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10.4 Cascade-Control Design

Tuning the cascade controller consists of two steps. First, tune the inner-loop controller [gc2(s)]
based on the secondary process [gp2(s)] and use the inner-loop/closed-loop transfer function
[Equation (10.2)] to find an effective process transfer function [Equation(10.4)] for tuning the
outer-loop controller [gc1(s)].

The inner-loop control system design can be based on IMC-based PID or any other procedure, such
as frequency-response gain and phase margins. Once the inner-loop is tuned, the effective outer-
loop transfer function can be used to tune the outer-loop controller. Again, any control design
procedure can be used.

Figure 10-9. Series cascade structure using a closed-loop transfer

function for the inner-loop.

Rules of Thumb for Cascade Control

l Cascade control can be successfully used to reject secondary-process disturbances when the
primary process has a much larger time constant and a time delay or RHP zero while the
secondary process has a small time constant and little or no dead time or nonminimum-
phase (RHP zeros) behavior.

l The most common cascade-control loop involves a flow controller as the inner loop. This type
of loop easily rejects disturbances in fluid stream pressure, either upstream or downstream of
the valve.

l The inner loop (secondary, slave loop) in a cascade-control strategy should be tuned before
the outer loop (primary, master loop). After the inner loop is tuned, and closed, the outer
loop should be tuned using knowledge of the dynamics of the inner loop.

l Cascade control is widely used on chemical processes, and should not be considered an
"advanced control strategy."

l There is little or no advantage to using cascade control if the secondary process is not
significantly faster than the primary process dynamics. In particular, if there is much dead

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time in the secondary process, or if there is an RHP zero, it is unlikely that cascade control
will be much better than standard feedback control.

l Cascade control can be easily combined with other forms of control, such as feed-forward
control.

l Any of your favorite methods can be used for tuning the inner and outer loops. Indeed, the
IMC strategy can be used on either or both of the inner and outer loops.
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