RESULT AND DISCUSSION

Cascade control was being used basically during the single loop of the process where not
effective and also can influence to the process that need to control. The primary objective in
cascade control is to divide an otherwise difficult to control process into two portions, whereby a
secondary control known as a slave control loop is formed around a major disturbances thus
leaving minor disturbances to be controlled by the primary controller. In this experiment, there
were two sub-experiments that have been conducted in order to achieve the objective which are:
1. Open Tank Operation (Self-Regulating Process)
Self-regulating process known as an open system which the process were expose to the
atmospheric pressure. The principle characteristic that makes a process regulating is that it
naturally seeks a steady state operating level if the controller output and disturbance variable are
held constant for a sufficient period of time.
2. Level Flow Cascade of Open Tank (Self-Regulating Control)
The process can be remarkable challenging to control.
The experiment was started with the start-up procedures where it needs to be conducted for PID
trial values and the set-point variable (SV) always in manual mode (M). The red line represented
the flow of water.
LIC31, PID I, Loop 1 FIC31, PID2, Loop 2

First (I) trial Second (II) First (I) trial Second (II)
PID trial PID PID trial PID

SV1 200-600mm 200-600mm SV2 0.9-2.4m3/hr 0.9-2.4m3/hr

PB1 30% 10% PB2 50% 100%

TI1 25sec 15sec TI2 10sec 6sec

TD1 0sec 0sec TD2 0sec 0sec

PL1 640mm PL2 0.5m3/hr

Table 1: PID Trial Values

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 Figure 1: System operated as an open tank and self-regulating process and first trial for Loop 1
and Loop 2
The graph pattern showed when the system operates as an open tank and it was self-regulating
process.
From the graph, when the first and second PID were practicing. The graph shown a lot of
oscillatory trend which this means that the level were unable to regulate itself and it does not
suitable for both 2.1m3/hr and 1.8m3/hr flow rate. But however, when the SV2 was turned to
1.5m3/hr, there is none oscillatory trend occur. On the next step, a step responses test being held.
From level of 800mm it is being decreasing to almost 730mm. this obviously tells that the cascade
control that in charge in the system was satisfactory tuned. As a test disturbances being apply
toward the process, the graph showed a quick oscillatory graph. Then disturbance was applied by
decreasing from SV2=1.8m3/hr to 1.5m3/hr. this change can been seen on the graph where there
was slight fluctuate. Then it followed by a quick tuned up to Auto Mode. A quick response towards
the graph clearly showed it was a pulse disturbances. Pulse disturbance can be defined as a problem
that occurs during the process and it were adjusted accordingly to overcome the disturbance to be
set into the desired level.

Figure 2: Loop 1
On the next test, basically it needs to study the characteristics of the level control. Comparison
between PID 2 and PID 2 were not exactly to differ but it still showed different trend. For PID 1,
the graph more oscillation response and takes a longer time to sustain towards the set point.
However, graph for PID 2 show less oscillation and it only takes several times to recover to its
desired level. Other than that, when we switched the process to Auto mode. The responses from
2
the red pen shows an over dumped graph before it achieves the desired level which the set point
were set at 400mm.

Figure 3: Loop 2
On the testing of step test and pulse disturbances, both PID 1 and PID 2 been used were exactly
same with the startup procedure. As a discussion, the resulting more stable and less settling time
for PID 2. Other than that, the graph shown an under dumped oscillatory responses which it will
take longer time to achieve the set point rather than having an over dumped function.

3
Conclusion and Recommendation

The cascade control primary objective is to divide an otherwise difficult to control process
into two portions, whereby a secondary control known as a slave control loop is formed around a
major disturbances thus leaving minor disturbances to be controlled by the primary controller. In
this experiment, there are two sub-experiments that have been conducted in order to achieve the
objectives stated. First, self-regulating process known as an open system and second, the level
flow cascade of open tank. From the graph obtained, it can be conclude that, oscillatory trends
shows unsuitable at flowrate of 2.1m3/hr and 1.8m3/hr, but suited at 1.5m3/hr for the first and
second PID practice. Then a step responses test by decreasing the level that obviously showed the
cascade control that in charge in the system was satisfactory tuned. An Auto Mode was tuned up
then the pulse disturbance was occurred. Next, to study the characteristics of the level control. For
PID 1, the graph more oscillation response and takes a longer time to sustain towards the set point.
However, graph for PID 2 showed less oscillation and it only takes several times to recover to its
desired level. An exactly same result as startup procedure for step test and pulse disturbance was
showed for both PID 1 and PID2.

There are several problem need to overcome in order to achieve an accurate and successful
conducted experiment. As a new experimenter, ask the lecturer or technician in charge how to
control and to run the experiment frequently this can assure an understanding of the experiment
that is being carry out. Experimenter who have done the experiment in previous session should
have conducted and explained clearly the steps for running the equipment under the supervision
of the technician. Next, make sure the objective of the experiment was clear before starting the
experiment that can lead a better explanation and understanding the experiment topic. Beside that,
familiar with the equipment and learn to carry out a solution for every problems happened, this is
an advantage in critical thinking solving skills as an engineer technology. Moreover, ensure the
graph paper was put in a good condition and make sure to switch on before starting the procedure.
This to prevent from the lost data that shows the behavior of the equipment in the early stage.