OBJECTIVES

1) To identify the important components of the level and flow control system.
2) To carry out the start-up procedures systematically.
3) To study Level-Flow cascade control.

SUMMARY

This experiment’s objectives are to identify the major components of the Level-Flow
cascade control system, to carry out the start-up procedures systematically, and to study
Level-Flow cascade control. Based on theoretical research, in comparison with the
controllers’ performances, the Cascade control is mainly used to achieve fast rejection of
disturbance before it propagates to the other parts of the plant. Besides that, the PID control
usually calculates an 'error' value as the difference between a measured process variable and a
desired set point. It attempts to minimize the error by adjusting the process control inputs.
Cascade controller when compared with PID controller, has a much shorter retention time.
Cascade controller took less time to settle and stabilize because it depends on the slave
(secondary) loop to control the parameter of the master (primary) loop. It can be observed on
the resulted chart, for PID controller, when the flow rate of the process is being manipulated,
the level and the flow started stabilizing simultaneously. However, the level’s oscillation did
not settle as fast as the flow’s oscillation. Furthermore, whereas for Cascade controller, both
parameters, level and flow, oscillates and stabilizes simultaneously. It can be deduced that the
objectives of this experiment were achieved.
 INTRODUCTION

The cascade control can be used as an improved control system performance, be it

over single loop control whenever either the disturbances affect a measurable intermediate or
secondary process output that directly affects the primary process output that we wish to
control or the gain of the secondary process, including the actuator, is nonlinear. There are
two cases; first case is that a cascade control system can limit the effect of the disturbances
entering the secondary variable on the primary output. Next, for the second case a cascade
control system can limit the effect of actuator or secondary process gain variations on the
control system performance. The main objective of this experiment is to identify the
important components of the level and flow control system and to carry out the start–up
procedures systematically. Another objective of this experiment is to study Level–Flow
cascade control. In this experiment, there are two conditions of the instrument which are self-
regulating where the level process can control itself to reach a steady state at some level
position, and non-self-regulating where the level process can’t control itself to reach a steady
state and can overflow or run dry. Also, there are two conditions of tank operation which are
open tank operation and closed tank operation. The experiment will begin with tank T32
being filled with water at a specific level and all bypass valves, globe valve will be at specific
condition whether shut or open. Pump will be started, the compressed air will be supplied and
the main power supply will be turned ON. The experiment starts with open tank operation at
self-regulating process condition, followed by closed tank operation at self-regulating process
condition. After that, the Level–Flow Cascade will be conducted at open tank and self-
regulating control condition.
 THEORY

The controller driving the set point (the level controller in the example above) is
called the primary, outer, or master controller. The controller receiving the set point (flow
controller in the example) is called the secondary, inner or slave controller.

The simplest cascade control scheme involves two control loops that use two
measurement signals to control one primary variable. In such a control system, the output of
the primary controller determines the set point for the secondary controller. The output of the
secondary controller is used to adjust the control variable. Generally, the secondary controller
changes quickly while the primary controller changes slowly. Once cascade control is
implemented, disturbances from rapid changes of the secondary controller will not affect the
primary controller. In single-loop control, the controller’s set point is set by an operator, and
its output drives a final control element. For example: a level controller driving a control
valve to keep the level at its set point.

Single Loop Control

 In a cascade control arrangement, there are two (or more) controllers of which one
controller’s output drives the set point of another controller. For example: a level controller
driving the set point of a flow controller to keep the level at its set point. The flow controller,
in turn, drives a control valve to match the flow with the set point at which the level
controller is requesting.

Cascade Control
RESULTS
 DISCUSSION

This experiment is all about the operational procedure of the Level Flow Plant
Control. Experiment to identify the important components of the level and flow control
system, to carry out the start-up procedures systematically, and to study Level-Flow cascade
control has been carried out using the instrument shown in Figure 1 (Refer to Appendices).
The variables involved in this experiment are volumetric flow rate (m3/hr) and level (mm).

As for the experimental procedure, the related valves were opened and closed
beforehand. Then, the experiment was first started by switching on the main switch on the
control panel. After that, the identification of major components in the plant was made. In
addition to that, the open tank operation and the closed tank operation (self-regulating
process) were also conducted accordingly. Moreover, the Level-Flow cascade, open tank and
self-regulating control were also carried out in a proceeding manner. Procedures including
settings related to the experiment were followed accordingly as shown in the laboratory
manual. As to provide better clarification, specific configurations are shown in the
Appendices section.

