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Cascade Tuning

This document discusses how to tune cascade control loops. It begins with background on the company providing the document. It then outlines that it will cover an overview of cascade control, tuning cascade control loops, and provide a case study. It goes on to describe cascade control and how it can improve system performance. It provides examples of cascade loops and discusses temperature-flow and level-flow cascades. It describes how to tune the inner and outer loops and test the tuning. It defines relative response time and how it should relate between the inner and outer loops. It concludes with a case study on dissolved oxygen control in waste water treatment.

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Didik Riswanto
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100% found this document useful (1 vote)
175 views18 pages

Cascade Tuning

This document discusses how to tune cascade control loops. It begins with background on the company providing the document. It then outlines that it will cover an overview of cascade control, tuning cascade control loops, and provide a case study. It goes on to describe cascade control and how it can improve system performance. It provides examples of cascade loops and discusses temperature-flow and level-flow cascades. It describes how to tune the inner and outer loops and test the tuning. It defines relative response time and how it should relate between the inner and outer loops. It concludes with a case study on dissolved oxygen control in waste water treatment.

Uploaded by

Didik Riswanto
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 18

How to Tune Cascade Loops

Peter Thomas Control Specialists Ltd ExperTune User Conference Austin Texas April 2007
www.controlspecialists.co.uk

Background
Established 1989 - British Standards Institute (BSI) ISO9001:2000 Tick IT registered Certified Suppliers of FDA / GAMP Validated Control Systems for AstraZeneca -international Pharmaceutical Manufacturer Approved Solutions Partner (Sales, Support & Training) of ExperTune Inc. Experience of working in Oil, Pharmaceuticals, Chemicals, Glass, Food and Water.

How to Tune Cascade Loops


An overview of Cascade Control. Tuning Cascade Control Loops. Case Study.

Cascade Control

In the the right right circumstances, circumstances, In Cascade Control Control can can greatly greatly improve improve Cascade the performance performance of of a a control control system. system. the

Temperature Control Loop


Steam Header To other User

TIC

TT

Heat Exchanger

Temperature Control Loop


Steam Header To other User

TIC

FLOW

TEMP

TIC

TT

Process Schematic

Heat Exchanger

Temperature Control Loop


Steam Header

TIC

TT

Response to a Load Change

Heat Exchanger

Temperature Control Loop


Steam Header To other User

TIC

FLOW

TEMP

TIC

TT

Process Schematic

Heat Exchanger

Temperature Flow Cascade


Steam Header To other User
FIC FT TIC

TT

Temperature Flow Cascade


Steam Header To other User
FIC (Slave) TIC (Master)

TIC

FT

FIC

FLOW

TEMP

TT

Process Schematic

The Cascade Loop

What's The Inner Loop For?

Reduces phase lag of inner process Disturbances to the inner loop are compensated for before they upset the outer loop Prevents non-linearities in the inner loop from reaching the outer loop

Temperature Flow Cascade


Steam Header

FT

FIC (Slave) TIC (Master)

TT

Response to a Load Change

The Cascade Loop

Master Cascade Signals


PV

OP PV MASTER

REM SP SLAVE

OP

Master Cascade Signals


PV

OP TRK PV MASTER

REM SP REM SLAVE

OP

When slave is NOT in Remote/Auto mode Master OP is to track Slave Setpoint.

Master Cascade Signals


PV

OP TRK PV MASTER INT

REM SP REM SLAVE OP LIMIT

OP

Integral action in Master is to be Inhibited when OP limit reached in Slave

Other Examples of Cascade

Batch Reactor Temperature Control (Batch Temperature onto Jacket Temperature) Level Flow Control

Level Control

LT

Level loops are Integrating Processes

Level Control
IN > OUT: Level Rises
LT

IN < OUT: Level Falls IN = OUT: Level Holds

IN

OUT

Level loops are Mass Balance Systems

Level Control Problems (Non Linear Responses)

LT

LIC

IN

Head Variations OUT

Level Control Problems (Valve Hysteresis)

LT

LIC

IN

OUT

A failure of the control valve to reposition itself correctly following a reversal in the control signal level will cycle !!

10

Fixing the problems Level Flow Cascade

LT

LIC

IN
FT FIC

OUT

How to Tune Cascade Loops


An overview of Cascade Control. Tuning Cascade Control Loops. Case Study.

11

What happens when cascade loops are poorly tuned?

Loops fight each other Create oscillations Neither variable is properly controlled Operator puts loop in manual.

1. 2.

3.

4.

Tuning Cascade Loops Always check for measurement and valve-related issues. Inner Loop Tuning - put slave into Local Auto or Manual and tune the slave controller as a normal PID loop. Outer Loop Tuning - put slave into Cascade and tune master controller as a normal PID loop. Adjust outer loop tuning values to ensure that the RRT (Relative Response Time) of outer loop is 3-5 times slower than the inner loop.

12

Test Data - Inner Loop

Outer loop PV

Inner loop SP Change

Inner loop PV

Inner loop CO

Test Data - Outer Loop

Outer loop PV Outer loop SP change

Inner loop PV

Inner loop CO

13

Relative Response Time What is it ? 1. 2. 3. 4. An indication of the closed loop response of a control loop. Loops with short RRTs are fast loops Loops with long RRTs are slow loops. The RRT approximately defines the period of any load disturbance initiated oscillations when the controller is in automatic.

Relative Response Time and Cascade Loops 1. The closed loop response (i.e its RRT) of the outer loop MUST be 3 5 times slower than the inner loop. After tuning, adjust outer loop PID values to achieve this. Our example: Inner: 38 seconds Outer: 400 seconds

2. 3.

14

Determining the Relative Response Time

Relative Response Time (RRT)

1/0.0677 = 15s

15

How to Tune Cascade Loops


An overview of Cascade Control. Tuning Cascade Control Loops. Case Study.

Cascade Control A Case Study Waste Water Industry Dissolved Oxygen Control

16

Dissolved Oxygen Control As Found


CASP 1 DO
100 90 80
Valve position

4 3.5 3
DO (mg/l)

70 60 50 40 30 20 10 0
Time

2.5 2 1.5 1 0.5 0

AV302 QI503

Oxygen Concentration controlled by QIC adjusting the flow of air. PID Control implemented in a Siemens S7 PLC. PIC used to control blower speed. Flow measurement for information only. If the blower speed exceeded 95% the second blower started (at the same speed) to assist the duty blower. Poor control.

Dissolved Oxygen Control As Left


CASP 1 DO
100 90 80
Valve position

4 3.5 3
DO (mg/l)
AV302 QI503

70 60 50 40 30 20 10 0
Time

2.5 2 1.5 1 0.5 0

Control Specialists Ltd modified the software at the request of the end user. Flow loop quickly rejects disturbances due to duty-standby boosters coming on and off line. Blower operating costs reduced. Control dramatically improved.

17

Bridging the gap between Industrial Processes and the Programmable Systems that control them.

www.controlspecialists.co.uk

18

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