PROPOSAL

FOR

AUTOMATION & CONTROL SYSTEMS

IN SUGAR MILLS

Submitted by ENERGY VENTURES 1249, Sector-A, Pocket-B/C Vasant Kunj, New Delhi 110 070 Phone: 26898204, 26898215 Fax: 26121782 e-mail: energy_ventures@vsnl.com

CONTENTS

1. SYSTEM OVERVIEW 2. TYPICAL CONFIGURATION DIAGRAM

3.

SPECIFIC CONTROL PHILOSOPHY FOR

1. MILL HOUSE 2. BOILER STATION 3. CLARIFICATION 4. EVAPORATION 5. PAN STATION 6. SUGAR HANDLING 4. PRODUCT CATALOGS LOGIX CONTROLLERS RSVIEW32 MMI SOFTWARE

5. COMPANY PROFILE 6. CUSTOMER REFERENCE LIST

ENERGY VENTURES PROPOSAL FOR AUTOMATION & CONTROL SYSTEMS

ANNEXURE I

1.0 1.1

SYSTEM OVERVIEW It is proposed to install an integrated PLC/DCS Control System to enhance the level of automation & control in the plant and also to enable all plant data to be collected and viewed from any operator station through networking. For this purpose, the total plant shall be divided into following sections for automation & control : a) b) c) d) e) Mill House Boiler Station Clarification Station Evaporator Station Pan Station.

1.2

It is proposed to install PLC/DCS Controllers and Input/Output modules, housed in control panels, in each of the above sections of the mill, alongwith PC based Operator Stations with MMI software. These Operator Stations will display all process parameters on color graphic dynamic screens, plot graphs of multiple related parameters, generate alarms and shift reports. All Controllers, I/O modules and Operator Stations will be interconnected through ControlNet data highway network, so that the total information about the plant can be accessed from any Operator Station. However, in case of any problem with any PC the controllers shall continue to control the process to avoid any production loss due to downtime of PCs. In the next phase, all plant data can be transferred to the plant ERP system and displayed online, on all client terminals on the existing ERP system. CONTROLLERS : The Controllers shall receive process data through a set of Digital and Analog Input modules. Based on these process conditions and control logic requirements, Controllers will determine action to be taken and will give commands to the control valves, solenoid valves, tripping devices, alarm annunciators etc. through Digital and Analog Output modules. Functions of Controllers shall generally be as follows: a) b) c) d) Sequential Interlocking of drives in Mill House & Boiler Station. Generation of Alarms in case of abnormal process conditions. Integrated PID Control of Process Parameters. ON/OFF Control of Molasses conditioners, etc. cont..2

1.3

1.4 2.0 2.1

2.2

ENERGY VENTURES

page..2

2.3

Controllers shall be designed to operate in the industrial environment of heat, dust, vapor, vibrations and voltage variations. Controllers shall rugged and reliable in design, able to withstand ambient temperatures upto minimum 55 deg. C, 95% RH and voltage variations in power supply of 220v AC +/- 15%. Controllers shall be from the latest family of Logix Controllers, which have been specially designed for process control applications and have full functionality of DCS systems for small & medium sized plants. A brief comparison between PLC & Logix Controllers is given below to highlight the advantages of Logix Controllers over PLC Controllers for process control applications: S.No. FEATURE 1. Programming Language 2. 3. 4. Basic design No. of simultaneous programs Communications PLC CONTROLLER Ladder Logic (Circuit Diagram) For Sequence Control (can do process control) Single Program Proprietary Allen Bradley Networks Sequential, Master / Slave system Non- deterministic address based, tags reside in individual nodes LOGIX CONTROLLER Functional Block Diagram (FBD) and Ladder Logic For Process Control Multiple Programs (Multi-tasking) Open Networks, such as ControlNet, DeviceNet, EtherNet, Fieldbus, Profibus Simultaneous, Producer/ Consumer system Deterministic Global Name based, tags reside in a single node

