Click to Sugar

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Green
Summit
- 2013

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Advanced technologies for improving performance in the
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Sugar Industry Avisek Maitra

My Introduction
Avisek Maitra
National Sales Manager
Modular Systems (PLC & DCS)
Honeywell Process Solutions
Phone: 9763716944
Email: avisek.maitra@honeywell.com

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Whats the need for the sugar plants?

Expand and Grow the business

But, shortage in cane supply/water/power/Manpower
etc!!
Hence, the prime need is to increase plant efficiency
One of the Solutions:
Automation for Efficient Use of Plant Equipment,
Energy Savings, &
Better Production to Manpower Ratio
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Automation designed to get the following:

Reduction in Steam % Cane
Reduction in Power consumption
Overall Manpower Reduction
Overall increase in Plant Efficiency

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Intranet

Lab

Production Schedule
Plant Health Data

Corporate

Cane
Dept.

Report
Generator

e-Server

1. Shift Reports

Production
Management

2.Operator Logs

Cane
crushing
rate

3. Daily Production Reports.

Steam
%Cane

4. Alarm History.
10 % 10 %
15 %

15 %

15 %

15 %
10 % 10 %

Decision Support

5.Down time Logs.

Down Time

6.Critical Process Trends.

Maintenance
Management

7. Performance Trends

Maintenance
Planning

Redundant Application
Servers
Application
Real time
Services
Process Data

Decisions

Equipment Database
Plant Management

8. Statutory Formats

Grid
Demand

Enterprise
Management

Equipment Logs

Process Management

Maintenance
Schedule Library

Process
History

Sugar &Cogen Common

Plant Control Network

Set Points

Operator's
Work
DCS Controllers and Process Interfaces Stations
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Operator's
Work
Stations

Utilities Planning and Management

Cane
Syrup
Power Crushing
Mill
Water

Juice

Juice
Treatment
and
clarification

Evaporation
and Syrup
treatment

Inefficiency
or
Breakdown

Inefficiency or
Breakdown

Automation by DCS
Immediate
communication and
corrective decisions

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Sugar
Separation
(Centrifuge)

Manual
communication

Bagasse

Vapour

Crystallization
(Pan and
Crystallizers)

Manual
Communi
Inefficiency or
cation
Breakdown

Process
Management

Inefficiency
or
Breakdown

Advanced Sugar
Plant Automation by
Honeywell

The Advanced Sugar Plant Automation Solution is

targeted at
Measurable Benefits (Sugar)
Throughput - Improve Crushing efficiency
Yield -Improve Extraction
Energy Savings-Reduced Steam % Cane
Energy Savings - Reduced Power Consumption
Manpower Reduction
Quality - Improvement in Color ,reduced ICUMSA
Consistent Performance
Coordinated controls with Cogeneration /Distillery
High Return on Investment

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The Advanced Sugar Plant Automation Solution is

targeted at
Measurable Benefits (Cogen)
Throughput Increased Power Generation
Future ready system for Advanced Power Applications
Fuel Savings through unique combustion control
Building the biggest invaluable asset Experience Database of Plant
experts
Quality Standards- Ready to use Formats for Plant documentation
Coordinated controls with Sugar Plant
Advance Performance calculation

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The Advanced Sugar Plant Automation Solution is

targeted at
Intangible Benefits
Improved Visibility to processFast Response to Upsets
Decision support , Cane management and logistics
Production Accounting-Accurate accounting of RM Usage and Produce
- Equipment Usage and downtime analysis
-Manpower resource usage

Controlled Process environment

Reduced Stress on mechanical Equipment , Life extension
Condition Monitoring with real-time measurements
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Sugar plant Automation

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Areas of Automation

Cane carrier.

Mill or Fibrizer.

Juice Flow stabilization.

Juice Heater

Evaporator

Lime

Sulphur Burner

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Areas of Automation

Juice/Syrup clarifier

Vacuum filter

Batch & continuous pan

Storage tank

Horizontal XLR

Transient Heater.

Continuous centrifuge

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Areas of Automation

Air Dryer

Hopper level

Molasses conditioner

Storage tank

Interface with Existing system

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Power plant Automation

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Boiler Automation

Closed Loops

Interlocks.

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Closed Loops

Drum Level control

Furnace pressure control

Combustion control

Superheated Temperature control

Dearator level & Pressure control

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Closed Loops

Hot well Level control

Turbine Gland steam Pressure control

HP Heater Level Control

LP Heater Level control

MP steam Temperature control.

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Boiler interlocks

ID FAN Start/Stop

FD FAN start/stop.

SA FAN start/stop.

Boiler Feed Pump start/stop

Coal feeder start/stop.

Sootblower.

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Turbine interlocks

Main oil Pump Start/Stop

Auxiliary Oil pump Start/stop.

Emergency oil pump start/stop.

