Procedure

2.1 DCS Delta-V Emerson (FLOW)

2.1.1 Liquid Flow Plant
Open Loop Test for FIC21
1. The Liquid Flow Plant, FIC21 was selected.
2. After the overall diagram of the plant has opened, the controller of FIC21 was double
3.
4.
5.
6.

clicked to open the faceplate.

The Process History View was clicked to see the trend of the process.
The process need to be stabilized in manual.
The initial value of MV was recorded and the step change of 10% was taken.
After the response has reached the steady state, the response graph was printed

and calculation for obtaining the RR, td and tc.

7. The calculated value of PI controller was obtained by using Ziegler-Nichols and
Cohen-Coon method.
Closed Loop Test for FIC21
1.
2.
3.
4.

The controller was set to auto mode.

The detail icon was clicked at the faceplate in order to set the controller setting.
The calculated value of Gain, Kc and Reset, I was entered in the detail.
After the response has reached the steady state, the value of the optimum PI

controller was recorded.

5. Load disturbance test was done by turn the process into Manual mode and make a
step change of MV by 10% for three second and change into Auto mode again.
6. After the process has stabilized, the process response after changed the MV was
observed.
7. The set point test was done by adding the previous set point with 10% from total
value which is 0.6m3/h.
8. After the process response has reached the steady state, the response was
observed.
9. Both graph for load disturbance test and set point test was printed.

2.1.2 Level Control Plant

Open Loop Test for LIC11
8. The Liquid Level Plant, LIC11 was selected.

9. After the overall diagram of the plant has opened, the controller of LIC21 was double
clicked to open the faceplate.
10. The Process History View was clicked to see the trend of the process.
11. The process need to be stabilized in manual.
12. The initial value of MV was recorded and the step change of 10% was taken.
13. After the response has reached the steady state, the response graph was printed
and calculation for obtaining the RR, td and tc.
14. The calculated value of PI controller was obtained by using Ziegler-Nichols method.
Closed Loop Test for LIC11
10. The controller was set to auto mode.
11. The detail icon was clicked at the faceplate in order to set the controller setting.
12. The calculated value of Gain, Kc and Reset, I was entered in the detail.
13. After the response has reached the steady state, the value of the optimum PI
controller was recorded.
14. Load disturbance test was done by turn the process into Manual mode and make a
step change of MV by 10% for three second and change into Auto mode again.
15. After the process has stabilized, the process response after changed the MV was
observed.
16. The set point test was done by adding the previous set point with 10% from total
value which is 0.6m3/h.
17. After the process response has reached the steady state, the response was
observed.
Graph for load disturbance test and set point test was printed.

2.1.3 Gas Pressure Control Plant

Open Loop Test for PIC92
1. The Liquid Flow Plant, PIC92 was selected.
2. After the overall diagram of the plant has opened, the controller of PIC92 was double
3.
4.
5.
6.

clicked to open the faceplate.

The Process History View was clicked to see the trend of the process.
The process need to be stabilized in manual.
The initial value of MV was recorded and the step change of 10% was taken.
After the response has reached the steady state, the response graph was printed

and calculation for obtaining the RR, td and tc.

7. The calculated value of PI controller was obtained by using Ziegler-Nichols and
Cohen-Coon method.
Closed Loop Test for FIC21
1. The controller was set to auto mode.

2. The detail icon was clicked at the faceplate in order to set the controller setting.
3. The calculated value of Gain, Kc and Reset, I was entered in the detail.
4. After the response has reached the steady state, the value of the optimum PI
controller was recorded.
5. Load disturbance test was done by turn the process into Manual mode and make a
step change of MV by 10% for three second and change into Auto mode again.
6. After the process has stabilized, the process response after changed the MV was
observed.
7. The set point test was done by adding the previous set point with 10% from total
value which is 2.5 psig
8. After the process response has reached the steady state, the response was
observed.
9. Both graph for load disturbance test and set point test was printed.
2.2 DCS FOXBORO
Open Loop Test for LIC11
1. The Level Control Plant, (WLF922) was selected.
2. LIC11 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 LIC11
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.
The trending active window was selected and then the image was inverted to black and
white. The process response than was printed.

Discussion

This project was tittle controllability of level control using various tuning rule .
The objective of this project is to compare the value of the level control calculation by
using a method of:
Tuning Rules by Ziegler Nichols
In this project equipment LIC 21 is used to control the level. From the method,
the value of dead time (

td

, time control (

+ integral + derivative (PID) and also

Kc

tc

), response rate (RR), proportional

need to be calculated. The purpose of

PID mode is to fast process response and noisy processes like flow, pressure and
liquid level control.
This project is start with open loop test. First, the manipulated variable (MV) is at
30% at level 500 mm. Then, we set the controller to manual mode and increase the

MV by 15%. Ensure that the process has stabilize, at 638 mm the controller is set to
auto back. The step is repeated four more times at MV of 10%, 10%, 20% and
15%. After that, the value of response rate (RR), dead time (T d), time control (

tc

is calculated from the graph we obtained. The value of P and is the calculated. The
tabulated data is as follows :
RUN
1

MV (%)
15

RR
0.0231

RRTd
0.0231

P
P = 2.31

PI
P =2.566

10

0.0189

0.03874

P = 3.8745

I = 3.33
P = 4.3046

10

0.019

0.07505

P = 7.505

I = 6.8265
P = 8.3381

P = 6.003

I = 13.1535
P = 6.6693

P = 6.0001

I = 8.6913
P = 6.666

15.5

20

0.023
0.023

0.06003
0.05999

I = 8.68697

Next, the calculation of Gain(Kc ) and Reset can be calculated from the
average values of the result based on the graph which concludes the open loop test
and will be used to proceed for the closed loop test.
After that, we proceed to next step which is set point test by using the method of
tuning rule stated above. For this set point test, we calculate using 2 difference
modes which are P and PI. These 2 modes consist of different type of calculations.
After that we wait until the graph become stable then repeat the same step for load
disturbance test. There will be 4 different graphs because of using 4 different
calculations.
In order to stabilize the graph, we need to increase the value PB and I and also
decrease the value of KC. When the value of PB increasing, the controller action
become slower which in turn slows down the process response and shift the graph to
the right. An increasing I value, the controller action will also become slower and
lower the peak of the graph. The value of K C should be decrease because
decreasing the KC value will increase the PB value. PB value is inversely proportional
to KC value.