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SUGAR PLANT AUTOMATION

MILL HOUSE BOILING HOUSE REFINARY CENTRIFUGE CO-GENERATION


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Sugar Plant Overview

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Mill House Automation


ACFC-Auto Cane Feed Control Preparatory Device Load Control
Belt Carrier & Cane Carrier Cascade Control

Mill Load Control


Chute Level Control Mill Load Control

Imbibitions Water Control


Water Flow Control w.r.t Crushing Rate

JFS-Juice Flow Stabilization


Tank Level Control Juice Flow Control

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ACFC Screens

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Mill Load Control Screens

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Mill House Motor Locations & Control

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Parameters For ACFC Unit 1&2

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Parameters For Mill House Unit 1&2

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Boiling House Control


Raw Juice Heater Temp Control Defecator Raw Juice Clarifier Defecated Juice Heater Temp Ctrl. Quad Body Bricks/Level Control Evaporator Continuous Pan/Batch Pan
Temp & Bricks Control

Molasses Conditioner
Bricks & Temperature Control

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Quad Bodys Screen

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Evaporating Station Screen

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Batch Pan Screens

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Continuous Pan Screens

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Molasses Conditioners Screen

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Refinery
Raw Sugar Melter
Temperature & Brix Control

Melt Clarifier
Flow, Chemical Dosing & Brix Control

Multi Bed Filters


Filtration & Auto Backwash Cycle

Ion Exchange Columns Control Brine Recovery System

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Melting Station

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Melt Clarifier Screen

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Clarifier System
SCS-Syrup Clarifier System
Temperature Control Chemical Dosing Control

FCS-Filtrate Clarifier System


Temperature Control Chemical Dosing Control Temperature Control pH Control

SRT-Short Retention Tank


Dosing & pH Control (with JFS)

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FCS Screen

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CO-Generation
CONTROLS Boiler Drum Level Control Furnace Draft Control Combustion / Fuel Feeder Control O2/CO2 Control Atemperator Temperature control Deareator Level and Pressure Control PRDS & DSH Control Turbine Hot well level controller INTERLOCKINGS Interlocking of various equipments and devices Safety Interlocks Various devices control and interlocking such as Feed-water Pump, ID/FD Fans, Fuel Feeders MONITERING Interfacing to the Energy meters for the Load Monitoring Monitoring of various parameters of the Boiler and Turbine such as temperature and pressure, level, speed, load and frequency etc.
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Boiler Control & Monitoring

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Water & Steam System

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Deaerator System

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PRDS Control

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Combustion Control

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Turbine Control & Monitoring

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References For Sugar


Titawi Sugar: (Unit of Mawana Sugar) Centralised Control For
Unit1: Mill House, Boiling House, Continuous & Batch Pan, Molasses Conditioners, SCS, FCS,Boilres(1,2 & 3) Unit2: Mill House, Boiling House, Continuous & Batch Pan for Refined & Raw Sugar, SCS, FCS, Juice Heaters

Bajaj-Kinauni: Refinery, Syrup, Filtrate, & Melt Clarifier Renuka Sugar: ION Exchange (Athani) , Brine Recovery (Haldia) Bharat Sugar: Refinery DSM Sugar: Mill & Plant Drives, (SRT, JFS.(Mansoorpur / Asmoli / Rajpura)) JK Sugar: Mill & Plant Drives Kesar Sugar: Mill & Plant Drives, Fcs Palia Sugar: Centrifugal M/c Automation Balrampur Sugar: Fcs , Scs. Chemical Systems pvt. Ltd: FCS, SCS, MCS, MS, SRT, JFS, Ion Exchange, BRC, MBF Mawana Sugar: Boiling House, Refinery (Mawana). Shakti Sugar: Refinery. Assalaya Sugar- (Sudan) Cogeneration 13 MW Ugar Sugar: Fcs , Scs , Mcs. Bajaj Sugar: . Upgradation of Mill House and Boiler. AMC for Clarifier and Refinery: UDSM Shamli, Seohara, Oudh, Harinagar, Riga, Bardoli, Nanglamal, Titawi, Bajaj Kinoni.

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Control Structures For Titawi Sugar


SATCOM Internet Firewall
DELHI

ADDITIONAL HARDWARE / SOFTWARE REQUIRED

485 TO 232 CONVERTOR

LOGGER

TSC / MAWANA

SQL Server

Boiler SCADA

Clarifier SCADA

Pc : INTERNET CONNECTIVITY Software : Web server Connectivity

TCP/IP MODBUS

ETHERNET BACKBONE

10Base2 or 10BaseFL

Approx 250 m

ETHERN ET MB+ BRIDGE

BOILER 1 BOILER 1&2 MODBUS

MILL MODBUS

PAN MODBUS

CLARIFIER MODBUS

ETHERNET MODULE / WEB SERVER MODULE


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TITAWI CONTROL AND MONITORING ARCHITECTURE FUTURE PLAN

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Control Structures For Titawi Sugar

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Mill House Control System

Boiling House Control System

CASE STUDY Sugar Centrifuge

DC Drive Application

Sugar Centrifuge

Regenerative DC Drive

Centrifuge

Operation principle

Centrifuge separates particles from basic liquid The operation is cyclic, most motor power is needed for accelerating and decelerating Regenerative brake is needed

Centrifuge
What is actually being controlled?
The processing sequence duty cycle

Speed Control

Special requirements of the application?


High inertia to be accelerated and decelerated Regenerative drive for the efficient braking Often a part of the multiple drive system Demanding environment High reliability

Sugar Industry
RPM 1200 kW 800 300 200 400 100 Charging 0 -100 -200 -300

Centrifuge process cycle


Spinning

Speed (RPM) Power (kW)

+
Ploughing

3 -

Time 5

Benefits Centrifuge
Process Benefits

Optimum centrifugal speed gives high production of the right quality Increased production capacity No harm from the dusty environment Low energy consumption with regenerative unit = Cost of power per batch is minimised