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 ANNEXURE I

PROPOSAL FOR AUTOMATION & CONTROL SYSTEMS

1.0 SYSTEM OVERVIEW

1.1 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) Mill House
b) Boiler Station
c) Clarification Station
d) Evaporator Station
e) 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.

1.3 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.

1.4 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.

2.0 CONTROLLERS :

2.1 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.

2.2 Functions of Controllers shall generally be as follows:

a) Sequential Interlocking of drives in Mill House & Boiler Station.

b) Generation of Alarms in case of abnormal process conditions.
c) Integrated PID Control of Process Parameters.
d) ON/OFF Control of Molasses conditioners, etc.

cont..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%.

2.4 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 PLC CONTROLLER LOGIX CONTROLLER

1. Programming Language Ladder Logic Functional Block Diagram
(Circuit Diagram) (FBD) and Ladder Logic
2. Basic design For Sequence Control For Process Control
(can do process control)
3. No. of simultaneous Single Program Multiple Programs
programs (Multi-tasking)
4. Communications Proprietary Allen Bradley Open Networks, such as
Networks ControlNet, DeviceNet,
EtherNet, Fieldbus,
Profibus
5. Data Transfer Sequential, Master / Slave Simultaneous, Producer/
method system Consumer system
6. Data Transfer Time Non- deterministic Deterministic
7. Tag Data Base address based, tags Global Name based, tags
reside in individual nodes reside in a single node

3.0 OPERATOR STATIONS :

3.1 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.

3.2 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
ENERGY VENTURES page..3

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.

3.4 The Operator Stations shall also generate shift wise log reports, which can be printed for
record purposes.

3.5 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

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ENERGY VENTURES ANNEXURE II

CONTROL PHILOSOPHY

MILLING SECTION

1.1 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.

1.2 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.

1.3 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.

1.4 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.

1.5 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.

1.6 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.
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 ENERGY VENTURES page..2

BOILER SECTION

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.

2.4 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.

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cont..3
 ENERGY VENTURES page..3

CLARIFICATION SECTION

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
operator’s attention.

3.2 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%.

3.3 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
 ENERGY VENTURES page..4

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.

3.5 MUD WITHDRAWAL CONTROL

Mud flow from Clarifier shall be controlled based on level of mud in Mud Tank.

3.6 Measurement of Water Flow to each Vacuum Filter.

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cont..5
ENERGY VENTURES page..5

EVAPORATOR STATION

4.0 EVAPORATOR CONTROLS

4.1 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) Juice Flow Control to semikestner

b) Brix sensing at outlet of quad set
c) Vacuum Control of last body
d) 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.

4.3 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.

4.4 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.

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cont..6
ENERGY VENTURES page..6

PAN STATION

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.

5.2 PAN VACUUM CONTROL

Condensor Water Flow for each batch Pan shall be controlled to maintain its vacuum during
the pan boiling cycle.

5.3 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 operator’s 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.

5.4 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.

5.5 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.

5.6 LEVEL MONITORING OF PAN STORAGE TANKS

Level of syrup, melt and molasses storage tanks shall be measured and displayed on the
operator station screens.

5.7 LEVEL MONITORING OF CRYSTALLIZERS

Level of massecuite in crystallizers shall be measured and displayed on the operator station
screens.
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cont..7
ENERGY VENTURES page..7

SUGAR HANDLING

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.

6.2 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.

6.3 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.

6.4 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.

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