Cascade Control SE665

EXPERIMENT 6
Cascade Control
6.1 Objective
(i) To demonstrate the characteristics of On/Off control

(ii) To demonstrate the characteristics of PID control
(iii) To demonstrate the characteristics of Proportional Band, Integral Action and Derivative Action
on a cascade process control loop.
(iv) To demonstrate the characteristics of cascade control
6.2 Introduction
The Cascade Control Module has been designed for students demonstration and to give them
better understanding on how open and closed tank level measurement and level control is done,
and to provide them with a hands on experience on manipulating various control parameters
using a microprocessor based controller. It can be coupled with a flow metering loop to enable
cascade control studies. The equipment consists of industrial grade instrumentation to exhibit a
realistic working environment of a true level process using various types of measuring
instruments and control strategy.
The equipment is self contained and constructed on an epoxy coated mild steel frame with four
lockable castor wheels. The pumps, tanks, instrumentation and valves are strategically located
for easy access. For safety reasons, the control panel is protected against water splashes. The
process piping is made of stainless steel pipes. A mimic diagram is included showing the flow of
the process. The Cascade Control Module is a mobile self contained unit requiring only the
available 240VAC/50Hz and 6 bar(g) instrument air supply.
The control panel is connected to a Distributed Control System (DCS), which can remotely control
the process plant using supervisory control mode (SCADA) or direct digital mode (DDC). A
selector switch at the control panel is used to select between SCADA and DDC mode. In SCADA
mode, the DCS can monitor and control the process through the process controller and in DDC
mode, the DCS can directly control the plant through the Field Control Station.
6.2.1 Process Description
The SOLTEQ Model: SE 665 Cascade Control Trainer is a water process. Water from the sump
tank, T-601 is pumped by P-601 to the level tank, T-602. There are two discharge possibilities
from the T-602 back to the T-601. One is known as the “self-regulatory” mode using gravity flow
for the water to return to the sump tank. The other is the “non self-regulatory” mode, using a
pump P-602 to drain the water from the tank.
6.2.2 Control Strategy
Various types of instrumentations are installed in the process. There are two PID control loops in
the process controller that controls the process, namely FIC-601 and LIC-603. There is a switch
at the local control panel, which allows selection of either flow control or level control or a
combination of the two, called the flow/level cascade control.
6.2.3 Level Control Loop
The level transmitter LT-603 feed the signal to LIC-603, which controls the valve FCV-601.
6.2.4 Flow Control Loop
The orifice flow transmitter FT-601 feed the signal to FIC-601, which controls the valve FCV-601.
6.2.5 Cascade Control Loop
In this mode, the level transmitter LT-603 feeds the signal to LIC-603. The output from LIC-603 is
then used as the setpoint for FIC-601. The orifice flow transmitter is the measurement signal for
FIC-601 and the output from FIC-601 is used to control the valve FCV-601. LIC-603 is also
known as the primary loop and the FIC-601 is known as the secondary loop.
Open and closed tank measurement studies can also be carried out by pressurization of the tank
T-602 using PCV-602. Another method of local level measurement is made via a bubbling tube
and the hydrostatic pressure in the tank is read from PI-603.
Load changes can be made within the system by manipulating various hand valves, depending
upon the process loop being experimented upon, to observe the effectiveness of the controller in
use.
6.2.6 Experimental Capabilities
PID Single Loop Flow Control
PID Single Loop Level Control
Self-Regulating
Non Self-Regulating
On/Off Control
PID Level and Flow Cascade Control
Table 6.1 Instrument function and capabilities

