CHAPTER 14: CASCADE CONTROL

When I complete this chapter, I want to be able to do the following.

Identify situations for which cascade is a good control enhancement Design cascade control using the five design rules Apply the tuning procedure to cascade control

CHAPTER 14: CASCADE CONTROL

Outline of the lesson.

A process challenge - improve performance Cascade design rules Good features and application guidelines Several process examples Analogy to management principle

CHAPTER 14: CASCADE CONTROL

F 1

feed
T 1

L 1

product

Discuss this stirred tank heat exchanger.

TC 2

PID controller

T 3

F 2

heating stream

CHAPTER 14: CASCADE CONTROL

Class exercise: What do we do?
F 1 L 1
IAE = 147.9971 ISE = 285.4111 76

TC

75 temperature

74

feed
T 1 Disturbance = heating pressure Control performance not acceptable!

73

minimum
20 40 60 80 100 120 140 160 180 200

72 0

TC 2

T 3

F 2

Pressure disturbance

heating stream

CHAPTER 14: CASCADE CONTROL

Lets think about the process behavior. Causal relationship from P disturbance to T (without control) What measurable effect always occurs when P changes? v (valve) ??? Q
T 3 F 1

feed
T 1

L 1

product

TC 2

F 2

P
heating stream

TC

P (heating oil)

CHAPTER 14: CASCADE CONTROL

Lets think about the process behavior. If we can maintain this variable approximately constant, can we reduce the effect of the disturbance? v (valve) ???
F 1

feed
T 1

L 1

product

TC 2

T 3

F 2

P
heating stream

TC

P (heating oil)

CHAPTER 14: CASCADE CONTROL

F 1

feed
T 1

L 1

product

Sketch a Proposal here.

TC 2

PID controller

T 3

F 2

heating stream

CHAPTER 14: CASCADE CONTROL

A New Control Structure!!
F 1

feed
T 1

L 1

T2=CV1
primary TC 2

product

Key variables for the two PID controllers.

SP1 from person

SP2 = MV1

T 3

v=MV2

FC 2

secondary

F2=CV2 heating stream

CHAPTER 14: CASCADE CONTROL

Class exercise
plant
T 2

computer

computer person

T2SP

Define the calculations performed in the computer.

F 2

CHAPTER 14: CASCADE CONTROL

Class exercise
plant
T 2

computer
E T 2 = T2 sp T2

computer person

1 E T 2 + MV1 = (K c ) T 2 E T 2dt' + I T 2 (TI ) T 2 0 F 2 SP = MV1

T2SP

Each controller is a PID!

F 2

E F 2 = F 2 sp F 2 1 MV2 = (K c ) F 2 E F 2 + (TI ) F 2 v = MV2

E F 2 dt' + I F 2 0
t

CHAPTER 14: CASCADE CONTROL

Control Performance Comparison for CST Heater Single-Loop
IAE = 147.9971 ISE = 285.4111 76 76

Cascade
IAE = 11.5025 ISE = 1.6655

75 temperature

75

74

74

73

73

72 0

20

40

60

80

100 120 140 160 180 200

72

50

100

150

200

Much better performance! WHY?

CHAPTER 14: CASCADE CONTROL

Cascade Control Performance for CST Heater
IAE = 11.5025 ISE = 1.6655 76 75 temperature 74 73 72

TC
Small deviation, returns to set point
0 50 100 150 200 IAE = 11.6538 ISE = 11.2388

WHY? Disturbance in flow is quickly corrected. This compensates for the disturbance!
SAM = 5.8711 SSM = 4.4807 58 heating valve (% open) 56 54 52 50

20.5 20 heating flow 19.5 19 18.5 18 0

FC
Disturbance affects flow sooner than T2
50 100 Time 150 200

Valve adjustment is not aggressive!

0 50 100 Time 150 200

CHAPTER 14: CASCADE CONTROL

What have we gained and lost using cascade control? For each case, is cascade better, same, worse than single-loop feedback (TC2 v)?
F 1 feed T 1 CV1 TC 2 product L 1

SP1 for person

SP2 = MV1 FC 2 MV2 CV2 heating stream

T 3

A disturbance in heating medium inlet pressure A disturbance in heating medium inlet temperature A disturbance in feed flow rate A change to the TC set point

CHAPTER 14: CASCADE CONTROL

What have we gained and lost using cascade control? For each case, is cascade better, same, worse than single-loop feedback (TC2 v)?
F 1 feed T 1 CV1 TC 2 product L 1

SP1 for person

SP2 = MV1 FC 2 MV2 CV2 heating stream

T 3

Cascade better A disturbance in heating medium inlet pressure

A disturbance in heating medium inlet temperature same Both the A disturbance in feed flow rate A change to the TC set point
Both the same Both the same

CHAPTER 14: CASCADE CONTROL

CASCADE DESIGN CRITERIA Cascade is desired when 1. 2. 3. 4. 5. Single-loop performance unacceptable A measured variable is available Indicate the occurrence of an important disturbance Have a causal relationship from valve to secondary (cause effect) Have a faster response than the primary Very important

A secondary variable must

CHAPTER 14: CASCADE CONTROL

ADVANTAGES OF CASCADE CONTROL Large improvement in performance when the secondary is much faster than primary Simple technology with PID algorithms Use of feedback at all levels. Primary has zero offset for step-like disturbances. Plant operating personnel find cascades easy to operate. Open a cascade at one level, and all controllers above are inactive.

