Design and Implementation of a Cascade Control System for Continuous Process Based on Control Logix 5571 PLC

In modern industrial automation, one of the most frequent control systems in process industries is cascade control. If, in addition to the main process variable, additional system variables are measured and given back as secondary process variables, generating subordinate control loops, a cascade control system can be constructed. The integrated cascade control system based on Logix 5571 was developed to resolve the problem of nonlinear and more time delays in chemical process. Steam pressure, steam temperature, air/fuel ratio, drum level, and drum flow are all sensitive to variations in working conditions when considering the primary variables of the continuous chemical process. A temperature process is master control and a steam flow process is slave control have become so integrated. This paper used the velocity form algorithm in PID to optimize the values and design a cascade enhanced proportional integral derivative controller (PIDE) to solve the large time delay in chemical processes. The real-time monitoring, a process parameter actual values and configure I\O tag to Human Machine Interface (HMI) using a factory talk automation software. The logix structure of cascade control loops is especially important for obtaining quick dynamics and proper behavior in all real-world operating modes. In the field of industrial control, which uses PLC Modbus TCP/IP to communicate between one master station and more slave stations.