PIC Part-C Student Version

Part-C
2010
PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu
Cascade control
2010
Cascade Control
d S y d1 S1 d2 S2 decomposed process d3 S3 y3 y u u
y2
Undecomposed process
Cascade control is employed for controlling large and complex processes, where performance of a single controller is not acceptable due to (i) slow closed loop response and/or (ii) high sensitivity to plant gain changes and load/disturbances. In order to employ Cascade Control, there should be at least one measurable intermediate (secondary) variable which affect the primary process variable.
Such processes are called cascade decomposable
The process equation y = f (u,d)

Where u= input, y= primary PV and d is disturbance
2010
Cascade Control-II
The process equation y = f(u,d)
Where u= input, y= primary PV and d is disturbance
May be decomposable as follows y=f3(y3,d3)=f3{f2(y2,d2),d3} = f3[f2 {f1 (u, d1), d2},d3] y2 and y3 are intermediate variables which, in a cascade form, affects y, the primary PV,
d1 S1 d2 S2 d3 S3 y3 y
y2
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Cascade Control-III
Cascade control can substantially improve the performance of the controlled system over single-loop control whenever
(1) Disturbances affect the intermediate or secondary process or (2) the gain of the secondary process, including the actuator, is nonlinear.
In the first case, a cascade control system can limit the effect of the disturbances entering the secondary variable on the primary output. In the second case, a cascade control system can limit the effect of gain variations in the actuator or the secondary process on the closed loop performance.
Such gain variations usually arise from changes in operating point due to set point changes or sustained disturbances.
2010
Cascade control-IV
The structure of a (two loop) cascade controlled system with two controllers is shown below
Effect reduced by inner loop (2ry controller)
Effect of gain variation reduced by inner loop PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu 2010 (2ry controller)
Cascade control-V
We note the following:
The process is decomposed in two parts sometimes called the main/primary process and the inner/secondary process There are two feedback loops, two controllers and two transmitters The primary controller supplies the set point to the secondary controller - and are in cascade More than two controllers may similarly be cascaded
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Cascade control-VI
Official definition:
A cascade control system is a multiple-loop system where the primary variable is controlled by adjusting the setpoint of a related secondary variable controller.
The primary objective in cascade control is:

to divide an otherwise difficult to control process into two portions, whereby a secondary control loop is formed around a major disturbances thus leaving only minor disturbances to be controlled by the primary controller.
The method can also be extended to three or more loops

2010
Cascade control-VII
Only one controller, one control loop, one transmitter The sole controller has to take care of the lag and nonlinearity of the valve actuator and that of the heat exchanger
SET POINT
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Cascade control-VIII
SETPOINT
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Cascade control-IX
The secondary loop controls steam flow by directly manipulating the valve The primary loop controls the temperature of the process fluid by demanding appropriate flow of steam from the secondary controller One flow transmitter, one temperature transmitter, one temperature controller and a flow controller are required
SETPOINT
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Cascade control-X
The input to the FCE can be limited, either at the input or at the output of the 2ry controller. By moving the limiter to the input of the 2ry controller, the secondary PV can also be limited, if desired.
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Advantages of Cascade control

Disturbances arising within the secondary loop are corrected by the secondary controller and the primary PV is not affected. Phase lag existing in the secondary part of the process is reduced substantially by the secondary loop.
This improves the speed of response of the primary loop.
Effect of gain variations in the secondary part of the process are contained within its own loop. The secondary loop permits an exact manipulation of the flow of mass or energy by the primary controller.
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Advantages-II
With proper tuning of parameters cascade control generally provides faster and more robust performance, without using complex compensators By applying strong (with adequate proportional gain) inner loops the outer loop becomes
less dependent on the plant parameters and nonlinearities Not unduly affected by disturbances of the inner loop
With the use of limiters, the intermediate PVs may be kept within safe limits Cascade control usually provides more meaningful interpretation of the set point variable and the controller outputs.
This helps in understanding as well as applying feedforward compensation.
E.g. in the level control system, the output can be fed forward to the inflow controller
The inner loops provide easier way of controller tuning
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Advantages revisited
Better control of the primary variable Primary variable less affected by disturbances Faster recovery from disturbances Reduction of rise time, increased speed of response of the CL system Easier tuning of dynamic performance Provide limits on the secondary variable
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Disadvantages of cascade control

More sensors are required Either multiple controller or special purpose controllers have to be used Tuning of cascade controllers requires more skill Not all plants are amenable to cascade control
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Plants where cascade control is possible The plant can be modelled as a sequence of two or more subsystems each providing the excitation for the next The excitation variable should be measurable Each subsystem should have only one excitation and possible disturbances
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Feed Forward Control
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Feed Forward Control