No. Instrument Tag No. Description Range
FIC-601 Microprocessor based PID
1 PID Controller -
LIC-603 controller, controlling level / flow
LR-603 Continuous 2-pen chart
2 Recorder -
FR-603 recorder
Orifice D/P Primary flow measurement
3 FT-601 0 – 100 LPM
Transmitter device giving 4 – 20 mA output
Level measurement using 0-
4 D/P Transmitter LT-603
differential pressure. 1000mmH2O
1 inch globe type valve with
Cv=4.8, linear characteristic
5 Control Valve FCV-601 1 – 100%
with I/P positioner and I/P
converter
P-601
6 Pumps Water circulation pumps 0 – 100 LPM
P-602
T-601 Level control tank 80 L
7 Process Tanks
T-602 Sump tank 120 L
LAL 603 Level control tank alarm low
8 Alarm Annunciator -
LAH 603 Level control tank alarm high
PCV-602 Regulates the pressure within
9 Pressure Regulator 0 – 1 MPa
PCV-603 the system
Mechanically activated device,
spring loaded normally closed
10 Relief Valve PSV-602 valve. Opens and purges air to -
atmosphere in case of over
pressure in tank.
FI-601 Flowrate measurement for 0 – 100 LPM
11 Rotameter water
FI-602 Flowrate measurement for air 0 – 6 LPM
PI-601 0 – 4 bar
Dial gauge pressure indicator at
12 Pressure Indicator PI-602 0 – 4 bar
location.
PI-603 0 – 4 bar
SG-601 Observation of water level in
13 Side Glass -
SG-602 tanks.
6.3 Process Control
Student may refer to section 0.3.1 for theory of process control
6.3.1 On/Off Control
Student may refer to section 0.3.2 for theory of On/Off Control
6.3.2 Proportional Control
Student may refer to section 0.3.3 for theory of proportional control
6.3.3 Integral Control
Student may refer to section 0.3.4 for theory of integral control
6.3.4 PID Control

Student may refer to section 0.3.5 for theory of PID control
6.3.5 Loop tuning
Student may refer to section 0.3.6 for theory of loop tuning
6.3.6 Cascade Control
Student may refer to section 0.3.8 for theory of cascade control

6.4 Procedure
Table 6.2 Start up procedure
STEP ACTION REMARKS
Ensure that all valves are set according to Flow Control Initial
Valves Position outlined in Table 1
Table 1: Flow Control Initial Valve Positions
Open Close
1 HV612 HV611
HV614 HV613
HV615 HV616
HV617 HV618
HV620
2 Fill in Sump Tank T-601 with water to about 80% full.
3 Switch on the panel.
Set the Control Mode switch to Flow to engage the Flow

4
control loop.
5 Switch on Pump P-601
Put the Controller FIC-601 into manual mode, then set the
6
output to 100%.
7 Adjust HV618 to set flow measurement FT-601 to 100%.
8 You are now ready to proceed to the experiment.
Table 6.3 Proportional Only Flow Control
STEP ACTION REMARKS
Enter PB value of 1000, I value of 1000 seconds, and D

1 value of 0 second.
While the control loop is in "manual" mode, adjust the set

2
point to 50%.
Tune the output gradually so that the flow measurement
3
matches the set point at 50%.
Turn on the recorder, then put the control loop into "auto"
4
mode.
Stimulate load change by closing HV615 for 3 seconds, then

5
open HV615 back.
Once the measurement stabilizes, turn off the recorder. Put

6
the control loop back into "manual" mode.

7
8
mode.
Stimulate a set point change by increasing the set point to

9
75%.
Observe the response. Once the response stabilizes, turn off

10
the recorder. Put the control loop back into "manual" mode.
With the I and D values maintained, repeat step 2 to step 10

with the following PB values
11
PB
200
100
Table 6.4 Proportional and Integral Flow Control
STEP ACTION REMARKS
Enter PB value of 200, I value of 30 seconds, and D value of

1 0 second.
While the control loop is in "manual" mode, adjust the set

2
point to 50%.

3
4
mode.
Stimulate load change by closing HV615 for 3 seconds, then open

5
HV615 back.
Once the measurement stabilizes, turn off the recorder. Put the
6
control loop back into "manual" mode.
Tune the output gradually so that the flow measurement matches

7
the set point at 50%.
8 Turn on the recorder, then put the control loop into "auto" mode.
9 Stimulate a set point change by increasing the set point to 75%.
Once the measurement stabilizes, turn off the recorder. Put the
10
control loop back into "manual" mode.
With the PB and D values maintained, repeat step 2 to step 10 with

the following I values
11 I
15
6
2
Table 6.5 PID Flow Control
STEP ACTION REMARKS
Enter PB value of 200, I value of 6 seconds, and D value of 0

1 second.
Put the control loop into "manual" mode, adjust the set point
2
to 50%.

