INDIANA SUCRO-TECH

( PUNE ) PVT. LTD.

CONTINUOUS PAN
OPERATIONAL MANUAL
 INDEX

 OPERATING PRINCIPLE

 DESCRIPTION

 TECHNICAL SPECIFICATION

 AUTOMATION

 P.I.DIAGRAM

 ISOMETRIC DRAWING
 OPERATING PRINCIPLE OF CONTINUOUS VACUUM PAN &
DESCRIPTION.

OPERATING PRINCIPLE :

The Continuous Vacuum Pan is a vertical tube rectangular Calendria with Shell,
catchall and Bottom trough. The Massecuite Chamber is divided into multiple
compartments by means of vertical baffles placed in a bottom trough, downtake and
above top tube plate.

Each compartment is provided with individual downtake. The seed magma enters
into first compartment and overflows from the top into second compartment, from
second compartment to third compartment, flows from the opening at the bottom and
So on massecuite flows.

Each compartment is fed both with the massecuite coming from the preceding one
and makeup liquor introduced at the bottom of each compartment by distributors.
Seed is continuously feed to first compartment through a screw pump at desired flow
rate.

The discharge of massecuite is by overflow from last compartment through a large

pipe sealed in a receiving crystalliser. The discharge is by gravity. A minimum
vertical height of 24” is to be maintained from discharge point to the sealing level of
receiving crystalliser. The overflow of crystalliser can be connected to the
neighboring crystalliser or direct to pugmill.

 REQUIREMENT OF CRYSTALLISER & PUMPS :

A vacuum crystalliser of respective holding capacity will be required for storage

seed magma. Seed footing is to be prepared in a batch pan and transferred to vacuum
crystalliser.

A Screw Pump with variable Speed Drive will have to be provided for seed magma
feeding at controlled rate. A receiving crystalliser has to be provided, if clear
vertical height of 24” from sealing level of crystalliser to discharge point of pan is
available. In this case no massecuite pump will be needed, otherwise in non gravity
plants, receiving crystalliser has to be installed on ground floor and massecuite to be
pumped to the other holding crystallisers and pugmill. In your case existing
crystallisers for ‘B’ massecuite are connected together to work continuously with
sealing of discharge pipe to first crystalliser.
 STARTING UP

When Pan is washed & steamed thoroughly and all the valves are tightly closed viz.
Massecuite Drain Valve, massecuite discharge valve, vacuum break valve, calandria
and body water valve etc. Throttle condensor water valve so that vacuum in the pan
will start building up when vacuum is reached to desired level then pan is ready for
commissioning. Simultaneously transfer clean and uniformly boiled grains to
vacuum crystalliser and check for the first filling whether semi boiled massecuite is
ready in another batch pan. If material is ready, open cut over valve connected to
C.V.Pan Now open individual compartment drain valve for compartment no. 1 and 2
( 8” rising spindle valve) Now open cut over valve of batch pan gradually and
vacuum break valve. Now massecuite will start transferring to C.V.Pan. Please
check periodically whether massecuite is not stuck up in the cut over line and smooth
transfer is taking place. When batch pan is emptied check sample keys of individual
compartment and ascertain up to which compartment massecuite is filled up. If
necessary , transfer some more massecuite from another batch pan in order to
completely fill the pan.

Once pan is filled completely check the brixes in individual compartment and slowly
open the vapour valve of 9th Compartment . Similarly, throttle the valve provided at
5th no. compartment. Wait and see. As boiling picks up, open the valve provided for
10th and 11th no. Compartment.

Open the seed by starting screw pump provided at vacuum crystalliser, initially keep
R.P.M. of the pump at high e.g. 600 to 700 R.P.M. Before starting the pump ensure
that 6” seed valve provided below compartment No. 1 is fully open. Now close the
re-circulating valve provided on the delivery line of the screw pump.

