C04_Automation of Sugar Boiling Process in Batch Vacuum Pans Using ABB
Specialized Instruments for Sugar Industry Instruments for Sugar Industry.pdf · Complete Sugar...
Transcript of Specialized Instruments for Sugar Industry Instruments for Sugar Industry.pdf · Complete Sugar...
YUTECH Complete Specialized Instrumentation
Solutions for Sugar Factories and Sugar Refineries
YU Technologies Pvt. Ltd.Registered Office:
315, A1, 22, Manishanagar, Off Sahyadrinagar, Sangli – 416 416, Maharashtra, India.
HO & Works:
B 8/5, MIDC, Miraj, 416 410, Distt: Sangli, Maharashtra, India.
T: + 91 233 6451803 – 6; F: +91 233 2644042
W: www.yutech.in
Serving the Sugar Industry since 1978
www.yutech.in; [email protected]
www.yutech.in; [email protected]
YUTECH Sugar Instrumentation and
Automation Solutions
• Experience of almost 40 years with Expertise of a very
highly qualified Engineering Team.
• In-house Control System Design, Engineering,
Manufacturing and Software Development.
• In-house Sensor, Analyzers & Instrumentation Design
and Manufacture.
• Highly accurate calibration facilities with traceability
certifications.
• Separate R & D Department
• Feature Rich State of the Art Technology developed and
matured in the Sugar Environment
www.yutech.in; [email protected]
YUTECH Sugar Instrumentation and
Automation Solutions
• Several Turnkey Sugar Plant Automation Projects Successfully
Commissioned
• Several Turnkey Co-Generation Power Plant Automation Projects
Successfully Commissioned
• Several Turnkey Distillery Automation Projects Successfully
Commissioned
• Pioneer of Sugar Mill Automations Invented Many Instruments and
Systems which are now a Norm in the Sugar Industry
• Several Continuous Centrifugal Machine Automations in Sugar
Industries
• Wide Customer base in whole of India, East Asia, West Asia, Africa
Milling Section
� Infra Red Type Donnelly Chute Level Sensors, Indicators & Transmitters
� Hall’s Effect Type Cane Blanket Level Sensors Indicators & Transmitters
� Hall’s Effect Type Top Roller Lift Sensors Indicators & Transmitters
Sugar Process & Refinery Section
� Brix Analyzers for Clarified Juice, Evaporators and Molasses Conditioners
� Brix Analyzers for A, B and C Pans
� Brix Analyzers for Sugar Melt
� Conductivity Analyzers for Steam Condensate and Feed Water
� pH Analyzers for Sugar Cane Juice, Liming, Feed Water
� Concentric Split Diaphragm Control Valve also called Iris Valve for Continuous
Centrifugal Machines and Liming Controls
www.yutech.in; [email protected]
YUTECH Innovated Solutions for Highly Critical and Challenging Applications in
Sugar Factories and Sugar Refineries with Specialized Instruments as below:
Mill Section
� Head Mounted RTD Transmitters for Bearing Temperature Sensing
� Head Mounted or Panel Mounted RTD Temperature Transmitters
� RPM Transmitters for All Types of Drives
� Current Transmitters for Electric Motor Drive Load Sensing
� Overhead Jumbo Displays
Sugar Process, Sugar Refinery & Boiler Section
� Vacuum Transmitters
� Draft Range Negative & Positive Composite Pressure Transmitters
� 3 Way Valve for Steam Condensate Bypass
� Head Mounted or Panel Mounted RTD Temperature Transmitters
� Thermo-couple Temperature Transmitters
� Pneumatic Linear Position Controllers for Bagasse Gates, Large Valves, Dampers etc
� Electric Actuators for Pan Discharge Valve
www.yutech.in; [email protected]
YUTECH also manufactures variety of other Instrumentation Products for
Sugar Factories and Sugar Refineries:
DCS or PLC Based Turnkey Automations:
� Complete Sugar Mill Automation with all Loops like Cane Feeding, Mill Speed Controls,
Imbibition and Juice Flow Controls etc
� Complete Sugar Process Automation with Loops like Evaporator, Pans, Continuous Pans,
