DEPARTMENT OF TECHNICAL EDUCATION

ANDHRA PRADESH
Name : K.Venkateshwarlu.
Designation : Sr.lecturer
Branch : A.E.I.E
Institute : K.D.R.G.P.T,Wnp,Mbnr Dist.
Semester : V Semester.
Subject : Process Control
Subject code : AEI-504.
Topic : Process control system configuration.
Duration : 100 min
Subtopic : Cascade controller.
Teaching Aids : PPTS, Animations,
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 Recap

In the previous session, we learnt about :

• Characteristics of variables.
• Multivariable control.

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 Objectives

On completion of this topic you would be able to

know about

• Block diagram of cascade controller with example

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 Cascade Controller

• Cascade means the output of one controller is given as

input to another controller

CASCADED
Block 1 Block 2
o/p i/p

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Cascade control

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 Cascade Controller

Fig 2 : Block diagram of Cascade controller

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 Description of Block Diagram

• Cascade controller consists of

• One primary controller

• One secondary controller

• Primary controller is also called master controller

• Secondary controller is also called slave controller

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• Primary controller controls the variable that is to be kept
at a constant value.

• Secondary controller controls the another variable which

causes the fluctuations in the first variable.

• Primary controller positions the set point of the

secondary controller and it in turn manipulates the
control variable.

• Cascade control system consists of two feed back

controllers but only one process variable (m) is
manipulated.

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• Primary controller maintains the primary variable (C1) at
its set point (r1) by automatically adjusting the set point
(r2) of the secondary controller

• Secondary controller controls the secondary loop

responding to both its set point (r2) and measurement
(C2)

• Secondary controller may be regarded as a final control

element positioned by the primary controller
• Cascade controller is an example for multiple loop
controller.
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Note :
• In designing cascade controller, the time constant of the
secondary control loop must be significantly faster than
that of primary loop.

• If above condition is not satisfied then the cascade

controller will not provide any benefits.

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In a cascade controller

• Inner variable = independent variable

• Outer variable = dependent variable

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Example 1

• Control of level in tank, level depends on in flow rate.

• level = f [in flow rate]

• In flow inner variable independent variable

• Level outer variable dependent variable

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 Inner loop consists of

Flow Flow controller

measuring (inner controller)
instrument
[Secondary controller]
(or)
[Slave
controller]

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 Outer loop consists of

Level level controller

measuring (outer controller)
instrument
[primary controller]
(or)
[master
controller]

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• Level (outer) controller adjusts
set point for flow (inner) controller.

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Example 2

• Control of temperature of the liquid in the vessel.

Temperature depends on heat input.

• Heat input means steam pressure.

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 temperature = f [steam pressure]

dependent variable independent variable

outer loop inner loop

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• Inner loop consists of
pressure measure instrument
pressure controller

• Outer loop consists of

temperature measure instrument
temperature controller

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Therefore temperature controller (outer) adjusts
the set point of pressure controller (inner)

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 Summary

We have discussed about

• Block diagram of Cascade controller with example

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 Quiz

1. Cascaded control is a

(a) single loop control

(b) two loop control

(c) multi loop control

(d) ten loop control

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 Quiz

• Set point of one control loop is decided by measuring

variable in

a. same loop

c. another loop

e. both loop

g. none
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 Quiz

3. Number of loops in cascade control are decided by

a. Measuring parameters

c. Set point

e. Both

g. None

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 Quiz

4. Outer (primary) controller output adjusts set point of

a. inner controller

c. secondary controller

e. a & b

g. tertiary controller

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 Quiz

5. In control of level in tank

(a) level depends on in flow rate

(b) in flow rate dependents on level

(c) any one

(d) none

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 Quiz

6. In temperature control of liquid in vessel

(a) temperature depends on heat input

(b) heat input depends on steam pressure

(c) above two

(d) none

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 Frequently Asked Questions

1) Define the cascade control.

3) Draw the block diagram of cascade controller and

explain.

5) Explain the cascade controller with examples

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