Control Philosophy Continuous Pan Jay Shree Sugar Mill

UttamSucrotech International Pvt.Ltd.
H-194, SECTOR-63, NOIDA, UP, INDIA, 201301
Control loops for B CVP
Client
Jay Shree Sugar Mill
Project/ Project Site

B Continuous Pan
UTTAM SUCROTECH INTERNATIONAL PVT. LTD.
DOC. NO. USIPL/BH/I/D-001
CLIENT Jay Shree Sugar Mill
CONTRACT DATE REV. NO. 00
SERVICE B Continuous Pan DATE 10.10.2013
This document is the property of
M/S UTTAM SUCROTECH INTERNATIONAL PVT. LTD.
and prepared based on SRI guide lines
and may be covered under IPR
Unauthorized use of this document including copying, tracing, duplicating the document in part or
complete, or any other use by person(s) for whom it is not intended, is not permitted.
Corporate Office – H-194, Sector-63, Noida, UP – 201301

Tel: +91-120-4726400, 2427446, Fax: +91-120-2427448, 4726464
E-mail – info@uttaminternational.com; www.uttaminternational.com Page 2 of 12
Contents
Close Loops: .................................................................................................................................................. 4
Head space Pressure Control loop ................................................................................................................ 5
Steam Flow control loop ............................................................................................................................... 6
Brix Control loop for Molasses/balancing water feed rate control to individual cells. ................................ 7
Seed Rate control loop.................................................................................................................................. 8
Massecuite level Manual control ................................................................................................................ 10
Throughput calculation ............................................................................................................................... 11
Open Loops for equipment monitoring ...................................................................................................... 12
Monitoring of the pressure inside the steam supply manifold .................................................................. 12
Monitoring of the pressure within the calandria of each module.............................................................. 12
Monitoring of the level in the x molasses supply tank ............................................................................... 12
Massecuite temperature in each module of the CVP ................................................................................. 12

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Close Loops:
I. Head space Pressure Control loop (if applicable)

II. Steam Flow control loop
III. Brix Control loop for each compartment
IV. Seed Rate control loop
V. Massecuite level Manual control
VI. Throughput calculation

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Head space Pressure Control loop (if applicable)
The aim of this control loop is to maintain Constant vacuum in the pan body the Vacuum shall be
measured at pan body near vapour line to pan condenser. The Vacuum shall be maintained by
increasing and decreasing the water flow quantity to the condenser.
In this control loop, the process variable signal is compared with the operator feed manual set point
in the DCS/PLC Close loop and the output of pressure control loop, will be fed directly to the control
valve of condenser. The action of the control loop shall be direct (that is as the Vacuum increases
above the set point, control output should increase).The control valve of Condenser water line shall
be default open condition.

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Steam Flow control loop
The aim of this control loop is to maintain required flow rate of steam to pan Calandria. The Steam
flow shall be measured by condensate flow meter.
The flow rate of the condensate leaving each calandria module is measured by the flow transmitters,
which send input signals to DCS/PLC their respective steam flow control loop. This assumes that for
each calandria the flow rate of steam entering and the flow rate of condensate leaving are the same.
[The loss of vapour with the venting of non-condensable gases is ignored (as it is minimal and of no
consequence for control).
The operator enters a steam flow rate set point for each calandria. The appropriate set point value
for each calandria is determined by the operator according to the level of x molasses in the supply
tank and the expected x molasses production of the factory over the next 4 to 8 hours.
In this control loop, the process variable signal Condensate flow is compared with the operator feed
manual set point in the DCS/PLC Control loop and the output of flow control loop, will be fed directly
to the steam control valves of steam control valve of each calandria module. The action of the
control loop shall be reverse (that is as the flow rate increases above the set point, control output
should decrease).The control valve of steam flow shall be default close condition.
The steam flow rate to the calandria of module 1 has a much stronger influence on the boil-on rate
of x molasses than that of the steam flow rate to the calandria of module 2.
Although not directly involved in the control loop the steam supply source pressure is measured by
the pressure transmitter and recorded to assist the operator in diagnosing problems e.g. pan’s
production rate slows due to lower steam supply pressure. Recording the steam supply manifold
pressure is beneficial and recommended.

