Reference Control Philosophy
Reference Control Philosophy
Reference Control Philosophy
FOR
Mill and Process House
INTRODUCTION
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design of the plant. Instrument controls will be applied to those unit operations
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that are critical in the overall performance of the plant. This control system will
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enable the plant to be operated in the most efficient manner possible for
individual process areas from the central control room.
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Control System station-wise and divided into the following:
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5. Boiler
6. TG
7. Utilities system
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1. Chute height of mill no.1 will control speed of shredder cane elevator and
main cane carrier speed.
2. Mill no.1 speed fix/adjust by potentiometer.
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3. Ratio and inter lock for pressure feeder and mill.
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4. Juice system such as pump will be operated manually.
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5. Inbibition control with have flow recorder is provided.
6. Intermediate carrier have running indicator.
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7. Chute height level sensor of mill no.2, 3 and 4 will send the signal to
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adjust speed of mill.
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The first mill is used as the reference point where the motor drive speed is set
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A bank of five heights vertically arranged sensing probes are mounted in the
side plates of No.1 Donnelly chute. A location approximately mid-point of
these probes (between Nos. 2 & 3 probes) is considered optimum feed
height.
At levels above this height, the signal transmitted to the V.S. drives of the
Shredded Cane Elevator and Main Cane Carrier requires this equipment to
decrease speed proportionally. Conversely, at levels below this point, the
preceding carriers must increase speed proportionally.
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A bridge-supported on load cells mounted in the apron of the Main Cane
Carrier controls the speed of the Side Carrier V.S. drives.
All Intermediate Carriers are fixed speed units. Height sensing probes are
again fitted in the individual feed hoppers of each mill. As feed height rises
above the optimum feed point, the signal to the turbine governor requires the
turbine to increase speed. Conversely, a decreased feed level necessitates a
slower mill speed for optimum performance.
Safety
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Interlocks are provided for “Tumbler Stopped”, “Kicker No.1 Stopped”,
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“Leveler Stopped”, “Knife 1 O/Load”, “Knife 2 O/Load”, “Kicker No.2 Stopped”
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and “Shredder Under speed”. All mill turbines are interlocked.
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Generally, all carriers (including bagasse elevator) are fitted with Zero Speed
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Sensors mounted on the tail shaft.
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Thus, should any carrier stop or any item of machinery trip for any reason, all
preceding carriers will stop.
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Imbibition water flow meter is installed at imbibition water line. Signal from
flow meter is sent to recorder to record flow rate of imbibition water. The flow
meter is also equipped with analog type flow indicator to indicate the flow
rate. Flow rate of imbibition water is regulated by manually operated valve.
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2. RAW HOUSE STATION
2.1 JUICE CLARIFICATION
Mixed juice from mills is weighed at a batch type juice weighing scale fitted
with electronic load cells connected to a processor that determine and
record the juice weight entering the process house.
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From weighed juice tank, the juice is pumped to warm juice receiving tank
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through three units of primary juice heater in series. Temperature probe is
installed at the juice outlet line of the third heater that sends signal to
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controller to control temperature of the juice to the set point by regulating
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the opening of the vapor valve of the heater.
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2.1.3 pH Control
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From warm juice receiving tank, the juice is pumped to secondary heaters
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through static mixer to mix the juice with lime saccharate. Sample of
resulting limed juice is extracted from the delivery line of the pump and
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a). Milk of lime head tank is provided with level sensor to detect milk of lime
level in the tank in low and high level modes. When level is low, signal
from level sensor will activate the on/off valve to open until milk of lime
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level reach the set high level, then valve is closed. Milk of lime discharge
valve is also provided at the bottom of the tank.
b). Raw syrup head tank is provided with level sensor to detect raw syrup level
in the tank in low and high level modes. When level is low, signal from
level sensor will activate the on/off valve to open until raw syrup level
reach the set high level and then, the valve is closed. Raw syrup
discharge valve is also provided at the bottom of the tank.
c). Lime saccharate preparation tank is provided with level sensor to detect
lime saccharate level in the tank in low and high level modes. When level
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is low, signal from level sensor will activate the on/off discharge valves of
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both syrup and milk of lime head tanks until lime saccharate level reach
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the set high level then, these valves will close.
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2.1.2 Temperature Control (Final Juice Heater)
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After static mixer, the juice is pumped to juice flash tank through three
units of secondary juice heater in series. Temperature probe is installed at
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the juice outlet line from the third heater to measure and send signal to
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controller that records the temperature and regulates the vapor supply
valve to the heater.
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Clarified juice tank is equipped with level sensor to indicate juice level in
the tank. The signal from juice level sensor is sent to recorder and alarm
when juice level is lower or higher than set point.
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2.2.2 Clarified Juice Flow Indicator
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outlet box. Signal from level sensor is sent to regulate juice feeding valve
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to the next evaporator and maintain juice level in the box to seal vapor
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from previous evaporator to the next evaporator.