Cascade controller when compared with PID controller, has a much shorter retention
time. Cascade controller took less time to settle and stabilize because it depends on the slave
(secondary) loop to control the parameter of the master (primary) loop. It can be observed on
the resulted chart, for PID controller, when the flow rate of the process is being manipulated,
the level and the flow started stabilizing simultaneously. However, the level’s oscillation did
not settle as fast as the flow’s oscillation. Furthermore, whereas for Cascade controller, both
parameters, level and flow, oscillates and stabilizes simultaneously.

Theoretically speaking, in comparison with the controllers’ performances, the

Cascade control is mainly used to achieve fast rejection of disturbance before it propagates to
the other parts of the plant. The simplest cascade control system involves two control loops
(inner and outer) of which also called the ‘master’ and ‘slave’ loops. On the other hand, the
PID control refers to a generic control loop feedback mechanism (controller) widely used in
industrial control systems. It usually calculates an 'error' value as the difference between a
measured process variable and a desired set point. It attempts to minimize the error by
adjusting the process control inputs. The instrument works by control cycle response
mechanism. PID controllers are mainly used in Temperature Controller systems.
 In general, there are two types of regulating processes which are the self-regulating
process and the non-self-regulating process. Self-regulating process is when the processes are
with integrating characteristics and the non-self-regulating process is when the processes are
not with integrating characteristics. To test a process for its characteristics, with an open
control loop you can either give an input jump to the system or an input pulse. The time
behavior is recorded and analyzed to determine the process.

There are several possibilities that might have contributed to the errors that occurred
during the experiment. One of those errors is physical errors (human error). The instrument
could have a leakage at the pipelines and it could affect the results or readings of the flow
ratio. While running the experiment, the configuration of the valves has to be followed
accordingly. For example a few valves need to be opened but they are still set as closed. This
will lead the results or readings of the experiment to an abnormal trend. Next, the parameters
weren’t allowed to be stabilized first when the readings were recorded, which could lead to
an abnormal trend of results. Not just that, the parameter in the field of another parameter
might have been recorded due to lack of focus. By doing so, the recordings will be inaccurate
and it will result in abnormality. Thus, the ideal expected results could not be achieved.
 CONCLUSION

In conclusion, the Cascade Controller in relation to the PID Controller was explained
in this experiment. Each of the components/devices/tools used in the experiment has its own
details by which has its own function in ways of conducting the experiment and most
definitely has aided the process throughout the experiment. The data and information
recorded from the experimentations were used to distinguish between Cascade Controller and
PID Controller. It was observed on the resulted chart, for PID controller, when the flow rate
of the process is being manipulated, the level and the flow started stabilizing simultaneously.
However, the level’s oscillation did not settle as fast as the flow’s oscillation. Furthermore,
whereas for Cascade controller, both parameters, level and flow, oscillates and stabilizes
simultaneously. From that, the objectives of this experiment were achieved based on the
values obtained.

RECOMMENDATIONS

To avoid physical errors (human error) from occurring during experimentation, any
leakages or faults that might contribute to any errors in the experiment has to be inspected
prior to experimenting. This will aid in preventing abnormal trends of results of the Level-
Flow Cascade Control system. Also, make sure all the preceding steps were followed
accordingly in order to acquire results as predicted/expected by the end of the experiment.
This is also to prevent any abnormalities in the results. Besides that, focus and attention have
to be contributed to the experimentation process so that no careless mistakes will be done.
This is to avoid taking results of the wrong parameters. Not just that, request help from the
technician or person in charge to guide through the experiment, to avoid damage to the
instrument as well as to learn the proper ways of handling the instrument. With these
recommendation steps taking into consideration, the ideal expected results could be achieved.
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http://www.bgu.ac.il/chem_eng/pages/Courses/oren%20courses/Chapter_10.pdf [25th
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[4] Anonymous C, (2014). What Is A PID Controller, [Online]. Available from:

http://www.ask.com/question/what-is-a-pid-controller [25th March 2014]

[5] Anonymous D, (2014). Cascade Control System, [Online]. Available from:

http://www.mathworks.com/help/control/examples/designing-cascade-control-system-
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[6] Anonymous E, (2014). Cascade, [Online]. Available from:

http://support.automation.siemens.com/WW/llisapi.dll?func=cslib.csinfo&objId=2826369
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 APPENDICES

Figure 1 – Proportional Term

Figure 2 – Integral Term

Figure 3 - Derivative Term