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Lecture36 Notes

Cascade control uses two nested control loops, where the setpoint of the inner loop acts as the process variable for the outer loop. This allows disturbances that affect the inner loop to be rejected before reaching the outer loop. Effective cascade control requires that [1] the inner loop variable responds faster than the outer loop variable, [2] the same disturbance affects both loops, and [3] the same actuator influences both loops. Cascade control is sometimes overused or improperly applied, such as when the inner loop is slower than the outer loop or when a single-loop controller could achieve the same results with less complexity. An example cascade control application maintains oil temperature by controlling fuel gas pressure in the inner loop and oil outlet temperature in

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42 views

Lecture36 Notes

Cascade control uses two nested control loops, where the setpoint of the inner loop acts as the process variable for the outer loop. This allows disturbances that affect the inner loop to be rejected before reaching the outer loop. Effective cascade control requires that [1] the inner loop variable responds faster than the outer loop variable, [2] the same disturbance affects both loops, and [3] the same actuator influences both loops. Cascade control is sometimes overused or improperly applied, such as when the inner loop is slower than the outer loop or when a single-loop controller could achieve the same results with less complexity. An example cascade control application maintains oil temperature by controlling fuel gas pressure in the inner loop and oil outlet temperature in

Uploaded by

Idriss Barça
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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More Cascade Control

Review
What is cascade control? Why use cascade control? What process dynamics are necessary? What types of controllers are used? How do you tune controllers?

Cascade Design
Characteristics for selecting early warning PV2 include: it must be measurable with a sensor the same FCE (e.g., valve) used to manipulate PV1 also manipulates PV2 the same disturbances that are of concern for PV1 also disrupt PV2 PV2 responds before PV1 to disturbances of concern and to FCE manipulations

Misconceptions and MisApplications of Cascade Control


Generally, adding a secondary controller does not make a feedback control system faster Secondary controllers are often more complicated, e.g., PI or PID, than they should be Cascade control is overused
Must be a disturbance to localize by secondary control Often, system can be improved by removing cascade control (replace with simpler single-loop systems)

Misconceptions and MisApplications of Cascade Control


A common form of a cascade controller is a valve positioner as a secondary controller
Electromechanical or pneumatic-mechanical, high gain controller mounted on the valve Overcomes frictional effects Minimizes hysteresis and deadband

You are asking for trouble if the dynamics of the secondary loop are commensurate with (or slower than!) the dynamics of the primary loop

Example from Seborg et al.


Goal:
Heat up oil stream

Controlled variable
Temperature of oil out

Manipulated variable:
Fuel gas flow rate

Problem:
(Fig. 16.1)

Fluctuating fuel gas pressure

Solution: Cascade Control


Primary loop:
Controls Tout of oil Makes set point for secondary loop

Secondary loop:
Measures and controls fuel gas pressure Could use flow rate instead of pressure

(Fig. 16.2)

Safety Video
Exothermic reaction Cooling jacket on batch reactor Operator-controlled cooling flow rate H2 production in reactor CSB video Special Problem 14

Control Station Example


Jacketed reactor with cascade control Initial conditions
Controller output = 50% Inlet Tjacket = 46C

P-only control for the secondary loop Tune

Question
p = 1.5 min for the inner loop p = 0.55 min for the outer loop Does this violate our rules for implementing cascade control?

Next Class---- Feed Forward

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