PID Controllers, 2nd Edition

Chapter 7.5.2 - Control Paradigms: Surge Tank Control

Surge Tank Control

The control problems that were discussed in Chapter 4 were all regulation problems where the task was to keep a process variable as close to a given setpoint as possible. There are many other control problems that also are important. Surge tank control is one example. The purpose of a surge tank is to act as a buffer between different production processes. Flow from one process is fed to another via the surge tank. Variations in production rate can be accommodated by letting the level in the surge tank vary. Conventional level control, which attempts to keep the level constant, is clearly not appropriate in this case. To act as a buffer the level should indeed change. It is, however, important that the tank neither becomes empty nor overflow.

There are many approaches to surge tank control. A common, simple solution is to use a proportional controller with a low gain. Controllers with dead zones or nonlinear PI controllers are also used. Gain scheduling is a better method. The scheduling variable is chosen as the tank level. A controller with low gain is chosen when the level is between 10% and 90%, and a controller with high gain is used outside the limits. There are also special schemes for surge tank control.

In many cases there are long sequences of surge tanks and production units, as illustrated in Figure 7.14. Two different control structures, control in the direction of the flow or opposite to the flow, are shown in the figure. Control in the direction opposite to the flow

07_5-6.jpg

Figure 7.14 Different structures for surge tank control The material flow is from the left to the right. The scheme in A is called control in the direction of the flow. The scheme in B is called control in the direction opposite to the flow.

is superior, because then all control loops are characterized by first-order dynamics. With control in the direction of the flow, it is easy to get oscillations or instabilities because of the feedback from the end of the chain to the beginning.

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