OBJECTIVES:

To identify the set point test.

To perform the load disturbance test with different manipulated variable.
To analyze the type of closed loop process response.

METHODOLOGY
Open loop test
1. The process is stabilized either in manual or automatic mode.
2. When the controller is in automatic mode and the process has stabilized, it was switched
to the manual mode.
3. The initial value of manipulated variable, 35 and the initial value of process variable
(PVi) were recorded.
4. A step change of 4 % was made to the manipulated variable (MV).
5. Once the process has increased about 7 to 10% of the process span, MV was set to the 35
or the controller was set to automatic mode, and the process is left to stabilize to the
original operating condition.
6. The entire event is printed.
7. The step is repeated for different value of manipulating variable which is 8% and 12%.
Performance test
Change in set point
1. The controller was set in automatic mode.
2. Change in set point was made to of less than 10% of the process span.
3. When the process becomes oscillatory or unstable, the controller was set to manual mode.
Then, MV was set to the last stable value.

Change in process loading of Load variable

1. The controller was set to manual mode.
2. Change of MV value was made to the controller.
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3. Time taken about 3 seconds was required to the controller.

4. Then, the controller was set to automatic mode.
5. If the process becomes oscillatory or unstable, the controller was set to manual mode.
Next, MV value was set to last stable value.

EXPERIMENTAL RESULT AND DATA ANALYSIS

1)
=76 . 5

MV

a=

b=

= 4%

10
17 mm
15 s
11 . 5 mm
2

 PV = 8mm
Td = 1mm
RR =(

RR=

tan
a

MV ( b )
10
17
tan 76.5
(
4
15 )
11.5

= 0.4696/s
Td = 1mm x

15 s
11.5 mm

= 1.304 s
PV = 8mm

= 8mm x

10
17 mm

= 4.706%
b
1
Tc =(Pvf Pvi ) ( a ) ( tan
15
11.5
= 4.706( 10
17

) ( tan 76.5

= 2.505 s
P = 110RRTd
= 110(0.4696)(1.304)
= 67.359%

I = 3.3Td
= 3.3(1.304)
= 4.3032 s

100
Kc = PB
100
= 67.359
= 1.485

2)
=82
MV

= 8%

10
17 mm

a=

b=

15 s
11 . 5 mm

PV = 16mm

Td = 0.5mm
RR =(

tan
a

(
MV
b )

10
tan 82
17
(
)
RR=
(
8
15 )
11.5
= 0.4011/s
Td = 0.5mm x

15 s
11.5 mm

= 0.652 s
PV = 16mm

= 16mm x

10
17 mm

= 9.412%
5

b
1
Tc =(Pvf Pvi ) ( a ) ( tan
15
11.5
= 9.412( 10
17

) ( tan 82

= 2.933 s

P = 110RRTd
= 110(0.4011)(0.652)
= 28.77%

I = 3.3Td
= 3.3(0.652)
= 2.152 s

100
Kc = PB
100
= 28.77
= 3.476

3)
=83 .5
MV

a=

b=

= 12%

10
17 mm
15 s
11 . 5 mm

PV = 25mm

Td = 0.1mm
RR =(

tan
a

(
MV
b )

10
tan 83.5
17
(
)
RR=
( 15 )
12
11.5

= 0.3299/s
Td = 0.1mm x

15 s
11.5 mm

= 0.1304 s
PV = 25mm

= 25mm x

10
17 mm

= 14.706%

b
1
Tc =(Pvf Pvi ) ( a ) ( tan
15
11.5
= 14.706( 10
17

) ( tan 83.5

= 3.715 s

P = 110RRTd
= 110(0.3299)(0.1304)
= 4.732%

I = 3.3Td
= 3.3(0.1304)
= 4.732 s

100
Kc = PB
100
= 4.732
= 21.133

RESULT

MV (

RR (s-1)

Td (s)

Tc (s)

P (%)

I (s)

Kc

%)
4

0.4696

1.304

2.505

67.359

4.3032

1.485

0.4011

0.652

2.933

28.77

2.152

3.476

12

0.3299

0.1304

3.715

4.732

0.4303

21.133

Types of Closed Loop Process Response

MV (%)

PB (%)

I (s)

Set point test

Load disturbance test

67.4

4.3

Overdamped

Oscillatory

8
12

28.8
4.7

2.2
0.4

Unstable
Unstable

Unstable
Unstable

Note : Proportional (P) and Integral (I) is calculated by using Takahashi Tuning rule.

