will still have higher tendency to give inaccurate result
compared to numerical method.
To calculate time constant in numerical method, the value of
PVi anf PVf from table 3 were used to determine the value of
PV(63.2%) which is 59.3927%. Then, the value of PV(63.2%)
was interpolated with another two value, PVi and PVf to get
the value of T(63.2%) which is 2.9759s. In 2-point method,
the value of T(63.2%) and T(28.3%) were needed, thus
T(28.3%) which is 2.0294s were obtained by using the same
steps as for T(63.2%). Tc value gained was 1.4198s. next, in
Tangent Method, the value of Tc which is 1.0816 s was
obtained by using the graph in figure 13 whilst for Tangent-2-
point Method, the value of Tc which is 0.0612s was obtained
from the graph in figure 12. From here, it is genuinely that by
using 2-point method, it gave the greatest value of Tc and
Tangent-2-point method gave the smallest value of Tc.
The value of RR, Td and Tc from previous experiment were
used Cohen Coon and Ziegler-Nichol’s Tuning Rules to obtain
the value of PB and I. this experiment were done to observe
and determine the optimum controller setting as stated in the
calculation part, the value of PB by using Cohen Coon is
higher than in Ziegler-Nichols Method which were
1143.9013% and 96.97% and 24.4531% respectively.
Meanwhile for I value, the Cohen Coon gave smaller value of
I compared to Ziegler-Nichols method which were 0.3091 s
and 6.0952 s and 3.33s respectively. Both tuning test are for
QAD, performance test settling criteria with disturbance in
load variable.
The proportional band is defined as the amount of change in
input (or deviation), as percent of span, required to cause the
control output to change from 0% to 100% A narrower
proportional band gives greater output change for any given
deviation, it therefore also makes the control performance
more susceptible to oscillation. At the same time, a narrower
proportional band reduces the offset. The integral time (I) is
defined as the time required to develop, when a stepwise
change in deviation is imposed, an output change due to
integral action that is exactly equal to the change due to
proportional action. The longer the integral time set, the
slower the change in output; the smaller the time, the faster the
output changes. PB is inversely proportional to MV, hence
MV is faster if the value of PB is decrease. Also, I is inversely
proportional to MV thus if I value increases, MV will getting
faster. MV is directly proportional to process response PV. A
faster MV will make PV become faster and a faster PV is
indicated by shifting the process response curve to the left.
This means the curve will tend to oscillate tremendously and
vigorously than the initial one.
Hence, Cohen Coon gave the best and smallest value of I
compared to Z-N method. The most common classical
controller tuning methods are the Ziegler-Nichols and Cohen-
Coon methods. These methods are often used when the
mathematical model of the system is not available. The
Ziegler-Nichols method can be used for both closed and open
loop systems, while Cohen-Coon is typically used for open
loop systems. The Cohen-Coon method of controller tuning
corrects the slow, steady-state response given by the Ziegler-
Nichols method when there is a large dead time (process
delay) relative to the open loop time constant; a large process
delay is necessary to make this method practical because
otherwise unreasonably large controller gains will be
predicted. Also, Ziegler-Nichols tuning rules work well only
on processes with very long time constants relative to their
dead times, and on level control loops. However, its
performance is not good on flow, liquid pressure, and many
other loops that require fast adjustment. In contrast, the
Cohen-Coon tuning rules work well on virtually all self-
regulating processes and were designed to give a very fast
response.
VIII. CONCLUSION
A. summary of the results
In contrast, a small nonlinear relationship between the process
response and the manipulated variable for both the
FOXBORO and EMERSON flow control loops is dependent
on the outcome. To evaluate the optimal condition for the
process control loop, the closed loop test, load disturbance test
and set point testing can be performed. The process output, as
the controller gains value, PV will be slower, Kc will
decrease, making the process curve change to the right. The
process response will also be increased by PB value, PV
slower and the process response curve shifted to the right. The
process response would also be slower by increasing the I
value, making the process response curve move to the right.
We may also assume that using the Numerical Method is the
most reliable data corresponding to the tuning rules compared
to using the Tangent and Reformulated Tangent Method.
B. Recommendations
Throughout the experiment, there are a few guidelines to
ensure reliable data and outcomes. Firstly, the tangent line
must be drawn straight and fit to the curve to prevent
measurement error in calculating the data from the method
curve.
Furthermore, since it could impact the measurement and the
final result in deciding the process linearity, the manipulated
variable should be set to an acceptable range, such as 15%-
25% percent. For the decimal places taken, the numerical
method is sensitive. The number of decimal places in the
experiment must be constant which the 4 digit of decimals.
To ensure that the maximum RR can be determined for the
experiment, the value of RR needs to be calculated for all data.
Apart from that, to ensure that the PB and I value is the
optimum value, the product of the response rate curve must be
expanded.
IX. REFERENCES
Ang, K. &. (2005). PID Control System Analysis, Design, and
Technology. . Control Systems Technology, IEEE
Transactions on. 13. 10.1109/TCST.2005.847331. ,
559 - 576.
Engr. Joseph, E. A., & M.Tech. (2018). Cohen-Coon PID
Tuning Method: A Better Option to Ziegler.
Computer Engineering and Intelligent Systems IISTE.
Hambali, N. &. (2015). Process controllability for flow control
system using Ziegler-Nichols (ZN), Cohen-Coon
(CC) and Chien-Hrones-Reswick (CHR) tuning
methods. . Proc. of the IEEE International
Conference on Smart Instrumentation, Measurement
and Applications (ICSIMA) .
nd. (n.d.). Chapter 12 Controller Tuning. Retrieved from
https://sites.chemengr.ucsb.edu/~ceweb/faculty/sebor
g/teaching/SEM_2_slides/Chapter_12.pdf
REX Controls s.r.o. (n.d.). PID control lab 3.1. PID control
laboratory: PID tuning in one minute.
Rice, R. C. (2010). PID Tuning Guide: A Best-Practices
Approach. 4-25.
Ziegler-Nichols Tuning Rules for PID. (nd). Retrieved from
Microstar laboratory web site:
http://www.mstarlabs.com/control/znrule.html