Melters Conditioners, Heaters, Condensers etc
� Complete Boiler and Power Plant Automation
� Complete Sugar Plant Automation
� Complete Distillery Automation
� Condenser Automation
� Continuous Centrifugal Machine Automation
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YUTECH also undertakes Turnkey Automation Projects:
www.yutech.in; [email protected]
YUTECH Presence:
Pan India and
SAARC Region
ASEAN
Countries
West Asia
South
America
African
Continent
Donnelly Chute Level Indicator
Cum Transmitter
Product Code: ASD-DCLIT-IR-1005-1-6
Infra Red Type Donnelly Chute Level Sensor
Product Code: ASD-IRS-10
YUTECH Infra Red Type Donnelly Chute Level
Sensors and Indicating Transmitters
www.yutech.in; [email protected]
� Infra Red Sensing
� 100% True Level Detection, No False Level Detections
� IR Sensors Sense Level Through Dirt, Juice Films, Bagasse Powder
and also Juice and Water Mist in the Donnelly Chute
� IR Sensors have Built-in Raining Bagasse Compensation and easily
Sense Level through Raining Bagasse and Juice Moisture
� Water Ingress and Dirt Proof
� YUTECH invented this Technique in 1986
� More than 400 Sugar Mills use YUTECH IR Sensors in India, Asia
Pacific and African Regions
� IR Light is Known for Deep Penetration and used in Medical
Applications like Deep Fomentation hence the choice of IR for this
Critical Application
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YUTECH Infra Red Type Donnelly Chute Level
Sensors or IR Sensor Features
Infra Red Type Donelly Chute Level SensorsYUTECH
Infra Red Sensor Installation.
100% True DC Level Detection
No False Indications
No Problems due to Bagasse
Particles or Juice
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Cane Blanket Level Indicator
Cum Transmitter
Product Code: ASD-HE-CBLIT-1005-1-2
Hall’s Effect Type Cane Blanket Level Sensor
Product Code: ASD-HE-CBLS-10
YUTECH Hall’s Effect Type Cane Blanket Level
Sensors and Indicating Transmitters
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� Hall’s Effect Type Electromagnetic Sensor
� Pendulum Type Primary Level Sensor Floats on Cane Blanket
� Extremely Rugged Heavy Duty Enclosure to suit the Physical abuse of
Flying Cane from Leveller / Cutter / Knives
� 100% True Level Detection through all the Shocks, Vibration, Moisture
and Dirt
� No False Level Detections
� Water Ingress and Dirt Proof
� YUTECH invented this Technique in 1986
� More than 400 Sugar Mills use YUTECH CBLS Sensors in India, Asia
Pacific and African Regions
YUTECH Hall’s Effect Type Cane Blanket Level
Sensor Features
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Top Roller Lift Indicator
Cum Transmitter
Product Code: ASD-HE-TRLIT-1005-1-2
YUTECH Hall’s Effect Type Top Roller Lift
Sensors and Indicating Transmitters
Hall’s Effect Type Top Roller Lift Sensor
Product Code: ASD-HE-TRLS-10
www.yutech.in; [email protected]
� Hall’s Effect Type Electromagnetic Sensor
� Telescopic Primary Level Sensor rests on Mill Pressure Plate
� Extremely Rugged Heavy Duty Enclosure to suit the Physical abuse of
Cleaning, Moisture, Sugar Cane Juice and Juice Mist, Bagasse and
Steam
� 100% True Top Roller Lift or Float Detection through all the Shocks,
Vibration, Moisture and Dirt
� Water Ingress and Dirt Proof
� YUTECH invented this Technique in 1992
� More than 300 Sugar Mills use YUTECH TRL Sensors in India, Asia
Pacific and African Regions
YUTECH Hall’s Effect Type Top Roller Lift
Sensors and Indicating Transmitters
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Hall’s Effect Type Top Roller Lift Sensor
Assembly Diagram
Hall’s Effect Type Top Roller Lift Sensor
Sensor Mounting Assembly
Extension to rest on Mill Pressure Plate
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www.yutech.in; [email protected]
