InduSoftWeb Studio, parameters at every step in the process aremonitored
for quality assurance.
engineers and operators can easilymake adjustments to the system
themselves; there is little need for field support.
InduSoftWeb Studio, RRB Sugar Mills can easily evaluate systemefficiency,
reducing the per-unit generation cost.
Sugar Mills Ltd. is one of India’s largest sugar producers, with
a cane-crushing capacity of 400 Tons of Cane per Day (TCD). While
most industries rely on external power sources to fuel their operation,
sugar manufacturers can produce their own power in a process called
cogeneration. As part of the process of producing sugar from sugar
cane, by-products such as bagasse a left-over fiber from the crushing
and extraction process can be employed as an eco-friendly fuel for
power cogeneration. The bagasse can be incinerated to fuel a boiler
furnace, which can be used to produce electricity. The power, produced
by the furnace can be used in the production of more sugar cane
a net positive energy gain.
sugar mills in India were permitted to produce only the energy they
needed for their own operations. Most Indian sugar companies therefore
adopted the practice of installing inexpensive boilers and turbines,
which also happen to be notoriously inefficient. They typically
would operate only during the sugar season. After all, why invest
money in an expensive, efficient system, when there’s very little
opportunity for a return on that investment?
the mid-1990s, though, the Indian ministry of power began permitting
companies to generate surplus energy. The energy could then be exported
to the state electricity board or to other manufacturers, which
in turn subsidizes production costs, promotes competition, and makes
electricity more plentiful for everyone.
exportation of energy was permitted, many plants, including RRB
Sugar Mills, began looking for ways to increase the efficiency of
their power plants. At its Wategaon, India, facility, RRB installed
backpressure turbo-alternators with two high-pressure boilers, a
turbine generator and a backpressure turbine generator.
required a new control system, and InduSoft Web Studio was chosen
to develop an HMI/SCADA system that would ensure an efficient plant.
Although the system was initially installed only to control the
boilers, it worked so well that RRB expanded it to also control
the entire sugar-making and wastewater processes.
managers at RRB knew they needed a Systems Integrator to develop
and implement the automation and control system, and they turned
to Control and Solutions India Limited (CSIL). CSIL was chosen because
they specialize in automation and control systems for the Process
Industries, Building Automation, and Substation Automation. After
reviewing the existing cogeneration system, CSIL provided RRB several
options for a centralized system that would meet their requirements.
Ultimately, RRB selected an InduSoft Web Studio-based HMI/SCADA
System with Honeywell PID loop controllers.
boiler control has many useful features that have made the process
much more manageable. For example, it reads boiler process parameters
from primary sensors and secondary instruments, which helps RRB
control critical points in the process. The system also controls
threshold deviations and activates alarms if thresholds are breached.
History data logging is built into the system and a browsing feature
provides access to the logs for a complete history of the operation.
for Microsoft Windows environments, InduSoft Web Studio uses open
technologies to connect to monitoring and control hardware and third-party
software applications. Honeywell’s PID controllers are based on
open technology and were easily networked to the InduSoft-based
monitor the boiler temperature, temperature scanners were easily
integrated into the InduSoft system through a Modbus communication
driver. The application collects temperature data from these scanners,
displays temperature values on color graphic screens, and logs the
data where it can be used to generate graphs.
and RRB engineers developed the HMI/SCADA applications, which included
control algorithms, alarm and reporting systems, and data logging
functions. This full-featured, performance management system was
developed and implemented using InduSoft Web Studio’s menu-based
Rapid Application Configuration Environment (RACE). The InduSoft-based
system presents real-time data from the boilers and turbines to
the analyzing logic, and then downloads appropriate set-point changes
to the PID controllers.
the power generation control system was updated, CSIL and RRB turned
their attention to automating the sugar production process with
InduSoft Web Studio. In the sugar industry, capacity utilization
is conceptually different than most industries.
depends on three crucial factors:
- The TCD rate
- The recovery
rate, which primarily depends on the quality of the cane
- The length
of the crushing season.
production tonnage is a function of the plant capability and variables
governed by the other two factors (cane quality and crushing season),
both of which are dependent on plant location. The quality of the
cane is outside factory control, because cane is not usually transported
great distances. Production plants must therefore rely on local
cane crops, the quality of which depends on climate and weather
patterns as well as soil and geography.
the length of the crushing season also depends on local climate.
Southern India, which has a tropical climate, has the longest crushing
season and plants in that region tend to produce the greatest tonnage.
the refining process the natural sugar stored in the cane stalk
is separated from the rest of the plant material as it moves through
the sequential production phases:
- The cane
is pressed to extract the juice.
- The juice
is boiled until it begins to thicken and the sugar begins to crystallize.
- The crystals
are moved to a centrifuge to remove the syrup, producing raw sugar.
- The raw sugar
is then sent to a refinery where it is washed and filtered to
remove remaining non-sugar ingredients and color.
you might imagine, the equipment that performs each step in the
process is very complex and careful monitoring is necessary to ensure
both an efficient process and a safe work environment.
a complex system comprising a boiler, a deareator, and a Pressure
Reducing and Desuperheating Station (PRDS) is employed. The plant
also contains a Boiling House that contains a Mill, Pan, and Crystallizers.
Finally, a steam distribution system and a wastewater system are
employed to distribute steam and bleed off condensation.
InduSoft Web Studio, parameters at every step in the process are
monitored for quality assurance of the raw sugar, to maintain efficient
cogeneration of power, and above all to ensure personnel safety.
addition to the production and quality gains they realized, RRB’s
engineers and operators were quickly trained on the new system.
They can easily make adjustments to the system themselves, so there
is little need for field support.
systems send information to the master control room where hourly
MIS reports are generated and sent to the central office server.
These reports can then be accessed by the executive office and quality
InduSoft Web Studio-based solutions running on both boiler systems,
the sugar-making processes and the wastewater system, RRB Sugar
Mills can easily evaluate the system’s overall efficiency. In the
cogeneration system, improved efficiency reduces the per-unit generating
cost. Also, because the system is less volatile, the costly boiler
and turbine are less prone to wear.
system’s hardware modules also continue to perform reliably. Service
calls have been substantially reduced and costly spare parts are
rarely needed. The overall reduction in maintenance expenses is
the end of the day, RRB was able to gain a competitive advantage
by automating their operation using an InduSoft Web Studio-based
solution. Reduced cost and improved productivity, a natural by-product
of this sort of high-tech automation, ensures a triumvirate achievement:
more plentiful sugar for local consumption and export, an economic
benefit to the local population, and plentiful, affordable power
for the region a combination that’s hard to beat.
Electronics supplies single board computers, embedded core modules,
programmable controllers, graphical displays and associated software
products. Dominion Electronics represents Indusoft in Australia
and New Zealand.