CHAPTER 14: CASCADE CONTROL

CLASS EXERCISE: SOME QUESTIONS ABOUT CASCADE CONTROL Why do we retain the primary controller? Which modes are required for zero steady-state offset? Which modes are recommended? What is the additional cost for cascade control? Normally, each PID controller represents one independent controlled variable. Is anything different in a cascade structure? What procedure is used for tuning cascade control?

CHAPTER 14: CASCADE CONTROL

heating stream

Discuss this packed bed reactor.

F 1

F 2

T 2 T 3

feed
T 1 A 2

packed bed reactor

Notes: 1. A1 measures reactant concentration 2. Circle is shell & tube heat exchanger 3. Feed valve is adjusted by upstream process 4. Increasing temperature increases reaction rate A 1

product

CHAPTER 14: CASCADE CONTROL

Class exercise: Design a cascade control structure to improve performance.
heating stream

Performance not acceptable

F 1

F 2

Disturbance in heating medium temperature

T 2 T 3

feed
T 1 A 2

0.2 0.15 CV1 0.1 0.05 0 -0.05 0 100 200

AC maximum

packed bed reactor

AC 1

300

400

500

product

CHAPTER 14: CASCADE CONTROL

Class exercise: Design a cascade control structure to improve performance.

1. 2. 3. 4. 5.

Cascade design criteria Single-loop not acceptable Secondary variable is measured Indicates a key disturbance Causal relationship, valve secondary Secondary dynamics faster than primary

A2

F1

F2

T1

T2

T3

Lets use the cascade design rules!

Remember: The disturbance is the heating medium inlet temperature and the primary is AC-1.

CHAPTER 14: CASCADE CONTROL

Class exercise: Design a cascade control structure to improve performance.

1. 2. 3. 4. 5.

Cascade design criteria Single-loop not acceptable Secondary variable is measured Indicates a key disturbance Causal relationship, valve secondary Secondary dynamics faster than primary

A2 Y Y N N N/A

F1 Y Y N N N/A

F2 Y Y N Y N/A

T1 Y Y N N N/A

T2 Y Y Y N N/A

T3 Y Y Y Y Y

Lets use the cascade design rules!

T2 is the disturbance but cannot be used in cascade! T3 satisfies all of the rules and can be used as a secondary in a cascade.

CHAPTER 14: CASCADE CONTROL

heating stream

Sketch your design on this drawing.

F 1

F 2

T 2 T 3

feed
T 1 A 2

packed bed reactor

Notes: 1. A1 measures reactant concentration 2. Circle is shell & tube heat exchanger 3. Feed valve is adjusted by upstream process 4. Increasing temperature increases reaction rate A 1

product

CHAPTER 14: CASCADE CONTROL

heating stream
F 2

MV2
F 1 T 2 TC 3 secondary

feed

T 1

A 2

CV2

SP2 = MV1 packed bed reactor

primary AC 1

CV1

SP1 from person product

CHAPTER 14: CASCADE CONTROL

Control Performance Comparison for Packed Bed Reactor Single-Loop
IAE = 24.4229 ISE = 3.4639 0.2 0.15 CV1 0.1 0.05 0 -0.05 0 100 200 300 400 0.2 0.15 0.1 0.05 0 -0.05 0 500 100 200 300 400 500

Cascade
IAE = 6.3309 ISE = 0.19017

Much better performance! WHY?

CHAPTER 14: CASCADE CONTROL

Cascade Control Performance for Packed Bed Reactor
IAE = 6.3309 ISE = 0.19017 0.2 0.15 CV1 0.1 0.05 0 -0.05 0 100 200 300 400 500

AC

WHY? Disturbance in temperature is quickly corrected. This compensates for the disturbance!
4 3 SAM = 4.3428 SSM = 0.59949

0.5

IAE = 37.2971 ISE = 18.6031

TC
-0.5

CV2

MV

2 1 0

Disturbance affects T sooner

100 200 300 Time 400 500

Valve adjustment is not aggressive!

