CASCADE CONTROL

The second alternative to simple feedback control is cascade control. In this

setup there is
 one manipulated variable
 more than one measured variable

An inner and outer control loop are formed each with an individual feedback
controller. The outer loop controller is also known as the master or primary controller.
 The input to this controller is the measured value of the variable to be
controlled.
 The setpoint is supplied by the operator.
 It passes its output signal to the inner control loop.

The inner loop controller is known as the slave or secondary controller.

 It measures a second variable whose value affects the controlled variable.

 The setpoint is supplied by the output from the outer loop.
 Its output signal is used as the signal to the manipulated variable.

The above points can be shown clearly in a diagram.

The major benefit from using cascade control is that disturbances arising within
the secondary loop are corrected by the secondary controller before they can affect the
value of the primary controlled output. Cascade control is especially effective if the inner
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loop is much faster than the outer loop and if the main disturbances affect the inner loop
first.

Below are described examples of cascade control in practice. It should be noted

that in two of the three examples, the secondary loop is used to compensate for flowrate
changes. In process systems this is generally the case.

Example 1 - Reactor Temperature Control

In this example the aim is to keep T2 at its setpoint. The primary control loop
detects and eliminates changes in T1, the temperature of the reactants. The secondary
control loop detects changes in the temperature of the cooling water. Hence it can adjust
the flow accordingly before the effects are detected by the primary control loop. If there
was no second controller the effect of the cooling water would take a long time to
materialize and hence eliminated.

Example 2 - Distillation Bottoms Temperature Control

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In this example the primary loop detects changes in the temperature brought about
by changes in composition, pressure, etc. The secondary loop detects changes in the
steam flowrate and hence eliminates anticipated effects on the temperature.

Example 3 - Heat Exchanger Temperature Control

This is similar to example 2. The aim is to keep T2 constant. Again the secondary
loop is used to compensate for flowrate changes.

SPLIT RANGE CONTROL

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The final alternative to simple feedback control is Split-Range Control. This is

distinguished by the fact that it has
 one measurement only (the controlled variable)
 more than one manipulated variable

The control signal is split into several parts each associated with one of the
manipulated variables. A single process is controlled by coordinating the actions of
several manipulated variables, all of which have the same effect on the controlled output.

Below are described two situations where split-range control is used in chemical
processes.

Example 1 - Control of Pressure in a Reactor

The aim of this loop is to control the pressure in the reactor. It may be possible to
operate this system with only one of the valves but the second valve is added to provide
additional safety and operational optimality.

In this case the action of the two valves should be coordinated. Thus for example
if the operating pressure is between 0.5 and 1.5 bar then the control algorithm could be

 If the pressure is below 0.5 bar then valve 1 is completely open and 2 is
completely closed.
 If the pressure is between 0.5 and 1 bar then valve 1 is completely open while
2 is opened continuously as the pressure rises. Note that both these actions
lead to a reduction in pressure.
 If there is a large increase in pressure and it rises to above 1 bar then valve 2 is
completely open while 1 is closed continuously.
 If the pressure reaches 1.5 bar then valve 1 is shut and 2 is open.

A graph of these valve positions with respect to pressure is shown below.

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Example 2 - Control of Pressure in a Steam Header

The aim of this control loop is to maintain a constant pressure in the steam header
subject to differing demands for steam further downstream. In this case the signal is split
and the steam flow from every boiler is manipulated. An alternative manipulated variable
could be the steam production rate at each boiler via the firing rate. A similar control
scheme to the above could be developed for the pressure control of a common discharge
or suction header for N parallel compressors.