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2.2.4 Brix Indicator and Controller
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Brix Indicator is installed at the raw syrup outlet box of the last
evaporator. Signal from brix indicator is sent to recorder/controller. In
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case of outlet raw syrup concentration is lower than set point, the
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controller will send signal to regulate opening of raw syrup bypass valve
to circulate some of raw syrup to the last evaporator.
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Raw syrup flow indicator is installed at the raw syrup delivery line of raw
syrup pump. Signal from this flow meter is sent to recorder to record flow
rate of raw syrup supply to the process.
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2.2.6 Vacuum Control for Evaporator
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Signal from level sensor is sent to controller and to control valve installed
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at delivery line of exhaust condensate pump to regulate the opening of
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this valve in order to maintain the condensate level at the set point.
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2.3 CRYSTALLIZATION STATION
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output from the vacuum controller regulates the control valve opening of
the injection cooling water line to the barometric condenser. It
progressively opens the valve when the vacuum is too low and closes it
when the vacuum is too high. The valve opening is limited if the
condenser tail pipe temperature is below a minimum pre-set value.
The Raw syrup flow into the pan is measured by magnetic flow meters
and the combined signal is used to vary the speed of the magma pump
through a ratio station.
Because of the on/off nature of the feed, the flow signal is filtered by a
first order damping function with a time constant of between 15 and 30
seconds.
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When the pan is stopped, seed (or magma) is re-circulated to avoid
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having to stop the pump and steam out the line. This automatically
closes the seed valve into the pan and opens the recycle valve to the
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seed pump. The seed pump speed is automatically set to a fixed value
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of 50% to allow seed re-circulation. The seed pump will not start
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automatically unless the seed valve into the pan or the recycle valve is
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open. When the pump is re-started, the seed valve into the pan opens
and the recycle valve is closed. The pump speed is again controlled by
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The level of the Raw syrup in tank is continuously monitored while the
pan is foiling. If the level of the tank is less than 15%, then the A-
molasses tank level controls the pan evaporation rate. In other words,
the A-molasses tank level loop is used in cascade to set the set point of
the condensate flow, which in turn is the cascade set point of the
calandria steam pressure control loop. If the level of the Raw syrup tank
recovers and exceeds 25% then the evaporation rate of the pan will
again be controlled by the ‘A’ crystallizer level controller.
If the Raw syrup level falls further to less than 5%, then the pan is
shutdown. The operator is alerted by the alarm signal. A low rate
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selector is used between the two level control outputs so that the pan
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runs as slow as possible.
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2.3.1.5 Pan Discharge Pipe Level Control
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The output of the level controller on the discharge pipe controls the
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2.3.1.2 Feed Control (RF readings)
The ‘A’ molasses flow into the pan is measured by magnetic flow meters
and the combined signal is used to vary the speed of the magma pump
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through a ratio station.
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Because of the on/off nature of the feed, the flow signal is filtered by a
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first order damping function with a time constant of between 15 and 30
seconds.
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When the pan is stopped, seed (or magma) is re-circulated to avoid
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having to stop the pump and steam out the line. This automatically
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closes the seed valve into the pan and opens the recycle valve to the
seed pump. The seed pump speed is automatically set to a fixed value
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of 50% to allow seed re-circulation. The seed pump will not start
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automatically unless the seed valve into the pan or the recycle valve is
open. When the pump is re-started, the seed valve into the pan opens
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and the recycle valve is closed. The pump speed is again controlled by
the syrup and molasses/seed flow ratio.
The level of the A-molasses tank is continuously monitored while the pan
is foiling. If the level of the tank is less than 15%, then the A-molasses
tank level controls the pan evaporation rate. In other words, the A-
molasses tank level loop is used in cascade to set the set point of the
condensate flow, which in turn is the cascade set point of the calandria
steam pressure control loop. If the level of the A-molasses tank
recovers and exceeds 25% then the evaporation rate of the pan will
again be controlled by the ‘B’ crystallizer level controller.
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If the A-molasses level falls further to less than 5%, then the pan is
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shutdown. The operator is alerted by the alarm signal. A low rate
selector is used between the two level control outputs so that the pan
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runs as slow as possible.
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The output of the level controller on the discharge pipe controls the
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to each compartment.
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2.3.2.3 Ratio Control ‘B’ Molasses Flow and ‘C’ Seed Pump Speed
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The ‘B’ molasses flow into the pan is measured by magnetic flow
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meters and the combined signal is used to vary the speed of the
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Because of the on/off nature of the feed, the flow signal is filtered
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and 30 seconds.
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the pan is boiling. If the level of the tank is less than 15%, then the
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B-molasses tank level controls the pan evaporation rate. In other
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words, the B-molasses tank level loop is used in cascade to set the
set point of the condensate flow, which in turn is the cascade set
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point of the calandria steam pressure control loop. If the level of
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the syrup tank recovers and exceeds 25% then the evaporation
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rate of the pan will again be controlled by the ‘C’ crystallizer level
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controller.
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If the B-molasses level falls further to less than 5%, then the pan is
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The output of the level controller on the discharge pipe controls the
speed of the massecuite discharge pumps. A selection switch
(software button) is provided to enable the computer to determine
which of the two massecuite pumps is running.