Jacking oil Pump start/stop

Condensate extraction Pump start/stop.

Vacuum Breaker valve open/close.

Turbine Gear motor start/stop

.Turbine trip.

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Belt Conveyor Speed Control Logic Diagram.

First mill chute level is measured using a Level Transmitter. The operator then enters the desired speed of
conveyor depending on the crushing rate, in DCS as a set point for belt conveyor. Besides speed he will also
enter the set point for desired chute level and Raw Juice Tank level in the DCS in their respective PID loops.
Whenever the Chute Level or mill Load or Raw Juice Tank Level rises above the set value then because of the
control action from the PID block output speed of the belt conveyor will reduce to automatically control level in the
raw juice tank so does the load on the mill is controlled.

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Mill Drive Speed Control Logic Diagram.

To control Mill Drive Speed we first measure their level by level transmitters. We configure PID blocks in the DCS
for speed control of the mills (more than one mill considered for crushing cane)and the operator enters the desired
speed of individual mill as set point in the DCS.The operator also enters set point for required chute level and load
to be maintained on each mill in DCS. Whenever the chute level or mill load increases above the set value the
speed of the particular mill increases. This controls level and the load of the mill.

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Raw Juice Flow Control Logic Diagram

Raw juice flow is measured using a mass flow meter and its density corrections are done by using mass flow
meter. Thus we get mass flow rate. Required flow depends on the crushing rate which is manually fed by the
operator in the DCS as Set Point. If the flow rate is more than the desired rate then the VFD speed is reduced to
match the set flow. If we are using recirculation valve instead of VFD then the recirculation valve will open more to
the set flow rate.
Graphics is the Human Machine Interface between plant and the operator. Graphics are configured in the DCS for
controlling various plant sections. Typically there is an index sheet from where the operator can navigate to
various sections of the plant. Index graphics and other graphics are given below. A brief explanation of plant
operation using graphics is provided by referring to Batch Pan Graphics

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Index Sheet Graphics

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PAN Automation Graphics - Continuous

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PAN Automation Graphics - Batch

Referring to figure below, one can operate the entire PAN sequence at the click of a Sequence Button on the graphics. Automated sequence improves PAN
boiling cycle time and avoids development of false grains. Honeywell has developed special software for automating the entire PAN operation sequence to make
plant operation smoother by way of avoiding vacuum drop problem, automatic selection of PANs to be kept in idle or running conditions and bring the PAN to
normal operating conditions once the storage tank level is reached without any manual intervention.

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Pump Status Graphics

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Profit Loop Benefits

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Profit Loop Benefits

Improved Control
Increase Control Performance (tighter control, less oscillation)
Reduced Valve/Actuator Overtravel Increased Life
Increased Production Rates and Product Quality
Reduced Energy Costs ( increased plant efficiency, less air usage)

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PlantCruise By Experion DCS meets all of the above

demands
Robust and Reliable: PlantCruise By Experion is a robust system that provides high process uptime by
providing redundancy at every level. It has redundant- Controllers, Input Output Modules and power supplies.
Unique patented Fault Tolerant Ethernet network for robust communication between the system nodes. In case
any of failure of a switch or a communication segment communication between the nodes is not impacted.
Ensures Continuous Plant Operation: In an unfortunate circumstance of server failure our unique system
architecture ensures that there is no loss of control or view. When the server fails the work stations
communicate with the controllers and live plant data is available to the operator to operate the plant, making the
system Reliable.
Easy to use: By extensively using object oriented programming language building control system logics is not a
tedious activity. Our easy to use features ensure substantial reduction in application engineering time and easy to
configure and operate plant graphics does not require very skilled manpower to operate the plant.
Easy to Maintain - The system is designed to be maintainable, resulting in minimal time to diagnose and correct
troubles. Many maintenance activities can take place while the system remains on-line in control of the process.
The system uses many COTS-Commercial Off The Shelf equipments for power supplies and switches. We also
give the customer multiple choices to choose computer manufacturers for system nodes.
Quick After Sales Service: PlantCruise By Experion is sold through System Integrators. This offers distinct
benefits like proximity to the customer to provide quick service. Honeywell rigorously trains their system
integrators on the product and shares domain expertise and engineering practices of Honeywell with system
integrators. Thus Honeywells expertise is available to the customer at local level.
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The PlantCruise by Experion Architecture

ProfitSuite

PHD

Advanced
Applications

eServer

Advanced Applications Network

Direct
Station

Direct
Station

Engineering Stations
(Optionally Redundant)

SIM C300
Simulation
Node

FTE
Supervisory Control Network
Modbus
Profibus
Gateway
Module

PGM

C300

C300

Modbus

C300
Controller

Network

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Safety
Manager

Third Party Interface

Controller
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IO Link

IO Link

MasterLogic

Series 8 I/O

I/O

Architecture

Thank You

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