This will allow seed to enter into compartment no.1. Keep checking brixes of
massecuite from compartment 6 onwards to 11 compartments. When massecuite
attends 94 degree to 95 degree brixes in last compartment please open the massecuite
discharge valve (16” size) Before opening massecuite discharge valve, please ensure
that the receiving crystalliser is properly sealed with prepared massecuite. Now
massecuite from last compartment will start flowing through discharge pipe to
receiving crystalliser from other end so that massecuite can be pumped or flow to
pug mill. Now pan is commissioned. Check brixes in individual compartment from
first to last and determine the exact level of brixes for individual compartment and
accordingly adjust the molasses feed valve provided for each compartment. Please
ensure that molasses is thoroughly conditioned having 70 degree brix and 70 degree
Celsius Temperature. If molasses is unconditiond then massecuite may not be of a
uniform quality. If instrumentation is provided, check reading on each monitor and
it should be noted. Now automation to be set in auto mode operation , adjust set
point to desire valve. Open up air for each auto valve and once valves are in
operation close the manual compartments. Check the quality and quantity of grain in
first compartment and accordingly adjust the R.P.M. of screw pump so that adequate
no. of crystals are present in first compartment.

Now pan is in operation, properly tuned to deliver uniform quality of Massecuite.

Continue the observations with respect to molasses feed, seed feeding and vapour
availability.

If those conditions are maintained uniformly along with constant vacuum pan will
work very smoothly.

The Continuous Vacuum Pan for ‘B’ Massecuite is expected to operate continuously
over period of 30 to 35 days provided other conditions as mentioned in above
paragraphs are carefully maintained. If purities of ‘B’ Massecuite are very high, then
this period may be reduced to 20-25 days. Also intermittent working of the pan also
leads to reduced boil out period.

 CLOSING UP

When pan operates over a period of 30 to 35 days, it is essential to liquidate the pan
by emptying or some time it becomes inevitable to stop the pan due to break downs
rain or other problems. In such a case stop the molasses feed valve in first four to
five compartments, if it is manual. Or set the brixes uniform for all the
compartments on P.I.D. controller. Observe for 15 to 20 minutes so that the boiling
Massecuite attains more or less uniform conditions of brixes. Then close the vapour
valve and decide whether to transfer the material back to batch pan or dropping
directly into the crystallizer. In case if you find that massedcuite is easily curable
then it recommended to drop it in receiving crystallisers only. Whichever may be
the case close the massecuite discharge valve and break the vacuum and select the
compartments from which massecuite has to be transferred to respective batch pan
or crystalliser. It takes one to two hours for emptying the pan. Once pan is emptied
open the body washing valve and thoroughly steam the pan till body temperature
attains 100 degree C. This ensures dissolution of any crystals or lumps that may
remain in the pan as residue. Steaming for 20 to 30 minutes should be adequate for
cleaning the pan. The melt may be transferred to any batch pan. Now, fill the pan
with hot water up to the half of clendria level. Open up the vapour valve and start
vapour boiling. Water boiling for 1 hour to 11/2 hour will be thoroughly clean the
pan. Drain the water through wash out connection and refill the pan with clean
water boil again for 15 minutes and drain the same. Now, pan is ready for restart.
repeat as mentioned above.
  DESCRIPTION

1) THE SHELL
Made of one hooped cylindrical shell with internal catchall and standard
fittings constructed from M.S. Plate. This will be dispatched in segment to be
welded at site.

2) THE CALENDRIA
The calendria are made of M.S. Plate and baffles inside the calendria for steam
distribution. The tube plates are made of M.S. Plate. Heating tubes are secured
between two tube plates. This will be dispatched in three segments.

3) THE INTERNAL BAFFLES

Vertical partition plate of M.S. Plate.

4) LIQUOR FEEDING
Each compartment is provided with a manifold connected to main feed coils
for mother liquor and water.

5) CUT OVER PIPE

To transfer the massecuite from batch pan to continuous pan during
Starting up, main cut over connenction of pipe will be provided.

6) WASHOUT HEADER
Wash out drain connection of 4” size will be provided for disposal of washout
water.

7) WASHOUT STEAM
A common coil will be provided for washout steam of size 6”

8) SIGHT GLASSES & SAMPLE KEYS

Each compartment will be provided with 2 nos. of sight glasses and one no of
sample key.

9) SEED MAGMA FEED ARRANGEMENT

Appropriate size seed magma connections will be provided for first
Compartment.

10) PAN FIXTURES AND ACCESSORIES

On the upper part of the pan

  One vacuum dome with internal catchall and deflector plate.
 One vacuum break connection.
 Two Manholes.
 One vapour space pressure guage.
 Calendria Pressure guage.
 Sight glass wash water connecting pipe.
 Non condensable gases vent pipes.

On the lower part of the pan –

 Massecuite drain pipe with individual outlet for liquidation.

 Condensate removal connections at various points joined to header around
The pan only.

11) VALVES AND FITTINGS

All standard valves and fittings for above mentioned piping and connections

Separate list of valves attached.