Picture of YUTECH Continuous Vacuum Pan Automation using YUTECH Brix Analyzers:
YUTECH Sugar Process Automation Screen Shots
Systems using YUTECH Brix Analyzers:
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YUTECH Brix Analyzer
YUTECH Auto Cleaning Self Retractable Brix Sensor:
Brix Analyzer with
Auto Purity Compensation
Product Code: ASD-BA-1005-XX-XX
Auto Retractable Self Cleaning Brix Sensor
Product Code: ASD-BS-1005-2E-SC-AR
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YUTECH Brix Sensor
Self Cleaning Auto Retractable Brix Sensor in Operation
Auto Retracting Self Cleaning Brix Sensor
installed on Continuous Vacuum Pan
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Auto Retractable Self Cleaning Brix Sensor:Product Code: ASD-BS-1005-2E-SC-AR
Sensor operates on High Frequency Signal generated by the Analyzer cum Transmitter
2 Electrode operation where one acts a transmitter and other as detector as well as
Washer.
PT 100 RTD provided for Massecuite Temperature Sensing
Self Cleaning Auto Retraction by Pneumatic Cylinder
Sensor sheathed in Teflon Bar with Whiton Oil Seals hence no leakage when retracted
and the Oil Seals work as Scraping Cleaners as well
Sensor Material: SS 304
Sheath and Oil Seals: Teflon and Whiton respectively
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Brix Sensor and Analyzer:Product Code: ASD-BA-1005-XX-XX Please see product codes for different applications
Salient Features of YUTECH Brix Analyzer cum Transmitter:
• Brix Sensor Electrodes Receive High Frequency Signal from the Analyzer;
Receiving Electrode Detects Signal Deviation with respect to Solution Brix
• This Signal Deviation is then Processed to get Brix Reading
• YUTECH Brix Analyzer is equipped with Intelligent Auto Purity
Compensation Algorithm to derive the Brix accurately in Massecuites of
varying Purity
• Very Easy Calibration
• In-Built Automatic Temperature Compensation
• In-Built Self Cleaning and Washing of Sensor with pre adjustable timing
cycle
• 4-20 mA Output, Separate Modbus and Ethernet Communications
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Brix Analyzer:
Batch and Continuous Vacuum Pans:
B and C Type:
Accuracy for Brix Sensing of Continuous and Batch Type Pans of B and C Type is
better than that of A Type, as the purity-of and variation-in intake materials is not
drastically different as in A Type and Our Purity Compensation Algorithm gives
corrections for this change limiting our Accuracy to within 1 to 2% Brix.
Brix Analyzers for Batch Type Vacuum Pan:
Brix Analyzers for Batch Type Vacuum Pans come with different Purity
Compensation Algorithm and as Batch Pans undergo periodic washings, there is
Wash and Pan Drop Compensation Algorithm, with Alarms for Pan Drop.
Brix Analyzers for Continuous Type Vacuum Pan:
Brix Analyzers for Continuous Type Vacuum Pans are designed to work in
conditions where the Pan is not cleaned periodically.
www.yutech.in; [email protected]
Brix Analyzer:
The A Type Woes!
A Type Massecuite:
• Inputs to the A Pan are Syrup, A-Light/Heavy Molasses, Sugar Melt and Water.
• Sugar Melt and Molasses are materials of drastically different purities.
• These Materials are often introduced into the A Pan in the same batch or in
separate batches
• Cut-In Practice adds to difference in purities of the materials inside and
sensing becomes virtually impossible.
• After a lot of R & D we have developed the Integral Purity Compensation
Algorithm which compensates for all these purity variations to come to a
reasonably good accuracy of less than 2-3% Brix for A Pan.
• Claims of better accuracy than that stated above for A – Type Massecuite by
whatever on-line methods would be Unrealistic.
