Process Control Training Module

CHEN3005 Process Instrumentation and Control

Workshop 2
FOPDT Model Development via Step and Doublet Tests
Objectives
i.
ii.

To develop FOPDT model for a heat exchanger using Step and Doublet Tests.
To compare the predictions of the FOPDT models developed via Step and Doublet Tests.

Empirical Model Development

In empirical model development (i.e., model based on experimental data), one of the crucial
steps is to choose a suitable type of input perturbation, i.e., how should one change the input to
the system, should it be in the form step change or doublet change (see Figure 1). Doublet test
essentially combines two step tests in sequence, i.e., move down and move up before moving
back to old steady-state value. In this way, the doublet test can capture the dynamic information
below and above the old steady-state operating condition. By contrast, the step test can only
capture the dynamic information in one direction, either below or above the old steady-state
operating condition. From practical point of view, the doublet test is preferable to step test
because the former takes shorter time to complete than the latter.

Figure 1. Different types of input changes

Examples Step and Doublet Test

Figure 2 shows an example of step test application (in the input CO) to a heat exchanger. The
response of the temperature of the process fluid leaving the heat exchanger is displayed in the top
part of the figure. For the step test, the process response (i.e. Temperature) must settle to new
steady-state value before stopping the experiment.
Meanwhile, Figure 3 displays the doublet test application to the same heat exchanger. As can be
seen, the process fluid temperature eventually returns its old steady-state value once the CO
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returns its old value 39%. Unlike in the step test, the process response does not have to settle to
new steady-state value the objective of the doublet test is to capture the transient response of
the system.

Figure 2. Example of step test (step change from 39% to 49%)

Figure 3. Example of doublet test (sequential step test from 39% to 49% to 29% and back to 39%)

Exercise
i.
ii.
iii.

Set the operating conditions as follows: CO = 46%, warm liquid flow = 20 L/min, which
should give process fluid exit temperature = 135 oC.
Apply step test of magnitude = 10%, save the data and build a FOPDT model using the
Loop-pro software.
Repeat step (ii) by applying doublet test of magnitude =
10%, save the data and build a
FOPDT model using the Loop-pro software.
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iv.
v.

Record the FOPDT parameters for both test in Table 1 below.

Compare the model parameters.

Table 1
Test

 (gain)

 (time-constant)

 (deadtime)

Goodness of Fit

Step Test
Doublet Test

Procedure
i.
ii.
iii.
iv.
v.

vi.
vii.
viii.
ix.
x.
xi.

xii.
xiii.

Open Loop-pro, choose Case Studies and choose Heat Exchanger.

Ensure the heat exchanger is at steady-state. There should be no dynamic portion shown
on the window if there is any, let the portion scroll out of the window first.
Click Save icon to start saving data. Name the file as like, e.g., HTX, and click save,
click ok.
Apply the test (either step or doublet), i.e., change the CO from the current operating
steady-state value to a new one.
Observe until response reaches new steady-state value for Step Test case, click again the
Save icon to stop saving the data. For the Doublet Test, you can stop saving the data
when the process response settles to its old-steady-state value.
Click Design icon.
Click Open icon.
Select from browser the file that you just saved, e.g. HTX.
Click OK.
Click Select Model icon. Tick the FOPDT, and then click Done.
Click Start Fitting icon. It takes a while to run and stop giving you the plot comparison
between the model prediction (yellow line) and actual response (white line). Look ok,
then click Accept and Close.
On the lft hand side, find the Model Parameters. You can read from the table, Gain,
Time Constant, Dead Time and Goodness of Fit. Record all values.
End.