0 100 200 300 Time 400 500

-1 0

CHAPTER 14: CASCADE14: CASCADE CONTROL CHAPTER CONTROL

heating stream

What have we gained and lost using cascade control? How does the system respond to the following? A disturbance in T1
feed
T 1

F 2

MV2
F 1 T 2

A 2

CV2

TC 3 secondary

SP2 = MV1 packed bed reactor

primary AC 1

CV1

SP1 from person product

A disturbance in heating medium inlet pressure A disturbance in feed pressure A disturbance to feed composition, A2 A change to the AC-1 set point

CHAPTER 14: CASCADE 14: CASCADE CONTROL CHAPTER CONTROL

heating stream

What have we gained and lost using cascade control?

feed

F 2

MV2
F 1 T 2

How does the system respond to the following? A disturbance in T1

T 1

A 2

CV2

TC 3 secondary

SP2 = MV1 packed bed reactor

primary AC 1

CV1

SP1 from person product

Cascade better

A disturbance in heating medium inlet pressure A disturbance in feed pressure A change to the AC-1 set point A disturbance to feed composition, A2

Cascade better

Cascade better, but not perfect Both the same

Both the same

CHAPTER 14: CASCADE CONTROL

CV3
F 2

Three-Level Cascade!
MV3 SP3 = MV2

F 1

T 2 TC 3

feed

T 1

A 2

CV2

SP2 = MV1

No limit to number of levels of cascade! Each must meet criteria.

CV1

AC 1

SP1 from person product

CHAPTER 14: CASCADE CONTROL

Does cascade apply to instrumentation? Yes, a valve positioner is a secondary that reduces effects of friction!!
F 1 feed T 1 TC 2 L 1 product

T 3 heating stream

Valve positioner: Measures the stem position and adjusts the air pressure to (closely) achieve the desired position. This is located at the valve.

CHAPTER 14: CASCADE CONTROL

A cascade is a hierarchy, with decisions transmitted from upper to lower levels. No communication flows up the hierarchy. What are advantages of a hierarchy? What information should be transmitted up the hierarchy? What information should flow from secondary to primary in a cascade?

CHAPTER 14: CASCADE CONTROL WORKSHOP 1 Evaluate cascade control for a disturbance in the heating medium inlet temperature. You may add a sensor but make no other changes to the equipment.
F 1 feed T 1 TC 2 L 1 product

T 3

F 2 heating stream

CHAPTER 14: CASCADE CONTROL WORKSHOP 2 Prepare a detailed plan for tuning the two cascade controllers shown in the following sketch.
F 1 feed T 1 product L 1

CV1 TC 2

SP1 for person

SP2 = MV1

T 3

FC 2 MV2 CV2 heating stream

CHAPTER 14: CASCADE CONTROL WORKSHOP 3 Prepare a flowchart for the calculations performed by the packed bed cascade controllers. Show every calculation and use process variable symbols (e.g., A1), not generic symbols (CV1).
heating stream
F 2

MV2
F 1 T 2 TC 3 secondary

feed

T 1

A 2

CV2

SP2 = MV1 packed bed reactor

primary AC 1

CV1

SP1 from person product

CHAPTER 14: CASCADE CONTROL WORKSHOP 4 Identify process examples in which a valve positioner will improve performance and not improve performance. Draw a sketch of each process and discuss your recommendation of whether or not to use a positioner.

Note: Modern positioners provide diagnosis of the valve behavior that can be transmitted digitally for later evaluation. This can be very useful in maintenance and trouble shooting.

CHAPTER 14: CASCADE CONTROL

When I complete this chapter, I want to be able to do the following.

Identify situations for which cascade is a good control enhancement Design cascade control using the five design rules Apply the tuning procedure to cascade control

Lots of improvement, but we need some more study! Read the textbook Review the notes, especially learning goals and workshop Try out the self-study suggestions Naturally, well have an assignment!

CHAPTER 14: LEARNING RESOURCES

SITE PC-EDUCATION WEB - Instrumentation Notes - Interactive Learning Module (Chapter 14) - Tutorials (Chapter 14) S_LOOP - Dynamic simulation of linear system The Textbook, naturally, for many more examples

CHAPTER 14: SUGGESTIONS FOR SELF-STUDY 1. Prove that an integral mode is required for zero steadystate offset of the primary. Do we achieve zero offset for the secondary. Why or why not? Is there any advantage for achieving zero offset for the secondary? 2. Program a cascade control for one of the processes modelled in Chapters 3-5. 3. Determine a guideline for how much faster the secondary must be than the primary for cascade to function well.

CHAPTER 14: SUGGESTIONS FOR SELF-STUDY 4. Using block diagram algebra, derive the transfer functions in textbook equations (14.6) to (14.8). 5. Review the following publication to find other advantages for cascade control.
Verhaegen, S., When to use cascade control, Intech, 38-40 (Oct. 1991).

6. Discuss applications of cascade control (hierarchical decision systems) in business, government, and university. Explain advantages and disadvantages of these systems.