12) CONDENSOR
In your case single entry S.S. condensor is supplied by you of 1200 mm size.
We have equipped the same with condensor control system, vapour pipe
from pan to condensor ils also supplied by you.

 CONTINUOUS VACUUM PAN CONSISTS OF FOLLOWING

COMPONENTS.
1. Steam inlet Valve.
2. Catchall Body and internals.
3. Condensor complete.
4. Condensate Header.
5. Feed pipe and valve.
6. Light & Sight Glass.
7. Manholes with cover.
8. Molasses header with valves.
9. Pan body with stools.
10. Pan Calendria.
11. Sample Keys and Wash Basins.
12. Seed Pump.
13. Steam Header.
14. Water Header.
TROUBLE SHOOTING :

1. General problems which normally encountered in case of Batch Pan are common
in Continuous Vacuum Pan also such as disturbances due to poor vapour quality
and quantity, low/high syrup or molasses brixes, inadequate vacuum. However,
Continuous Pan boiling is a dynamic process. Hence Massecuite can not be
retained in the Pan at will. Once seed material enters first compartment and boil
along with mother liquor from subsequent compartment, it has to go out from
last compartment. Hence during troubled period, attention must be paid on above
points.

2. Seed quantities should be kept adequate. Otherwise false grain will form in last
compartment. Seed pump must be maintained and rubber spares should be
handy.

3. During any stoppages, massecuite conditioning is must in respective

compartments with minimum water dose. During this period, massecuite gets
tighten up and lumps may form. To avoid this, if stoppage is longer massecuite
must be kept at lower brix in all compartments.

4. Before starting and stopping the Pan, all respective valves should be opened or
closed as per process requirement. Since number of valves are much more than
Batch Pan, care must be taken to maintain the conditions of the valves.

5. No un-authorised person should temper the automation system.

AUTOMATION FOR CONTINUOUS VACUUM PAN

Automation in Pan Boiling improves crystallisation and exhaustibility of molasses

and reduces steam consumption. The same has been achieved sugar boiling process,
by determining conductivity during low grade massecuite. Continuous pan boiling
being a dynamic process, it is experienced that control loops are necessary to
maintain uniform condition of boiling process at various stages.

 MAKE UP LIQUOR FEED CONTROL

 SPEED CONTROL FOR SEED MAGMA PUMP

 OPERATING PRINCIPLE

 MAKE UP LIQUOR FEED CONTROL

 A single loop control for make up liquor feed for each compartment is provided
by means of automatic pneumatic valves, which operates on signals. To achieve
an especially designed cell will be provided in each compartment. The signals
from cells are received by a monitor that will be housed in main control. The
output of monitor will go to P.I.D. Controller. Where it will be compared with
preset value of and accordingly command signal will go to I/P converter for
converting electrical signals into pneumatic signals for operating control valves.
The feed of liquor will be regulated in each compartment automatically.

 SPEED CONTROL FOR SEED MAGMA PUMP.

It is experienced that during normal running condition vapour pressure various
this effects the rate of evaporation. In such a case if seed flow remains constant,
it affects the grain size and brix of massecuite. This can be regulated from
using speed control system to regulate flow of seed. On continuous pan brix
controller is to used to measure the valve of brix in various compartments. This
eliminates the need to take frequently the sample from sample key.
To achieve this purpose all compartment are provided with separate (Brix)
Controller loops. Similarly each compartment has independent control valve for
charge feeding.

In this first compartment the seed is introduced with the help of speed controlled
screw pump from seed vacuum crystalliser. This seed is taking from vacuum
crystalliser through variable speed control screw pump.

 SENSOR CELL MONITOR (TRANSMITTER)

The cell electrically sense the conductivity of material. The cell is designed
especially to measure the (brix) conductivity. It is driven by monitor.
The main function of monitor is to monitor (brix) continuously. It receives
signals from cell. Monitor also conditions the electronic signal from cell to
standard instrumentation signal. The cell will be mounted in side of pan, &
monitor will be at field panel or centralise panel.

 CONTROLLER
The output of monitor is given to the input of controller. Its range is calibrated to
0-100 %. The measure’s variable is compared with set value of controller. This
difference signal is error signal. The controller takes the suitable action
depending upon process error and it again process requirement. Final control
elements position is also shown on controller by vertical barograph on front
facia of the controller. The controller is also provided with auto to manual mode
switch.