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Brix Analyzer:Juice Filtrate, Evaporators, Molasses Conditioners & Sugar Melters
Juice Filtrate:
Brix Analyzer is Factory Calibrated for Clarified Juice Filtrate which has low Brix of
about 15 – 18 Brix.
Evaporator:
Brix Analyzers are Factory Calibrated for Sugar Syrup at the Evaporator Brix Range.
The Unit is suitable for all Evaporators Bodies. Its also suitable for Rising as well as
Falling Film Evaporators.
Molasses Conditioner and Sugar Melter:
Both these Equipment are similar in working and build. But Materials inside them
are different and of different purities. Hence Brix Analyzers come Factory
Calibrated for these applications.
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Controlled Centre Opening
Fully Closed
Concentric Split Diaphragm Control Valve
(also called Iris Type Valve):
Concentric Split Diaphragm Control Valve also
called Iris Type Valve
Product Code: CV-IR-1005-6-EP
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Concentric Split Diaphragm Control Valve
FACTS:
• Rugged Build Quality for Long Life.
• Heavy and Rugged Valve Construction absorbs all shocks and Vibrations.
• Valve Internals are of Heavy Gauge SS Construction and designed to operate under heavy Massecuite loads without bending or deformation.
• Precise Flow Control due to Concentric Opening of Split Diaphragm (similar to a camera aperture).
• Energy saving whilst Flow Control due to Free Passage through Concentric Opening
• Low-noise due to Easy Passage
• Maintenance free
• Pneumatic Actuation with Electro-Pneumatic Positioner for smooth Linear Control Action
• Operating Air Pressure 2 – 7 Kg/cm2
• Input 4-20mA from any external source
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Concentric Split Diaphragm Control Valve
FACTS:
Pneumatic Actuation:
• Pneumatic Actuation with Electro-Pneumatic Positioner for smooth Linear Control Action
• Operating Air Pressure 2 – 7 Kg/cm2
• Input 4-20mA from any external source
Electric Motorized Actuation:
• Electric Actuator Geared AC Induction Motor
• Operating Voltage: Single Phase 110 VAC 60Hz / 230 VAC 50 Hz or Three Phase 440 VAC 50 / 60Hz
• Input 4-20mA from any external source or Push Buttons
Hand Wheel:
• Geared Hand-Wheel
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Concentric Split Diaphragm Control Valve
Applications:
Flow Control of:
• Sugar Syrups, Massecuites and Solutions
• Various types of Slurries
• Various types of Viscous Fluids and Free Flowing Materials
• Wastewaters from Municipalities and Industries
• Paper Pulp and Fluids with Fibrous Suspensions
• Lime (CaOH) Slurry / Cement Slurry
Other Applications:
• Controlled Gravity Flow of Grains or Pellets or Powders with a particle size between 0.5 mm and 10 mm
• Ideal for Controlling Gravity Flow Control of Flow of Slurries / Semi Solids Concrete and other Fluids
• Ideal for Ratio Control of Two or More Ingredients falling in a Vessel
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Concentric Split Diaphragm Control Valve
Control Application Example:
Concentric Split Diaphragm Control Valve for Continuous
Centrifugal Machine Automation in a Sugar Factory:
Control of Sugar Massecuite Intake into the Continuous Centrifugal
Machine.
Sugar Massecuite is a very thick Slurry formed of Sugar Crystals and
Molasses and is very Sticky and Viscous Mass.
IRIS Type Valve provides perfect solution for dropping Sugar
Massecuite into Centrifugal Machine as the Massecuite falls in the
center of the Machine, it thus avoids spilling and splattering and so
facilitating a perfect Machine Operation.
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Concentric Split Diaphragm Pneumatic Control Valve
for Continuous Centrifugal Machine Automation:
Controlled Quantity of Massecuite drops
from the Concentric Opening (Split
opening from the Centre of the Valve)
Hence No Spilling or Splattering
Typical Concentric Opening Split
Diaphragm
Pneumatic Control Valve
Installation
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Concentric Split Diaphragm Control Valve:
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• Concentric Split Diaphragm Control Valve
provides perfect solution for dropping
Massecuite into Continuous Centrifugal
Machine as it split opens from the centre the
Massecuite falls in the center of the Machine
thus avoiding spilling and splattering and so
facilitating a perfect Machine Operation.