Feed Forward Path SP Controller Valve Actuator PV PLANT
PV
Traditionally feed forward control used the setpoint point signal to directly control the valve, bypassing the controller.
Hence the name Acted as a SP proportional bias Rarely used nowadays
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Another Classical FF Example
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10
Feed Forward-II
Now feed forward mostly uses measurable load and disturbance signals to actuate the FCE Very common in industrial control Used often with cascade control
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21
Feed Forward Control-III
The FF controller receives the disturbance measurement, computes control actions to counter its impending impact on the measured process variable, and transmits the result to the FCE. Feed forward is useful when load and measurable disturbances cause substantial change in the PV
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11
Feed Forward Control-IV

Advantages
Makes response to load/disturbance change faster Possible to reduce steady state error due to persistent load changes
Disadvantages
Load must be measurable More transmitters required Cannot be used as stand alone CLAW except for trivial systems
FF gain needs to be changed with change in plant parameter
Always used with feedback

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FF Control Example: liquid level control

Q1, P1
Configuration-1
Measures outlet flow Q2 and adjusts inlet valve by a feed forward controller In an attempt to match the two flows
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FF
Flow Xmitter omitted for clarity
Q2
Objective: To keep the liquid Level H at a desired value

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FF Control Example: liquid level II

Shortcomings:
Valve setting to inlet flow may not be known accurately, depends on
inlet pressure P1, fluid density Flow coefficient variation due to ageing, wear, fouling
Q1, P1
FF
Q2
FF gain cannot be set to ensure constant level

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FF Control Example: liquid level III

Configuration-II:
Flow loop to ensure the inlet flow matches the demanded flow= the outlet flow (FF gain=1) With perfect matching of flows, the level remains constant.
FT
Q1
FC
Limitation
though the level would remain constant, its exact value is undetermined. The matching cannot be perfect because of
Measurement errors There may be transient mismatch due to valve positioning loop and flow loop.
FF
Q2
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13
FF Control Example: liquid level IV

Configuration-III:
Cascade control with feed forward The FF attempts to match the input and outlet flows, the level remains approximately constant. The outer feedback loop has to take care of matching imperfections. Even a low proportional gain may be adequate.
2010
Q1, P1
FT
FC
SP2
FF LC Q2 SP
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Ratio Control
Ratio control is used to ensure that two or more flows are kept at the same ratio even if the flows are changing. Applications of ratio control:
Maintaining correct air and fuel mixture to combustion. Blending two or more flows to produce a mixture with specified composition for chemical reaction (feed). Blending two or more flows to produce a mixture with specified physical properties. e.g. in lubricant Blending two or more flows to produce a mixture with specified test or flavour
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14
Ratio Control-II
Inflows: Q1 Mixing Or Reaction
Q3 Qn
Q(n+1)
n number of input flows Each assumed to be measurable One input flow cannot be controlled by the ratio control system One outflow
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Ratio Control-III
Several cases may arise for ratio control, for example:
The composition of the mixture may not be measurable with reasonably costly transmitter.
One has to use feed forward control
One of the flows cannot be controlled because the flow is dictated by other conditions (wild flow).
This occurs in neutralizing application, where the quantity of the acidic flow is dictated by production volume. The wild flow is usually not constant and so it must be measured. Only the other (n-1) flows need to be controlled on the basis of measurements
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15
Ratio Control-V
Flow following configuration The wild flow is measured and this information is used to provide the set-point of the other flow through a flow controller. Requires manual setting of the ratio
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Ratio Control-VI
Configuration with feed back and cascade control. Also called Ratio Relay Control or automatic ratio adjustment The output composition is measured and from this the suitable ratio is inferred by the feed forward controller. From the desired ratio and quantity of wild flow, the set point for the other flow is determined.
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16
Air-Fuel Ratio Control
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17
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To Conclude
When designing a control system, be aware of the control objective
Also foresee any possible conflicts
Using a combination of feedback, feed forward, ratio, and cascade control, one can design flexible control systems More complex control systems are harder to tune and model, Complex loop structures are justified where
Performance is important. The complex loop outperforms simpler architectures
2010
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18

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Part-C

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

The process equation y = f (u,d)

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

The primary objective in cascade control is:

The method can also be extended to three or more loops

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

Advantages of Cascade control

The inner loops provide easier way of controller tuning

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

Disadvantages of cascade control

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

Feed Forward Control

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

Feed Forward Control

Another Classical FF Example

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

Feed Forward Control-III

Feed Forward Control-IV

Always used with feedback

FF Control Example: liquid level control

Objective: To keep the liquid Level H at a desired value

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

FF Control Example: liquid level II

FF gain cannot be set to ensure constant level

FF Control Example: liquid level III

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

FF Control Example: liquid level IV

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

Air-Fuel Ratio Control

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

PIC Lecture 2010 Prof. T.K.Ghoshal and Prof. Smita Sadhu

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