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Brix Control loop for Molasses/balancing water feed rate control to

individual cells.
There are 8 molasses/balancing water feed rate control loops in total for the CVP with one
control loop assigned for each of the 8 cells. The arrangement for feeding x molasses or
balancing water to the cells is as shown below.
Cells 1 to 6 Molasses supplied to the underside of the pan with the rate regulated using
Control valves regulated by Loops in DCS.
Cell 7 DCS / PLC Control loop is used to either modulate molasses control valve to
supply x molasses to the underside of the pan OR modulate Water control
valve to supply balancing water to the top side of the pan. The output signal
from the controller is switched to control the appropriate valve.
Cell 8 Balancing water to the top side of the pan with the rate regulated using DCS
/ PLC control loop modulating water control valve.
The brix of the massecuite boiling in each of the cells from 1 to 8 is measured by RF conductivity
transducers. In total 8 transducers are required on the pan.
The operator enters a conductivity set point value for the massecuite in each cell of the CVP
according to the required brix profile along the CVP.
The RF conductivity indicating controllers use the signals from the respective RF conductivity
transducers and the operator’s conductivity set point values to modulate the positions of the x
molasses/balancing water control valves.

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Seed Rate control loop
The total flow rate of x molasses feeding the CVP is measured by the flow transmitter located in
the x molasses supply manifold to the CVP. The signal is processed by the DCS / PLC to provide a
rolling time averaged input signal to the ratio control loop. The rolling average of the x molasses
flow signal is calculated for the previous 10 minutes.
The set point for the seed addition rate is determined as a ratio to the total (rolling time
average) x molasses flow rate to the pan. This ratio (R1) is predetermined and set by the
supervisor or production manager according to the expected mean sizes of the crystals in the
seed and the product massecuite. The calculation of ratio (R1) is provided hrewith. The operator
adjusts this ratio using the seed bias (Bias) according to his assessment of the composition of
the seed and the desired product conditions to create a new seed to molasses ratio (R2)
according to the following algorithm:
R2=R1 + (Bias-1) * R1
The seed bias should be managed by small infrequent adjustments (preferably not more than
once every 4 hours) to fine tune the characteristics of the product massecuite.
The flow rate of seed feeding the CVP is measured by the molasses flow transmitter which sends
an input signal to the seed flow loop in DCS/ PLC. The seed flow rate indicating control loop uses
the seed rate set point signal from the ratio control loop and the signal from the seed flow
transmitter to regulate the variable frequency drive which modulates the speed of the seed
pump.
Calculation of Ratio R1
Seed rate (t/h) = Desired Product rate (t/h) * C
Where
C = (Seed Size / Desired Product size) 3 * (Desired crystal content in product / Crystal content in seed)

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In practice, the control scheme for the x massecuite CVP does not provide for the x massecuite
rate to be set directly by the operator. The production rate of the pan is determined by the boil-
on rate of x molasses.
Once the ratio of seed rate to product rate is determined it is possible to determine, by a mass
balance, the x molasses rate required to achieve the production rate for the given seed rate by
the equation
Product rate (t/h) * Dry substance of product = Seed rate (t/h) * Dry substance seed + x
molasses rate (t/h) * Dry substance of x molasses
Where
R1 = Seed addition rate / x molasses rate = DS xmol *C / DSprod – (DSseed *C)

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Massecuite level Manual control
The operator manually sets the height of the sliding pipe in the discharge pipe to maintain the
desired massecuite level in the final cell of the CVP. The desired level is based on maintaining an
optimum level of massecuite in the pan to provide a strong circulation movement. The level in
the pan could be reduced during start up and shut down operations.

