Understanding Cascade Control Systems in Industrial Processes

Cascade control systems play a crucial role in improving process control efficiency by incorporating feedback loops within feedback loops. This type of control architecture helps to better handle disturbances and variations in the process by creating secondary loops that monitor specific parameters. Through examples like feedback control systems, cascade level feedback systems, and simple level feedback systems, we can see how these systems contribute to better control and regulation in industrial settings.

• Cascade control systems
• Industrial processes
• Feedback loops
• Process control
• Disturbance handling

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1. Basics of Cascade Control EMEC125 Lab 02

2. Basic Feedback Control Feedback control incorporates feedback that assists in controlling a process. Disturbance + Set Point Controller Output - Measurement

3. Basic Concepts TC 1 Sun Only heating is needed. Heat provided by steam radiator and forced air. Temperature xmitter is a conventional thermostat. Conventional feedback. Disturbances: Inlet air temperature. Flow rate of steam. Flow rate of air in the room. Variations of heat load in the room. External affects. Temperature of the radiator. Steam Air at variable temperature and flow rate Condensate Large Room TT Cold air return 1

4. Basic Feedback Cascade Control Cascade control is a control loop within a control loop. http://controlguru.com/wp-content/uploads/2015/08//cas-blockdia-big.jpg http://controlguru.com/the-cascade-control-architecture/

5. Basic Concepts TC 1 Sun Only heating is needed. Heat provided by steam radiator and forced air. Temperature xmitter is a conventional thermostat. Cascade control secondary loop monitors the incoming air temperture. Disturbances: Inlet air temperature. Flow rate of steam. Flow rate of air in the room. Variations of heat load in the room. TC 2 TT 2 Steam Air at variable temperature and flow rate Condensate Large Room TT Cold air return 1

6. Simple Level Feedback System Several streams of liquid flowing into the surge tank. Surge tank is feed into a distillation column. Simple feedback system senses tank level and adjusts valve opening. Disturbances can include: Variations in inlet flow. Changes in pressure in the distillation column. Changes in distillation pressure cause pressure drop across the valve which affects flow. Varying flows LT LC 1 1 Feed surge tank I P Column under variable pressure

7. Cascade Level Feedback System Several streams of liquid flowing into the surge tank. Surge tank is feed into a distillation column. Monitors feed flow rate and can respond to changes in pressure without waiting for level changes The flow is providing a set point for the valve and can modify the flow rate before the level change in the surge tank is detected. Varying flows LT LC 1 1 Feed surge tank FC 2 FT I P 2 Column under variable pressure

8. References Control Guru Practical Process Control. (n.d.). Cascade Control For Improved Disturbance Rejection. Retrieved October 27, 2016, from Control Guru Practical Process Control: http://controlguru.com/the-cascade- control-architecture/: Image URL: http://controlguru.com/wp-content/uploads/2015/08//cas-blockdia- big.jpg