honeywell sugar presentation

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Advanced technologies for improving performance in the Sugar Industry – Avisek Maitra

Green Sugar Summit - 2013

My IntroductionAvisek Maitra

National Sales Manager

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Document control number

National Sales ManagerModular Systems (PLC & DCS)Honeywell Process Solutions

Phone: 9763716944Email: [email protected]

What’s the need for the sugar plants?

•Expand and Grow the business

•But, shortage in cane supply/water/power/Manpower etc!!

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•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

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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• Overall increase in Plant Efficiency

e-Server

MaintenanceManagement

Corporate

Lab

ReportGenerator

15 %

10 %10 %

15 %

15 %

10 % 10 %

15 %

1. Shift Reports

2.Operator Logs

3. Daily Production Reports.

4. Alarm History.

5.Down time Logs.

6.Critical Process Trends.

7. Performance Trends

Decision Support

Down Time

Equipment Logs

Equipment Database

ProductionManagement

Intranet

Production Schedule

Plant Health Data

Canecrushing rate

Steam

Cane Dept.

%Cane

EnterpriseManagement

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DCS Controllers and Process Interfaces

Set Points

Redundant Application

Servers

Operator's

WorkStations

Operator's

WorkStations

Real timeProcess Data

Management

ProcessHistory

8. Statutory Formats MaintenancePlanning

MaintenanceSchedule Library

Equipment Database

Application

Services

Decisions

Plant Management

Process Management

Sugar &Cogen Common

Plant Control Network

Grid Demand

Utilities Planning and Management

Manual Communi

Manual communication

Vapour

Syrup

Water

Power

Cane

Crushing Mill

Bagasse

Juice Juice Treatment and clarification

Evaporation and Syrup treatment

Crystallization (Pan and Crystallizers)

Sugar Separation (Centrifuge)

Inefficiency Inefficiency or Inefficiency

or

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Communication

Inefficiency

or

Breakdown

Inefficiency or

Breakdown

Inefficiency or

Breakdownor

Breakdown

Process Management

Advanced Sugar Plant Automation by Honeywell

Automation by DCS –Immediate communication and corrective decisions

The The Advanced Advanced Sugar Plant Automation Solution is Sugar Plant Automation Solution is targeted attargeted at

Measurable Benefits (Sugar)

•Throughput - Improve Crushing efficiency

• Yield -Improve Extraction

• Energy Savings-Reduced Steam % Cane

• Energy Savings - Reduced Power Consumption

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• Energy Savings - Reduced Power Consumption

• Manpower Reduction

• Quality - Improvement in Color ,reduced ICUMSA

• Consistent Performance

• Coordinated controls with Cogeneration /Distillery

• High Return on Investment


Measurable Benefits (Cogen)

•Throughput – Increased Power Generation

• Future ready system for Advanced Power Applications

• Fuel Savings through unique combustion control

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• 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


Intangible Benefits

•Improved Visibility to process-

Fast Response to Upsets

Decision support , Cane management and logistics

Production Accounting-

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-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

�Cane carrier.

�Mill or Fibrizer.

�Juice Flow stabilization.

�Juice Heater

Areas of Automation

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�Juice Heater

�Evaporator

�Lime

�Sulphur Burner

�Juice/Syrup clarifier

�Vacuum filter

�Batch & continuous pan

Areas of Automation

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�Storage tank

�Horizontal XLR

�Transient Heater.

�Continuous centrifuge

�Air Dryer

�Hopper level

�Molasses conditioner

�Storage tank

Areas of Automation

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�Storage tank

�Interface with Existing system

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Power plant Automation

�Closed Loops

Boiler Automation

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�Interlocks.

�Drum Level control

�Furnace pressure control

Closed Loops

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�Combustion control

�Superheated Temperature control

�Dearator level & Pressure control

�Hot well Level control

�Turbine Gland steam Pressure control

Closed Loops

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�HP Heater Level Control

�LP Heater Level control

�MP steam Temperature control.

�ID FAN Start/Stop

�FD FAN start/stop.

�SA FAN start/stop.

Boiler interlocks

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�Boiler Feed Pump start/stop

�Coal feeder start/stop.

�Sootblower.

�Main oil Pump Start/Stop

�Auxiliary Oil pump Start/stop.

�Emergency oil pump start/stop.

�Jacking oil Pump start/stop

Turbine interlocks

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�Condensate extraction Pump start/stop.

�Vacuum Breaker valve open/close.

�Turbine Gear motor start/stop

�.Turbine trip.

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 - BatchReferring 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

• 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)

Improved Control

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• Reduced Energy Costs ( increased plant efficiency, less air usage)

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 systemarchitecture 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.

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•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 Honeywell’s expertise is available to the customer at local level.

Direct

Station

Engineering Stations

(Optionally Redundant)

SIM C300

Simulation

Node

Direct

Station

Advanced Applications Network

FTE

PHDProfitSuite eServer

The PlantCruise by Experion Architecture

Advanced

Applications

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Modbus

IO L

ink

IO L

ink

C300 Controller

Series 8 I/O

Supervisory Control Network

FTE

Profibus Gateway Module

Safety

Manager

MasterLogic

PGM C300 C300

Modbus

Network

Controller I/O

Third Party Interface

Architecture

Thank You

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Thank You

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