3
4
mode.
Stimulate load change by closing HV615 for 3 seconds, then
5
open HV615 back.

6

7
8
mode.

9
75%.

10
With the PB and I values maintained, repeat step 2 to step 10

with the following D values
11
D
5
10
Table 6.6 PI Flow Control Loop Tuning
STEP ACTION REMARKS
Enter a PB value of 200, I value of 1000 seconds and D

value of 0 second (setting the I to its maximum and D to its
1
minimum provides proportional-only control)
Put the control loop into “Manual Mode” adjust the set point
2 to 50% and tune the output gradually so that the
measurement matches the set point.
Turn on the chart recorder, and then put the control loop into
“Auto Mode”. Stimulate load change by closing HV615 for 3
3
seconds, then open HV615 back. After the measurement
stabilize, turn off the recorder.
While maintaining the I and D values, gradually reduce PB

4
until the measurement oscillates about the set point. Repeat
step 1 to step 3 with the following PB values. Suggested
values are as follows: -
PB
100
25
2
Determine the natural period using the following method
D
5 Natural Period, T 60 min
Trend Speed
Where D = Distance in mm between successive crests or
valleys
Set the Integral Time to the Natural period, repeat Step 3 and
6. The period of oscillation should increase by 40%. If the
6
period is longer than this, increase the integral time. If the
period is shorter than this, decrease the Integral time.
Finally, adjust (increase) the PB until the desire degree of

7
damping is achieved
6.4 Level Process Control
The Level Experiments can be run either in Self-Regulating mode or Non-Self-Regulating mode.
The Procedure of experiments in sections 3B to 6B are based on self-regulating (Flow Under

Head) operation mode.
For Non-Self-Regulating (Pump Discharge) operation, the load change in Step 5 will be
performed by opening HV623 to the Position 2 mark on HV623 valve body for 20 seconds.
Table 6.7 Self-Regulating (Flow Under Head)
STEP ACTION REMARKS
Ensure that all valves are set according to Level Control

Initial Valve Positions (Self-Regulating) outlined in Table 2.
Table 2: Level Control Initial Valve Positions (Self-
Regulating)
Open Close
HV612 HV611
1 HV614 HV613
HV615 HV616
HV619 HV618
HV620 HV621
HV624 HV622
HV623
HV625
2 Fill in Sump Tank T-601.
3 Switch on the panel
Set the Control Mode switch to Level to engage the level

4
control loop.
5 Switch on Pump P-601.
o
6 Align the mark on the HV620 handle to about 45 .

Table 6.8 Non-Self-Regulating (Pump Discharge)
STEP ACTION REMARKS
Ensure that all valves are set according to Level Control

Initial Valve Positions (Non-Self-Regulating) outlined in Table
3
Table 3: Level Control Initial Valve Positions (Non-Self-
Regulating)
1 Open Close
HV612 HV611
HV614 HV613
HV615 HV616
HV621 HV618
HV622 HV623
o
HV626 (30 ) HV625
Set the Control Mode switch to Level to engage the level

4
control loop.
Note : - Switch on pump P-602 when there is at least 30% of water in T-602 during experiment.
- For load change use HV626 instead of HV620.
Table 6.9 On/Off Level Control
STEP ACTION REMARKS
Turn off the PID control by simply setting P to minimum. This

1 will give On-off control.
Put the control loop into "manual" mode, then adjust the set
2
point to 50%.
Tune the output gradually so that the level measurement

3
4
mode.
Stimulate load change by opening HV620 fully for 20
5 seconds. (Be careful not to empty the tank during the
process) and restore it to its original position.

6
the control loop back into "Manual" mode.