2.4

5. 6. 7. 3.0 3.1

Data Transfer method Data Transfer Time Tag Data Base

OPERATOR STATIONS : PC based Operator Stations will be connected to the Controllers over a data highway network and will receive all information about the process conditions. These Operator Stations will have colour graphic MMI software (man machine interface), to display all process parameters on colour graphic dynamic screens. The MMI software shall be RSView32 Runtime version, suitable for 300 tags each. A common RSView32 editor will also be provided to enable changes to be made in any Operator Station screens. Selected parameters will be logged on the hard disk to generate present and historical graphs. Multiple graphs on a single screen shall enable the operators to study behavior of one parameter when there are disturbances in other related parameters. 8 hourly shift graphs shall be automatically printed to give a permanent record of working of the plant in each shift. cont..3

3.2

ENERGY VENTURES

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3.3

The Operator Stations shall display alarms in an Alarm Banner to draw attention of operators to any abnormal conditions in the plant. This Alarm Banner will appear irrespective of which colour graphic screen is being viewed at the time of alarm condition. These alarms shall also be shown in an Alarm Summary, with time of occurrence and can be printed at regular intervals to give a permanent record of Alarms. The Operator Stations shall also generate shift wise log reports, which can be printed for record purposes. PID faceplates will be provided on screens for all PID controls, to enable tuning of PID loops from the Operator Station itself. These PID faceplate screens will be protected by passwords so that only authorized persons can access these screens --------------------------------------------------

3.4 3.5

ENERGY VENTURES CONTROL PHILOSOPHY MILLING SECTION 1.1

ANNEXURE II

SPEED CONTROL OF CANE CARRIERS A PLC/DCS based control system for speed control of cane carriers shall be installed in the Mill house. A PC based Operator Station shall also be provided in the mill house control room. The complete control philosophy for speed control of cane carriers is given below. Cane Carrier speed shall be controlled automatically, based on Donnelly chute level, to ensure uniform feeding of cane to 1st Mill. Primary cane carrier shall follow speed of Secondary cane carrier in a fixed ratio. Load of all cane preparation devices shall over-ride the speed signal of each cane carrier. When load of any cane preparation device exceeds 70% of rated load, speed of that cane carrier shall be proportionately reduced. If load exceeds 100% of rated load, that cane carrier will stop. It will restart automatically when load on the cane preparation device fall below 100% of rated load. SPEED CONTROL OF MILLS Load on first Mill will be measured and in case load increases above a set value, speed of cane carriers will be reduced to avoid overloading and jamming of first mill. Speed of 1st Mill along with chute level will also be monitored and displayed. Normally, 1st Mill will run at a predetermined fixed speed. In case load on mill increases beyond set value, speed of mill will increase proportionately. Speed will reduce to pre set level after overload is removed.

1.2

1.3

1.4

Speed, Load and chute level of other three Mills will also be monitored and displayed. Speed of these Mills will be controlled based on set point. Chute level and load on the mill will give overriding signals, so as to ensure optimum loading of the mill under all feeding conditions. The operator will feed in the set point and the speed will be controlled depending on load and level feedback signals. MACERATION WATER FLOW CONTROL Maceration Water Flow will be controlled to maintain a fixed ratio of maceration water to cane. The desired ratio will be fed through the keyboard and the load on the third mill will be measured. The flow of maceration water will be regulated to maintain the ratio at various loads. If load of Mill III is below the minimum running load, maceration water flow will stop. If Mill III is bypassed, the system will be automatically controlled by Mill II load through software program without any extra hardware cost. MONITORING OF MILL BEARING TEMPERATURES All Mill Drive, Gearing & Mill Roller bearing temperatures will be monitored through Temperature Scanners and their data will be sent to the Operator stations over Modbus network for display, Trending & alarming in the Operator Station. ---------------------------------------------

