Cascade Tuning
Cascade Tuning
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.
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
TIC
TT
Heat Exchanger
TIC
FLOW
TEMP
TIC
TT
Process Schematic
Heat Exchanger
TIC
TT
Heat Exchanger
TIC
FLOW
TEMP
TIC
TT
Process Schematic
Heat Exchanger
TT
TIC
FT
FIC
FLOW
TEMP
TT
Process Schematic
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
FT
TT
OP PV MASTER
REM SP SLAVE
OP
OP TRK PV MASTER
OP
OP
Batch Reactor Temperature Control (Batch Temperature onto Jacket Temperature) Level Flow Control
Level Control
LT
Level Control
IN > OUT: Level Rises
LT
IN
OUT
LT
LIC
IN
LT
LIC
IN
OUT
A failure of the control valve to reposition itself correctly following a reversal in the control signal level will cycle !!
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LT
LIC
IN
FT FIC
OUT
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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.
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Outer loop PV
Inner loop PV
Inner loop CO
Inner loop PV
Inner loop CO
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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.
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1/0.0677 = 15s
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Cascade Control A Case Study Waste Water Industry Dissolved Oxygen Control
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4 3.5 3
DO (mg/l)
70 60 50 40 30 20 10 0
Time
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.
4 3.5 3
DO (mg/l)
AV302 QI503
70 60 50 40 30 20 10 0
Time
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.
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Bridging the gap between Industrial Processes and the Programmable Systems that control them.
www.controlspecialists.co.uk
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