7
8
mode.

9
75%.

10 the control loop back into "Manual" mode.
Table 6.10 Proportional only Level Control
STEP ACTION REMARKS
Enter PB value of 100, I value of 1000 seconds, and D value

1 of 0 second.
2
point to 50%.

3
4
mode.
6

7
8
mode.

9
75%.

10
the control loop back into "Manual" mode
With the I and D values maintained, repeat step 8 to step 16

with the following PB values
11 PB
10
6
2s
Table 6.11 Proportional and Integral Level Control
STEP ACTION REMARKS
Enter PB value of 100, I value of 60 seconds, and D value of

1 0 second.
2
point to 50%.

3
4
mode.
6 Once the measurement stabilizes, turn off the recorder.

7
8
mode.

9
75%.
10 Once the measurement stabilizes, turn off the recorder.
With the PB and D values maintained, repeat step 8 to step

16 with the following I values
11 I
30
15
5
Table 6.12 PID Level Control
STEP ACTION REMARKS
Enter PB value of 100, I value of 6 seconds, and D value of 0

1 second.
2
point to 50%.

3
4
mode.

6
7
8
mode.

9
75%.
Once measurement stabilizes, turn off the recorder. Put the

10
control loop back into "Manual" mode.
With the PB and I values maintained, repeat step 2 to step 10

with the following D values
D
11
1
6
12
30
60
Table 6.13 PID Level Control Loop Tuning
STEP ACTION REMARKS
Enter a PB value of 100, I value of 1000 seconds and D

value of 0 second. (Setting the I to its maximum and D to its
1
minimum providing proportional only control)
Put the control loop into “Manual Mode”. Adjust the output
2 gradually so that level of the tank measurement matches the
set point of 50%
Turn on the recorder. Put the control loop into “Auto Mode”.
3 Simulate a load change. After the measurement stabilizes,
turn off the recorder.
Maintain the value of I and D, and repeat step 1 to step 4

with reduced PB until the measurement oscillates about the
set point. Suggested values are as follows: -
4 PB
100
30
15
10
5
Determine the natural period using the following method:
5
D
Natural Period, T 60 min
TrendSpeed
Where D = Distance in mm between successive crests or valleys
Maintain the PB value. Set I to 0.4T and D to 0.15T. Repeat
Step 2 and 4 and observe the response. There should be a
6 25% decrease in period. If the new period of oscillation is
shorter than this, reduce derivative time, if the period is
longer increase integral time.
Finally, adjust (increase) the PB until the desire degree of

7
damping is achieved
LEVEL AND FLOW CASCADE PROCESS CONTROL
Table 6.14 Start-Up Procedure
STEP ACTION REMARKS
Ensure that all valves are set according to Level and Flow
Cascade Control Initial Valve Position outlined in Table 4.
Table 4: Cascade Control Initial Valve Positions
Open Close
HV612 HV611
1 HV614 HV613
HV615 HV616
HV619 HV618
HV620 HV621
HV624 HV622
HV623
HV625
Set the Control Mode switch to Cascade to engage the Level

4
and Flow Cascade control loop.
Put the Controller FIC-601 into manual mode, then set the
6
output to 100%.
7 Adjust HV618 to set flow measurement FT-601 to 100%.
Table 6.15 PID Level and Flow Cascade Control
STEP ACTION REMARKS
Enter PID values as obtained in Level loop tuning.

1
2 Enter PI values as obtained in Flow loop tuning.
Put the control loop into "Manual" mode. Adjust the output of
3 the controller gradually so that the level of tank matches the
set point of 50%.
Turn on the recorder, and then put the control loop into
4 "Auto" mode. Wait until measurement settle down and
stabilize.
Stimulate a load change by opening the HV620 for 20 sec

5
(Beware not to dry the level control tank.
Wait until measurement stabilizes, that return HV620 to its original

