CASCADE CONTROL

Smith & Corripio

Seborg
Stephanopoulos

FB (-ve) correction
taken after it
disturb the process

FF (-ve) requires an
accurate model

FBFF (-ve)
accurate tuning and
accurate model

Cascade

Cascade

Consists of 2
FB loops

Primary/Master/
Outer

Secondary/Slave
/Inner

Purpose

Eliminate the
effect of
disturbance

To improve the
dynamic
performance
of the control
loop

7:56 AM
Feedback control

TC

I/P
Heat exchanger

TT

Manipulated variable
(saturated steam)
Load variable
(Flow of saline solution)

80C

100C
30C
100 L/min

controlled variable
(temperature of
sterilised saline)
95C

What is feedback control?

A method of control that the action taken is based on past
result.

Manipulated variable
(Saturated steam)

Merit?
Simple design. Easy to tune (for linear, fast & short
deadtime processes: flow, level & pressure).

Demerits?
Slow recovery for slow process such as temperature control
upon load disturbance or change in setpoint. A process with
long deadtime may exhibit oscillatory process response
with long settling time.

The Process
Saline solution at 30C is sterilized by heating the
solution in a heat-exchanger system to 80C. The
temperature of the sterilized saline solution is
maintained by regulating the control valve of steam
input to the heat-exchanger.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Feedforward control
Ws

Cp
Hs

I/P
Wp T2 T1

FFC
FT

Manipulated variable
(saturated steam)
Load variable
(Flow of saline solution)

Heat exchanger
30C
100 L/min

controlled variable
(temperature of
sterilised saline)
95C

What is feedforward control?

A method of control based on process model: mass and
energy balances.

Merit?
Faster recovery than cascade or SISO. Compensate for
disturbances before they effect the controlled variable.

80C

Manipulated variable
(Saturated steam)

Characteristic of feedforward control:

Measurements of load variables online and Utilization
of computational blocks.

Demerits?
Cannot work if any of the sensors fail esp. load variable.
Requires process model in order to design feedforward
system.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

SP

Cascade control
I/P

FC
FT

TC
Heat exchanger

TT

Manipulated variable
(saturated steam)
Load variable
(Flow of saline solution)

80C

100C
30C
100 L/min

controlled variable
(temperature of
sterilised saline)
95C

What is cascade control?

A method of control of which the inner loop
controller obtains its setpoint from an outer loop
controller.

Manipulated variable
(Saturated steam)

Characteristic of cacade control:

Merit?
Faster recovery time as compared to SISO feedback
control.

Demerits?
Controllability will be worst than SISO if both
controllers were not properly tuned.

Two transmitters, two controllers and one

control valve (2-level cascade).

Application: Transform from SISO to cascade

strategy if faster recovery time is desired.

Abdul Aziz Ishak, Universiti Teknologi MARA Malaysia (2009)

Y(s)

Primary
controller

Secondary
controller

Process II

Process I

Example of cascade
A conventional FB regulating the
hot oil temperature despite the
disturbance in oil flow or cold oil
flow. The TC will take corrective
action by adjustig the fuel gas flow
once there is change in the hot oil T.

Cascade primary measurement is T

of hot oil is used by the master
controller (TC) to establish a SP for
the secondary (slave) loop controller.
The secondary measurement is the
fuel gas pressure. If a disturbance in
supply pressure occurs, the pressure
controller will act quickly to hold the
fuel gas at its set point.

Example of cascade

Conventional FB loop

Cascade loop

Example of cascade

Conventional FB loop

Cascade loop

Conventional FB loop

Cascade loop