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2.3.3 C seed – Batch Vacuum Pan Control
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when the vacuum is higher than the set point.
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2.3.3.2 Feed Control (RF readings)
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Each vacuum pan is fitted with an RF probe that measures
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control signal will regulate the main feed control valve to feed the
material continuously at a set massecuite concentration at any
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massecuite level.
2.3.3.3 Massecuite Level Measurement
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Hot water tank for vertical crystallizer is equipped with temperature
controlling system to control temperature of hot water to the set point
for reheating C- massecuite before centrifuging. Temperature
transmitter is installed at the bottom portion of hot water tank. Signal
from temperature transmitter is sent to regulate the opening of steam
feeding valve to the tank to control temperature to the set point.
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2.4.1 Temperature Control (For centrifugal washing water tank)
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Washing water for centrifugal tank is equip with temperature
controlling system to control temperature of hot water to the set point
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for washing sugar crystals and centrifugal basket. Temperature
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transmitter is installed at the bottom of hot water tank. Signal from
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measures water level in the tank. Signal from level transmitter is sent
to level controller to regulate the opening of water feeding valve to the
tank to keep water level at the set point.
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3. PRESSURE REDUCING AND DESUPERHEATING STATION
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3.2 Pressure Indicator and Recorder 32 bars
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The pressure of live steam from boiler is measured by pressure
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transmitter. Signal from pressure transmitter is sent to a recorder.
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Live steam with pressure 7 bars g from PRV 30 : 7 bar is sprayed by hot
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water to reduce the steam temperature to 150 0C. Hot water spray
nozzles are installed at the 7 bar g line. Water inlet to the spray nozzles
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3.4 PRDS 7: 1
Live steam 7 bar-g from PRDS 32: 7 is further reduced to 1.5 bar- g to
make up to exhaust steam line. Pressure transmitter is installed at
exhaust steam line to measure exhaust steam pressure and send signal
to recorder/controller to record the pressure and regulate the opening of
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7 bar reducing valve to feed steam to exhaust steam line to the set
pressure.
For safety reason, pressure release valves are installed to release
pressure in case of line pressure goes beyond set point.
Exhaust steam with pressure 1.5 bars g from PRV 7 : 1 bar and exhaust
steam from prime mover is sprayed by hot water to reduce the
temperature to 120 0C.
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Hot water spray nozzles are installed (insert) to the exhaust steam line.
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Water inlet to the spray nozzles is regulated by control valves which
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received signal from temperature transmitter installed at a proper
distance downstream of spray nozzles.
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Any excess water from the system is rained through steam trap.
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Service water head tank will be fitted with float type level indicator with
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high and low level limit switches. When the float level indicator touches
the lower level switch, it will actuate to run the raw water supply pump.
When the indicator touches the high level switch, it will stop the supply
pump.
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4. WHITE SUGAR STATION
4.1 Temperature Control (for melter)
The liquor in sugar melter is heated by third vapor from juice evaporator.
Temperature transmitter is installed at the liquor outlet line of direct
contact heater. Signal from temperature transmitter is sent to controller to
send signal to regulate the opening of vapor feeding valve to direct contact
heater.
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The concentration of melt liquor is controlled by:
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1. On/off valves for sweet water addition to the screw conveyor every
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time sugar is discharged from the centrifugal. Volume of sweet water
is controlled by timer.
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2. Final concentration is adjusted by regulating sweet water addition to
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probe is installed at the limed liquor sampling box. Signal from pH probe is
sent to pH controller to adjust the speed of lime wheel to feed the required
milk of lime to the remelt liquor.
Pressure of CO2 gas in the main line is controlled for safety purposes and
to avoid tripping of the CO2 compressor. Pressure transmitter is installed
at the main line near carbonators. Signal from pressure transmitter is sent
to controller to activate the safety relief valve when gas pressure reached
set point and closes when pressure is lower.
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Temperature of liquor in the first carbonator is controlled by regulating the
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amount of vapor supplied to this vessel Temperature transmitter is
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installed at the liquor outlet line of the first carbonator. Signal from
temperature transmitter is sent to controller to send signal to regulate the
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opening of vapor feeding valve to calandria of the first cabonator.
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Flow detector will be installed on the spray water supply line to CO2 gas
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scrubber to avoid any damage of pall rings inside the scrubber due to
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shortage of water. When there is no water flow in this line, the detector will
activate an alarm for the operator to take necessary action.
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continuously at a set massecuite concentration at any massecuite
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level.
massecuite level in vacuum pan during sugar boiling. Signal from level
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the volume of 5-7 bar- steam going into the air heater. .Temperature
transmitter is installed at the hot air outlet duct that measures and send
signal to controller to regulate the opening of steam feeding valve to air
heater.
High and low level sensors will be installed in the white sugar storage
bin. When sugar level in the bin is high, the sensor will actuate an
alarm to signal the bagging operators to speed up bagging operations.
When level is low, it will signal the operators either to slow down or
stop bagging operation
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