1.5

1.6

ENERGY VENTURES BOILER SECTION

page..2

2.1 DRUM LEVEL CONTROL The existing boilers are having cascade controllers for 3 element drum level control. However, when steam demand of process is suddenly increased, steam pressure falls and due to swelling phenomenon of water, water level in drum rises. Even though the present system acts to close the feed water flow control valve, drum level rises to a high value and sometimes get carried over in steam, causing damage to turbine blades. It is recommended to transfer these control loops to PLC/DCS control system and build a more comprehensive control philosophy and improve drum level control in these boilers. This control philosophy shall be based on comparison of steam and feed water flow with over-riding control from drum level. In case drum level falls below minimum level, the feed water control valve will open fully. In case drum level rises above maximum level, the feed water valve will close fully. 2.2 COMBUSTION CONTROL This will be an integrated control loop for maintaining the steam pressure and improving combustion efficiency of Boilers. The master controller will measure the steam pressure and speed of variable speed drive for bagasse feeders will be adjusted to feed more or less fuel to the boiler. The FD Fan Damper will also be adjusted to maintain the required amount of primary air. To ensure that this adjustment is correct, the O2 signal from flue gases will be taken in the loop to make final correction to FD Fan Speed. ID Fan Damper shall also be controlled to maintain a negative draft inside the furnace. 2.3 DEAERATOR CONTROL Deaerator Pressure & Level will be controlled by controlling the steam & water control valves, respectively. Temperature of deaerator water will also be measured and recorded in the operator station. PRESSURE REDUCING & DESUPERHEATING CONTROL 2 nos. Pressure Reducing Control Valves and 2 nos. de-superheating Control Valves shall be controlled from the PLC/DCS system for steady low steam pressures. ----------------------------------------------------

2.4

cont..3

ENERGY VENTURES CLARIFICATION SECTION

page..3

3.1

JUICE FLOW STABILISATION CONTROL Juice from milling tandem is collected in a weighed juice tank in the boiling house. Filterate return is also added in this tank. Total juice from this tank is pumped to juice heaters and sulphiters. It is proposed to stabilise juice flow to heaters and sulphiters to improve clarification efficiency. for a reasonable stability in juice flow to boiling house the capacity of the weighed juice tank should provide atleast 15 minutes retention of juice. The total juice flow will then be controlled as per a fixed set point according to the desired crush rate of the milling tandems. This set point will then be corrected according to the level in the weighed juice tank. Juice flow will be measured to give the feed back signal. The control logic will be such as to ensure that neither the weighed juice tank overflows nor the pumps run dry. In case of high or low level in weighed juice tank, alarms will be generated to draw the operators attention. AUTOMATIC LIMING Lime dosing into juice sulphiter shall be automatically controlled based on pre set ratio to juice flow. The total lime slurry will be pumped to an overhead tank and overflow from this will be fed to a Lime Proportioning Unit. The required amount of lime will be diverted to the process and rest will be sent back to the Lime storage tanks. Lime flow will be measured to give feedback signal to the Lime dosing control loop to ensure correct amount of lime is added to juice. In case Juice Flow reduces below 5% of crushing rate, the lime dosing unit will close 90%. pH CONTROL Proper working of pH control of treated juice is possible only with new Film type Sulphur Burners. pH of treated juice will be measured and signal given to control speed of sulphur dosing pump of new film type sulphur burner. Combustion Temperature of film type sulphur burner will be measured and air vent valve will be adjusted to control temperature of sulphur burner. In case Juice Flow reduces below 5% of crushing rate, the sulphur dosing pump will be stopped. As there is a reaction time of 6 to 8 minutes in the juice sulphiter, there will be a corresponding time lag between adjustment of sulpher dosing pump and change in pH. Hence, there will be some amount of hunting in this control loop. To improve this hunting to the maximum extent, the Controller will be programmed to take advance action by sensing a change in the average lime flow rate and taking action to correspondingly adjust speed of sulphur dosing pump. In addition to this the stroke of the sulphur dosing pump will have to be adjusted so that the variation in pump speed is within a narrow band of 50% to 80% only. The above measures will lead to fairly good control of sulphited juice pH. However, due to lot of dirt present in the sulphited juice, the pH sensing electrode gets frequently dirty and the performance of this total system will depend on how clean the pH sensing electrode is kept. cont..4

3.2

3.3

ENERGY VENTURES

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3.4

JUICE FLOW CONTROL TO CLARIFIERS It is proposed to control juice flow to clarifier so as to avoid frequent emptying of treated juice tank, as this causes fluctuations in juice flow to clarifier and disturbs the settling of mud in the clarifier. The proposed system shall measure level in treated juice tank and control the valve in the treated juice flow line to avoid emptying of this tank. MUD WITHDRAWAL CONTROL Mud flow from Clarifier shall be controlled based on level of mud in Mud Tank. Measurement of Water Flow to each Vacuum Filter. -------------------------------------------------------