 ELECTRO-PNEUMATIC CONVERTER
As its name indicate, it converts standard signal to proportional 3-15 PSI
pneumatic pressure. The input pressure for the electro-pneumatic converter is
20 PSI or 1 Kg. This pressure is called an operate pressure of the instrument.
 FINAL CONTROL ELEMENT (PNEUMATIC VALVE)
This valve operates regarding 3-15 PSI air pressure. This valve is double acting
double piston proportional positioned valve ( Butterfly valve constant and
continuous instrument air pressure of above 70 PSI to Kg is provided at
instrument input port.
The valves accept 3-15 PSI pressure from electro-pneumatic converter and
determine proportional position. The valve position can also be seen on valve
positioned, which is located on the top head of the actuator.

 ANNUCIATION SYSTEM
In the hazardous operation it is necessary to bring the operator’s attention
over to the process.
Our system is provided with one Audio and visual annunciation. The fail safe
condition in each compartment is shown on the annunciation by glowing light
of particular window. At the same stage until normal condition is achieved. It
alerts the operator to attain the normal conditions.

 VARIABLE SPEED DYNODRIVE CONTROL OF SEED PUMP

It normal mode, we can operate at desired speed according to our process
requirement by adjusting knob.

 OPERATION
The brix in each compartment is sensed by cell. The set point of controller
continuously compares the signal from individual compartment. Controller gives
necessary commands to control valve for feeding. Feeding based on set value
maintain desired condition in respective compartment.

PLESE NOTE THAT No. OF SENSOR VALVES SUBJECT TO No. OF

COMPARTMENT.

 SCOPE OF CLIENT
You have to provided a control room with A.C. cabin of appropriate size for
main control panel.
You have to provide a source of power supply of 230 V, and auxiliary
compressed air from your centrifugal compressor. (80 to 100 PSI). Near our
control panel air should be dry, dust and oil free. Cabin size will be informed
after designing of panel size.
Any change in design of automation will change supply and quantity.
  TROUBLE SHOOTING

TROUBLE PROBABLE CAUSES REMEDY

 PANEL TRIP  Short circuit inside  Check & rectify

panel  Switch on M.C.B.
 Abnormal supply
voltage
 WHEN CONTROLLER  Wire linking between  Check & rectify
SHOWS VERY LOW cell & monitor either
READING BELOW 10% short or open.
 Monitor & P.I. wire
discoupled.
 Short circuits.
 Diluted material in
contact of sensor.
 WHEN CONTROLLER  Cell & monitor  Check & rectify
SHOWS VERY HIGH wiring discoupled
READING  No sensing material
 Deposition on cell
 CONTROLLER SHOWS  Loose connection  Check & rectify
DRASTICALLY between looped
FLUCTUATION. instruments
 MONITOR IS NOT  Fuse blown up  Check & rectify
WORKING  Supply break
 Open input wire
connection
 CONTROLLER IS NOT  Fuse blown up  Check & rectify
WORKING  Supply break
 In manual operation
Mode
 Mode of controller
action & set point.
 Shortinput connection
 NO OUTPUT FROM I/P  Absence of 4-20mA  Maintain 20 PSI
signal from controller air pressure at the
 No air pressure input
 Choking of I/P nozzle of I/P
 Presence of oil &
water  Check & rectify
 Leakage’s in
connecting tube
 MAINTENANCE

1. Keep the panel always clean.

2. Regularly drain the pneumatic line.
3. Keep the proper pressure in pneumatic line.
4. Protect the system from hazardous operations viz. Welding, hammering etc.
5. In the off season dismantle all the sensors and instruments from the pan body
and the panel. Store in the safe place.
6. Keep the dust- free environment in the cabin, and warp pan body mounted
instrument with polythin cover.

SPECIFICATIONS

Input power supply to the panel 230 V, 50 Hz and instrument power supply through
stabilizer 230V, 50 Hz ( + 5 %)

 SPARES

1. Conductivity Cell
2. Conductivity Monitor
3. P. I. D. controller ; input –4-20 mA, output ; 4-20 mA Hi-Lo contact
4. I/P converter, input –4-20 mA & 20 PSI output –3-15-PSI.
5. T.P.L. tubing, brass connector for each loop; ¼ B.S.P.
6. Fuses ; 1Amp, 200 mA.
7. Filter & Pressure regulator ; 3-30 PSI filter regulator.
8. Pneumatic valve ; Drive.