DISCUSSION

The experiment has been conducted by using Flow Indicating Controller 21 (FIC 21). The
objective of this experiment is to analyze the closed loop process response based on 3 different
manipulated variables (MV). The values of manipulating variable used are 4%, 8% and 12%.
Different values of manipulating variables will result in different value of proportional (P) and
integral (I) . Since the experiment is a flow process control which resulting the fast process
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response, the mode of control used is P+I. Takahashi Rules have been used in order to obtain the
value of controller gain (Kc) and integral time ( I ) .
Based on the experiment, there are several steps that need to be considered in order to obtain the
results (graphs) for each manipulated variable. The initial MV is set up at 35% . A change in
manipulating variable (MV) of 4% is made. Thus the final value of MV is 39%. 4 % of change
in MV will produce changes in the process for the optimum PID calculation. The initial set point
is 2.0 m3/h . For this (MV), the response rate (RR) obtain is 0.4696/s, dead time ( T d ) is 1.304 s
and time constant ( Tc ) is 2.505 s . The proportional (P) and integral (I) are 67.36 % and 4.3032 s
respectively. Then, the controller gain (Kc) obtained is 1.485 . For second graph, the optimum
Proportional (P) and Integral (I) calculated from the Takahashi rule has been tested for graphic
performance analysis.
When testing the performance of Proportional(P) and Integral(I), a change in set point has been
made to of less than 10% of the process span which is 2.1 m 3/h . From the first graph (Figure 2)
of process response obtained, it can be seen that the graph of process response to set point (SP)
test is overdamped. The process is reaching the set point requirement. For the load disturbance
test, 5% value of MV has been made to the controller . The graph for the load disturbance test is
oscillation at the set point.
Second, manipulating a variable change (MV) is 8%. The response rate (RR) is 0.4011/s, dead
time ( Td ) is 0.652 s and time constant ( Tc ) is 2.933 s . The proportional (P) and integral (I) are
28.77 % and 2.152 s respectively. Therefore, the controller gain (K c) obtained is 3.476 . For this
MV , the graph ( Figure 3a ) for the set point (SP) test shows that the process response is
unstable condition . This is, the same goes to load disturbance test. In order to stabilize the
unstable process response, the value of Kc has been divided by 4 (K c /4) while the value of I is
multiplied by 4 (Ix4) . Thus, the new Kc and I are 0.869 and 8.608 s respectively. The stable
process response can be seen in Figure 3b.
The last manipulating variable change (MV) is 12%. The response rate (RR) is 0.3299/s, dead
time ( Td ) is 0.1304 s and time constant ( Tc ) is 3.715 s . The proportional (P), integral (I) and
controller gain (Kc) is 4.732 %, 0.4303 s and 21.33 respectively. From the graph in Figure 4a, it
can be seen that the process response is quite unstable for both set points (SP) test and load
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disturbance test. In order to get the stable response such in Figure 4b, the value of K c has been
divided by 16 (Kc /16 ) while the value of I is multiplied by 16 (I16) . So that, the new K c and I
are 1.321 and 6.885 s respectively.
Based on the graphs obtained, the different value of MV will result in a different type of
process response. The lowest change in manipulating variable (MV), the more stable process
response. From the result of the experiment, MV 4% has the best process response since it is
the only one that stable. Basically, the large value of proportional (P) typically means faster
response since the large error is occurred. In Figure 4a, an excessively large proportional gain
(Kc) will lead to process instability and oscillation. On the other hand, an excessively small
integral (I) term such as in Figure 4a causes the present value to overshoot the setpoint value
which resulting in instability process response.
Figure 2 (closed loop graph 1) shows that a small K c results in a small output response to a large
input error. It is a less responsive controlled which means the process is slow. Since the K c value
is too low, the control action is small when responding to a system disturbance. Generally, the
purpose of using Integral control is to eliminate the offset of the process response since the
controller output depends on the integral of the error signal over time. When an error is equal to
zero, no offset has been produced by the process.

CONCLUSION

There are several conclusion that have been obtained from this experiment. First of all is
the value of MV played the major role in this experiment which controlled the K c and I, the
smallest the value of MV. The more stable the graphical process response will be. On the other
hand, when the gain is greater, the output from the input will be also greater. The increasing of
gain, Kc the larger in error may obtained cause by the unstable loop. Other than that, in order to

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stabilized the oscillatory process response, the value of Gain,K c and Reset, I must be divided and
multiple respectively by 2, 4 or 16.

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P
P
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I
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