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Throughput calculation
3
For the case where the control system records the seed flow rate (m /h) and the x molasses flow
3
rate (m /h) – both from magnetic flow meters, the product massecuite flow rate (t/h) can be
calculated and displayed by using the method below. The method requires that the volumetric
flow rates of seed and molasses are converted to mass flow rates by the use of estimated
density values.
Seed Rate (t/h) = Seed rate (m3/h) * Density of Seed (t/m3)

Assume the density of the seed massecuite is 1.45t/m3
X molasses rate (t/h) = x molasses rate (m3/h) * Density of x molasses (t/m3)
Assume the density of x molasses is 1.32t/m3
The Calculation method is:
Product rate (t/h) = (Seed rate (t/h) * Dry substance of seed + x molasses rate (t/h)* dry
substance of x molasses)/Dry substance of product massecuite
It would be more accurate if the estimates of dry substance (by vacuum oven drying) for the
three streams are used rather than spindle brix. Single best estimate values can be used in the
calculation. Ideally these dry substance values are determined for a representative sample of
each stream and then used in the calculation.
The Dry Substance values will be approximately:

Seed massecuite 87
X molasses 69
X massecuite 91.5

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Open Loops for equipment monitoring
I. Monitoring of the pressure inside the steam supply manifold

II. Monitoring of the pressure within the calandria of each module
III. Monitoring of the level in the x molasses supply tank
IV. Massecuite temperature in each module of the CVP
Monitoring of the pressure inside the steam supply manifold

The pressure of the steam in the steam supply manifold is measured using the absolute pressure
transmitter. This pressure will be recorded on the DCS/ PLC system to provide real-time and
historical trends.
Monitoring of the pressure within the calandria of each module

The calandria pressure in each module is measured using the absolute pressure transmitters.
Each pressure will be recorded on the DCS / PLC system to provide real-time and historical
trends.
Monitoring of the level in the x molasses supply tank

The level of x molasses in the x molasses stock tank is measured using a level transmitter. This
level is recorded on the DCS / PLC system to provide real-time and historical trends.
The operator uses the level signal to observe trends of x molasses tank levels. By noting whether
the average x molasses tank level is rising or falling with time, the operators can determine if
the current x molasses boil-on rate is appropriate or if the production rate of the CVP should be
changed.
Massecuite temperature in each module of the CVP

The massecuite temperature in each module of the CVP is measured using resistance thermal
devices (RTD). These temperatures may be displayed on gauges or recorded on the DCS / PLC
system.

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Control Philosophy Continuous Pan Jay Shree Sugar Mill

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UttamSucrotech International Pvt.Ltd.

H-194, SECTOR-63, NOIDA, UP, INDIA, 201301

Control loops for B CVP

Project/ Project Site

This document is the property of

M/S UTTAM SUCROTECH INTERNATIONAL PVT. LTD.

and prepared based on SRI guide lines

and may be covered under IPR

Corporate Office – H-194, Sector-63, Noida, UP – 201301

Corporate Office – H-194, Sector-63, Noida, UP – 201301

I. Head space Pressure Control loop (if applicable)

Corporate Office – H-194, Sector-63, Noida, UP – 201301

Head space Pressure Control loop (if applicable)

Corporate Office – H-194, Sector-63, Noida, UP – 201301

Steam Flow control loop

Corporate Office – H-194, Sector-63, Noida, UP – 201301

Brix Control loop for Molasses/balancing water feed rate control to

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Seed Rate control loop

Seed rate (t/h) = Desired Product rate (t/h) * C

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R1 = Seed addition rate / x molasses rate = DS xmol *C / DSprod – (DSseed *C)

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Massecuite level Manual control

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Seed Rate (t/h) = Seed rate (m3/h) * Density of Seed (t/m3)

The Dry Substance values will be approximately:

Corporate Office – H-194, Sector-63, Noida, UP – 201301

Open Loops for equipment monitoring

I. Monitoring of the pressure inside the steam supply manifold

Monitoring of the pressure inside the steam supply manifold

Monitoring of the pressure within the calandria of each module

Monitoring of the level in the x molasses supply tank

Massecuite temperature in each module of the CVP

Corporate Office – H-194, Sector-63, Noida, UP – 201301

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R1 = Seed addition rate / x molasses rate = DS xmol C / DSprod – (DSseed C)