6
position. Observe the response of the system. Turn off the recorder.
Put the control loop into "Manual" mode. Adjust the output of the
7 controller gradually so that the level of tank matches the set point of
50%.
Turn on the recorder. Put the control loop back into "Auto" mode,
8 Change the set point to 75% and observe the response of the
system.
Wait until the measurement stabilizes, then turn off the recorder. Put
9
the control loop back into manual mode.
Compare the cascade chart with the chart obtained from Level PID
10
experiments.
Appendix
A ] FLOW CONTROL TUNING
P CONTROL PI CONTROL PID CONTROL
P 50 100 209.1 209.1 209.1 209.1 209.1 209.1 209.1
I 9999 9999 9999 2.4 7.9 20.9 2.4 2.4 2.4
D 0 0 0 0 0 0 2.0 4.0 5.0
B ] LEVEL CONTROL TUNING
P CONTROL PI CONTROL PID CONTROL
P 6.6 16.6 16.6 16.6 16.6 16.6 16.6 16.6 16.6
I 9999 9999 9999 5.6 13.6 25.6 13.6 13.6 13.6
D 0 0 0 0 0 0 0.2 2 20
6.5 References
1. Introduction to Process Control, Foxboro, USA.
2. Rys, R.A. August 20, 1984. Advanced Control Methods, Chemical Engineering. pp 49.
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EXPERIMENT 6

(i) To demonstrate the characteristics of On/Off control

6.2.2 Control Strategy

6.2.3 Level Control Loop

6.2.4 Flow Control Loop

6.2.5 Cascade Control Loop

PID Single Loop Flow Control

PID Single Loop Level Control

PID Level and Flow Cascade Control

Table 6.1 Instrument function and capabilities

6.3 Process Control

Student may refer to section 0.3.1 for theory of process control

6.3.1 On/Off Control

Student may refer to section 0.3.2 for theory of On/Off Control

6.3.2 Proportional Control

Student may refer to section 0.3.3 for theory of proportional control

6.3.3 Integral Control

Student may refer to section 0.3.4 for theory of integral control

6.3.4 PID Control

6.3.5 Loop tuning

Student may refer to section 0.3.6 for theory of loop tuning

6.3.6 Cascade Control

Student may refer to section 0.3.8 for theory of cascade control

Table 6.2 Start up procedure

STEP ACTION REMARKS

3 Switch on the panel.

Set the Control Mode switch to Flow to engage the Flow

5 Switch on Pump P-601

7 Adjust HV618 to set flow measurement FT-601 to 100%.

8 You are now ready to proceed to the experiment.

Table 6.3 Proportional Only Flow Control

STEP ACTION REMARKS

Enter PB value of 1000, I value of 1000 seconds, and D

While the control loop is in "manual" mode, adjust the set

Stimulate load change by closing HV615 for 3 seconds, then

Once the measurement stabilizes, turn off the recorder. Put

Tune the output gradually so that the flow measurement

Stimulate a set point change by increasing the set point to

Observe the response. Once the response stabilizes, turn off

With the I and D values maintained, repeat step 2 to step 10

Table 6.4 Proportional and Integral Flow Control

STEP ACTION REMARKS

Enter PB value of 200, I value of 30 seconds, and D value of

While the control loop is in "manual" mode, adjust the set

Tune the output gradually so that the flow measurement

Stimulate load change by closing HV615 for 3 seconds, then open

Tune the output gradually so that the flow measurement matches

9 Stimulate a set point change by increasing the set point to 75%.

With the PB and D values maintained, repeat step 2 to step 10 with

Table 6.5 PID Flow Control

STEP ACTION REMARKS

Enter PB value of 200, I value of 6 seconds, and D value of 0

Tune the output gradually so that the flow measurement

Once the measurement stabilizes, turn off the recorder. Put

Tune the output gradually so that the flow measurement

Stimulate a set point change by increasing the set point to

Once the measurement stabilizes, turn off the recorder. Put

With the PB and I values maintained, repeat step 2 to step 10

Table 6.6 PI Flow Control Loop Tuning

STEP ACTION REMARKS

Enter a PB value of 200, I value of 1000 seconds and D

While maintaining the I and D values, gradually reduce PB