• Heavy and Rugged Valve Construction absorbs
all shocks and Vibrations.
• Valve Internals are of Heavy Gauge SS
Construction and designed to operate under
heavy Massecuite loads without bending or
deformation.
• Solenoid Valve is provided for Wash Water
Entry to clear Hardened Massecuite formed
during non operation.
YUTECH Instrumentation Products Sugar Factories and
Sugar Refineries:
www.yutech.in; [email protected]
• CT Converter senses the Drive Load Current using a Current Transformer.
• AC Load Current is then converted to 4-20 mA Current Signal.
• Electrically Isolated 4-20mA Current Output.
• Non Invasive Potential Transformer with HT CT is used for Sensing HT Motor Loads along-with Isolating CT Converter.
LT and HT CT Converters:
ISOLATING CT CONVERTER WITH POTENTIAL TRANSFORMER
ISOLATING CT CONVERTER SCHEMATIC DIAGRAM
ISOLATING CT CONVERTER
YUTECH Instrumentation Products Sugar Factories and
Sugar Refineries:
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• RPM Sensing of Carrier Drives, Mills,
Preparatory Devices.
• Non Invasive RPM Sensors capable of Sensing
Speeds up to 10000 RPM.
• Electrically Isolated 4-20mA Current Output.
• RPM Indicator for Local Indication
RPM Transmitters:
ISOLATING F TO I CONVERTER USED WITH AC TACHO GENERATOR
FREQUENCY OUTPUT FOR SPEED SENSING
SPEED (RPM) SENSING USING ISOLATING FREQUENCY TO
CURRENT CONVERTER AND RPM SENSOR
ISOLATING RPM TRANSMITTER
RPM SENSOR
RPM INDICATOR CUM TRANSMITTER
YUTECH Instrumentation Products Sugar Factories and
Sugar Refineries:
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• 3 Wire RTD Input Panel and Head Mounted Transmitters.
• Thermo-Couple Input Temperature Transmitters.
• Optional Electrically Isolated 4-20mA Current Output.
• Universal Input Process Indicator
Temperature Transmitters:
ISOLATING RTD TEMPERATURE TRANSMITTER
ISOLATING RTD
TEMPERATURE TRANSMITTER
UNIVERSAL INPUT PROCESS INDICATOR
ISOLATING TC
TEMPERATURE TRANSMITTER
HEAD
MOUNTED RTD
TEMPERATURE TRANSMITTER
ISOLATING THERMO-COUPLE TEMPERATURE TRANSMITTER
YUTECH Instrumentation Products Sugar Factories and
Sugar Refineries:
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• Panel Mounted Draft Range Pressure Transmitters
• Positive Draught (Pressure) Transmitters
• Negative Draught (Vacuum) Transmitters
• Combination Draught (Pressure and Vacuum Range) Transmitters
• Standard Output is 4-20 mA on 2 Wire Transmitter for all ranges
• Isolated Output is available for all ranges as an option
Vacuum and Draught (Draft) Range Pressure Transmitters:
2-Wire Draft Range Pressure Transmitter
YUTECH Instrumentation Products Sugar Factories and
Sugar Refineries:
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• Globe Type Double Seated Valve
• Common Spindle
• 3 – Way Valve with Single Entry and Double
Exit
• Excellent for Condensate Bypass Application
(In case of Sugar Entrenchment)
3 Way Bypass Double Seated Globe Valve:
2-Wire Draft Range Pressure Transmitter
YUTECH-DALSONS 3 Way Globe Valve
THANK YOU!
For your Time and Presence
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SAVE FUEL
REDUCE CARBON FOOTPRINT
MAKE THE WORLD GREENER
AND YET, MAKE MONEY