Cascade

In cascade control system two controllers are cascaded to each other as

shown in the diagram below. Primary controllers output is fed to secondary
controller as a Set point. Both the controllers has their own sensing
elements but only secondary controller gives output to the control valve.
Primary controller receives set point from operator

For example in Batch reactor temperature is controlled using Cascade

control strategy. The output of temperature controller TC-1 adjusts the set
point of TC-2 in the batch reactor control system. The primary variable
batch temperature is controlled by the master controller, but not by directly
adjusting the cooling water valve. Instead, it manipulates the set point of
the slave or secondary controller, which in turn supplies jacket water at the
asked for temperature. There are twocontrolled variables, one manipulated
and one independent set point.

Cascade controller tuning 1.First,tune the secondary controller (with the primary controller in manual
mode)
2.Then,tune the primary controller (with the secondary controller in cascade
mode)
Cascade control has two functions :
1. Reduce the effect on the total control system of the dynamic elements in
the secondary loop.
2. Correct for disturbances which occur within the secondary loop before
they affect the master loop (such as cooling water temperature changes).
The slave controller need have only proportional response. The major time
constant must not be in the slave loop.
Cascade control is normally not applied in fast control loops - flow, pressure,
etc. It is more useful in temperature or composition control systems.