INTRODUCTION & THEORY

The cascade control was used as an improve alternative of the 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 involving, 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 was 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 was 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 start, the compressed air will be supply 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.

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