Process Control

Cascade Control
Chapter 16: Seborg
Chapter 14: Marlin
Chapter 9: Smith & Corripio
 Learning Objectives

• Understand when, why & how to apply cascade control

• Understand benefits of cascade control loops
• Draw a cascade block diagram and analyse response
• Be able to simplify cascade control loops

2
What about the “extra” disturbance
to the heat exchanger?
Cold fluid
T change • Steam supply
SP pressure may vary
TC • Steam flow will
101 change without
Hot fluid
valve movement
TT
Steam • This is a
101
disturbance to a
manipulated
Steam Pressure
Fluctuation /
variable
Disturbance
3
4
Cascade Control:
Controlling for Manipulated Variable Disturbances

Cold fluid
T change

TSP

FC FSP TC
101 101

Hot fluid
TT Steam
101

T control is the OUTER loop/ primary/ master

F control is the INNER loop/ secondary/ slave
 Features of Cascade Control

• TWO PID control loops connected

• A main outer loop
• An inner secondary loop
• Improved response to disturbances
• Very common in industry
• Requirement: Inner loop must be FASTER than
the outer loop

5
 Features of Cascade Control

• Only used if there is a disturbance to a manipulated variable

• This disturbance enters the inner loop on the block
diagram
• Outer controller sets the setpoint of inner controller
• The inner loop is usually simple
• Most frequently flow control
• Usually P control with high gain
• Sometimes temperature control
6
 Heat exchanger: Feedback Control
Smith & Corropio

7
 Heat exchanger: Cascade Control
Option 1 Option 2
Smith & Corropio

8
 Cascade control of a
jacketed reactor
Smith & Corropio

9
 Example of Double Cascade on a
Jacketed (External Coil) Reactor
SP

TC
101

FC TC
101 102

Cooling water
Variable T
& supply P

10
Example of Double Cascade on a Jacketed (External
Coil) Reactor

11
Example of Double Cascade on a Jacketed (External
Coil) Reactor

12
Example of Double Cascade on a Jacketed (External
Coil) Reactor

13
Example of Double Cascade on a Jacketed (External
Coil) Reactor

14
Example of Double Cascade on a Jacketed (External Coil)
Reactor

15
Example of Double Cascade on a Jacketed (External
Coil) Reactor

17
Example of Double Cascade on a Jacketed (External
Coil) Reactor

18
Example of Double Cascade on a Jacketed (External
Coil) Reactor

19
 Cascade Control Block Diagram
Valve inside inner loop D1
GD1
D2 GD2

FSP + +
SP E U FC + Y
Kc(1+1/Tis) Kc2 GV Gp
+ +
- -

Inner controller usually P only Outer loop ─

Inner loop ─
Tm
1

20
 Implementation and Analysis of a Cascade Loop:
1 – Simple, single loop

TD
FD 1e-s
1+5s

U Fs +
Ts E 0.5 4e-2s T
+
Kc(1+1/Tis) 1 +0.5s
+ 1 + 15s
-

Tm
1

• Simple, single temperature control loop

• What if there is a disturbance to FS?

21
 Implementation and Analysis of a Cascade Loop:
2 – Add a controller and feedback loop
TD
FD 1e-s
1+5s
FSP EF Fs +
Ts ET KC2 U 0.5 T
4e-2s +
Kc(1+1/Tis) + 1 +0.5s
+ = 10 1 + 15s
- -

Tm
1

• To account for potential disturbances to the single loop manipulated variable, FS, start by
adding a P-only controller, KC2, and feedback loop with a fast sensor

22
 Implementation and Analysis of a Cascade Loop:
3 – Simplify, check MV disturbance (FD)

TD
FD 1e-s
1+5s

Fs +
Ts E FSP 0.83 4e-2s T
+
Kc(1+1/Tis)
+ 1 + 0.083s 1 + 15s
-

Tm
1

• Inner CLTF: F
s  0.83
FSP 1  0.083s
• Need to consider FS/FD…

23
 Implementation and Analysis of a Cascade Loop:
4 – Include inner feedback loop to control FS
TD
FD 1e-s
1+5s

Fs +
Ts E FSP 0.83 4e-2s T
+
Kc(1+1/Tis)
+ 1 + 0.083s 1 + 15s
-
Tm
1

1 0.5
FS  s
• Inner OLTF: =1 Inner CLTF: F
s 6 6
FD FD 1  0.5 s
6

• FVT: Unit change in FD gives 1/6 change in FS, for KC2=10

24
 Reactor with preheater:
feedback control
Maintain constant temperature in the
reactor (controlled variable) by
manipulating fuel flowrate to the
preheater furnace:

Smith &25Corropio
Cascade control benefit:
Better control!
• Error integral is
reduced when
using cascade
control
• Deviate less,
return faster to SP

26
Smith & Corropio
CASCADE
CONTROL

Smith &27Corropio
 CASCADE
CONTROL
Outer loop
= reactor temp loop

Smith &28Corropio
 Tuning Cascade loops

• Inner loop is a “normal” feedback loop

• Tune by ZN ultimate frequency, ZN quarter decay, or CohenCoon method
• Then start tuning the outer loop :
• Set inner loop to automatic mode
• Tune by ZN ultimate frequency
• A one-step method (Austin and Lopez) also exists – see Smith Ch 9 and table
9.31
• Find gain, timeconstant and deadtime of both loops
• Set parameters via table

29
 Features of Cascade Control

• Only used if there is a disturbance to a manipulated variable

• This disturbance enters the inner loop on the block
diagram
• Outer master controller sets the set point of inner slave
controller
• The inner loop is usually simple
• Inner or slave loop must have a faster response than outer
loop
• Can improve feedback control performance for relatively
little cost and effort
30