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.

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How to Tune Cascade Loops
• An overview of Cascade Control.
• Tuning Cascade Control Loops.
• Case Study.

Cascade Control

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

2
 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

3
 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

4
 Temperature – Flow Cascade
Steam
Header

To other User

FIC
FT
TIC

TT

Temperature – Flow Cascade

Steam
Header

To other User

FIC
(Slave) TIC FIC FLOW TEMP
FT TIC
(Master)

TT
Process Schematic

The Cascade Loop

5
 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

FIC
(Slave)
FT TIC
(Master)

TT
Response to a Load Change

The Cascade Loop

6
 Master – Cascade Signals
PV

OP REM SP
PV MASTER SLAVE

OP

Master – Cascade Signals

PV

OP REM SP

TRK REM
PV MASTER SLAVE

OP

When slave is NOT in Remote/Auto mode

Master OP is to track Slave Setpoint.

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 Master – Cascade Signals
PV

OP REM SP

TRK REM
PV MASTER SLAVE
INT 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

8
 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

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 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 !!

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 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.

Tuning Cascade Loops

1. Always check for measurement and
valve-related issues.
2. Inner Loop Tuning - put slave into
Local Auto or Manual and tune the
slave controller as a normal PID loop.
3. Outer Loop Tuning - put slave into
Cascade and tune master controller
as a normal PID loop.
4. 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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 Test Data - Inner Loop

Outer loop PV

Inner loop PV
Inner loop SP
Change

Inner loop CO

Test Data - Outer Loop

Outer loop PV
Outer loop SP change

Inner loop PV
Inner loop CO

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 Relative Response Time – What is it ?

1. An indication of the closed loop

response of a control loop.
2. Loops with short RRT’s are fast loops
3. Loops with long RRT’s are slow loops.
4. 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.
2. After tuning, adjust outer loop PID
values to achieve this.
3. Our example:
Inner: 38 seconds
Outer: 400 seconds

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 Determining the
Relative Response Time

Relative Response Time (RRT)

1/0.0677 = 15s

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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 4
90 3.5
80
3
70

Valve position
60 2.5

DO (mg/l)
50 2
40 1.5
30
1
20
10 0.5

0 0
AV302
Time
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 4
90 3.5
80
3
70
Valve position

60 2.5
DO (mg/l)

50 2
40 1.5
30
1
20
10 0.5

0 0
AV302
Time
QI503

• 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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