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Cascade Control
Principle
by Editorial Staff

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What is Cascade Control?

In single-loop control, the controller’s set

point is set by an operator, and its output

drives a final control element. For

example: a level controller driving a control

valve to keep the level at its set point.

In a cascade control arrangement, there

are two (or more) controllers of which one

controller’s output drives the set point of

another controller. For example: a level

controller driving the set point of a flow

controller to keep the level at its set point.

The flow controller, in turn, drives a control

valve to match the flow with the set point

the level controller is requesting.

The controller driving the set point (the

level controller in the example above) is

called the primary, outer, or master

controller. The controller receiving the set

point (flow controller in the example) is

called the secondary, inner or slave

controller.

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Cascade control can improve control

system performance over single-loop

control whenever either: (1) Disturbances

affect a measurable intermediate or

secondary process output that directly

affects the primary process output that we

wish to control; or (2) the gain of the

secondary process, including the actuator,

is nonlinear. In the first case, a cascade

control system can limit the effect of the

disturbances entering the secondary

variable on the primary output. In the

second case, a cascade control system

can limit the effect of actuator or

secondary process gain variations on the

control system performance. Such gain

variations usually arise from changes in

operating point due to setpoint changes or

sustained disturbances.

When Should Cascade Control be

Used?

Cascade control should always be used if

you have a process with relatively slow

dynamics (like level, temperature,

composition, humidity) and a liquid or gas

flow, or some other relatively-fast process,

has to be manipulated to control the slow

process. For example: changing cooling

water flow rate to control condenser

pressure (vacuum), or changing steam

flow rate to control heat exchanger outlet

temperature. In both cases, flow control

loops should be used as inner loops in

cascade arrangements.

Does Cascade Control Have any

Disadvantages?

···

Cascade control has three disadvantages.

One, it requires an additional

measurement (usually flow rate) to work.

Two, there is an additional controller that

has to be tuned. And three, the control

strategy is more complex – for engineers

and operators alike. These disadvantages

have to be weighed up against the

benefits of the expected improvement in

control to decide if cascade control should

be implemented.

When Should Cascade Control Not be

Used?

Cascade control is beneficial only if the

dynamics of the inner loop are fast

compared to those of the outer loop.

Cascade control should generally not be

used if the inner loop is not at least three

times faster than the outer loop, because

the improved performance may not justify

the added complexity.

In addition to the diminished benefits of

cascade control when the inner loop is not

significantly faster than the outer loop,

there is also a risk of interaction between

the two loops that could result in instability

– especially if the inner loop is tuned very

aggressively.

···

How Should Cascade Controls be

Tuned?

A cascade arrangement should be tuned

starting with the innermost loop. Once

that one is tuned, it is placed in cascade

control, or external set point mode, and

then the loop driving its set point is

tuned. Do not use quarter-amplitude-

damping tuning rules (such as the

unmodified Ziegler-Nichols and Cohen-

Coon rules) to tune control loops in a

cascade structure because it can cause

instability if the process dynamics of the

inner and outer loops are similar.

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3 thoughts on “Cascade
Control Principle”

Akshay
November 6, 2017 at 5:07 pm

For cascade control above

example..there are two controller

used.So what are the process

Variable and control variable for

this two controller ?

Reply

Dheeraj
December 29, 2022 at 9:41 am

Master Controller’s variable will be

work as PV and SV. in the above

example Level controller will be the

master controller.

Reply

Innocent Menuchimso Bob-Weke

January 28, 2024 at 11:59 pm

Thanks

Reply

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