3.5
3.6

cont..5

ENERGY VENTURES EVAPORATOR STATION

page..5

4.0 4.1

EVAPORATOR CONTROLS The evaporation section has a set of Semikestner with vapour cell and three evaporator bodies. It is proposed to provide following controls on these evaporator sets:
a) b) c) d)

Juice Flow Control to semikestner Brix sensing at outlet of quad set Vacuum Control of last body Measurement of condensate flow from evaporator bodies to boiler station

4.2

Juice flow to evaporator shall normally be kept constant and syrup brix at evaporator outlet shall be measured. If brix of unsulphured syrup is below a set value, juice flow will be proportionately reduced. In case level of juice in clear juice tank rises, signal shall be given to mill house to reduce crush rate. Water flow to condensor of last body of evaporator set shall be controlled based on vacuum at that body. This will reduce average water consumption at condensing plant. Condensate flow from evaporators to boiler house shall be measured and recorded in the operator station, to enable estimation of exhaust steam consumption in the process.

4.3 4.4

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cont..6

ENERGY VENTURES PAN STATION

page..6

5.1

MOLASSES CONDITIONERS The temperatures of Molasses at outlet of molasses conditioners will be controlled by regulating the steam flow into the vessels. This brix of molsses will be controlled indirectly measuring the conductivity of molsses and controlling the water flow control valve. PAN VACUUM CONTROL Condensor Water Flow for each batch Pan shall be controlled to maintain its vacuum during the pan boiling cycle. PAN FEED CONTROL Feed of syrup / mollasses to each batch pan shall be automatically controlled to maintain desired supersaturation level during pan boiling cycle. Feed of syrup / mollasses shall be controlled based on conductivity measurement of the massecuite. The conductivity sensor shall be installed at the same level as the proof stick for proper co-relation between sensor reading and operators checking. As the level in the pan increases, the low grade massecuites becomes thicker and conductivity set point has to be changed to suit level in the pan. The conductivity set point for each of the six level sensors shall be fed into the control system by the operator before starting the pan boiling cycle. These set points shall automatically change based on look up table previously fed into the Controller Data Files. AUTOMATION OF BATCH PANS Operation of all batch pans shall be automated with installation of solenoid operated OPEN / CLOSE valves for vacuum breaking, steam washing, discharge valve opening, cutover line valve, etc. Sequence of operation of these valves shall be automatically controlled through PLC/DCS system. MELTER CONTROL Brix of sugar melt shall be sensed by conductivity sensor and flow of water to melter shall be regulated to maintain uniform brix. Temperature of melt solution shall also be measured and steam flow to melter shall be controlled to maintain melt temperature. LEVEL MONITORING OF PAN STORAGE TANKS Level of syrup, melt and molasses storage tanks shall be measured and displayed on the operator station screens. LEVEL MONITORING OF CRYSTALLIZERS Level of massecuite in crystallizers shall be measured and displayed on the operator station screens. ----------------------------------------------------cont..7

5.2

5.3

5.4

5.5

5.6

5.7

ENERGY VENTURES SUGAR HANDLING

page..7

6.1

BATCH CENTRIFUGALS Operation of all batch centrifugal machines shall be controlled by the PLC/DCS System. The complete cycle of each machine shall be displayed on the operator station screen and number of cycles of each machines shall be totallized. CONTINUOUS CENTRIFUGALS Temperature of massecuite before entry to the continuous centrifugal machines shall be controlled by controlling flow of hot water to the transient heaters. Flow of massecuite to each continuous centrifugal machine shall also be controlled based on load on the machine, to ensure each continuous machine is operating at full capacity. SUGAR DRYER CONTROLS In case of fluidised sugar dryers, the temperature of hot air shall be controlled to ensure proper drying of sugar and prevent damage to sugar crystals due to over heating of sugar. SUGAR BIN LEVEL CONTROL Level of sugar bin will be monitored through Level Switch and in case of low level of sugar in bin, signal will be given to stop operation of bagging machines, to avoid errors in bag filling. ------------------------------------

6.2

6.3

6.4