2004 IEEE International Conference on Industrial Technology (ICIT)

Automation of Sugar Boiling Process in Batch Vacuum Pans using ABB-Freelance

PLC (AC 800F) and Conductor NT SCADA
Maheshwarnath Behary, Robert T. F. Ah King and Harry C. S. Rughooputh
Faculty of Engineering
University of Mauritius
Reduit, Mauritius
r.ahking@uom.ac.mu

Abstract- In this paper, the design and implementation
of the sugar boiling process in batch vacuum pans using
the ABB-Freelance PLC and the Conductor NT is
proposed. With a wei-designed automated system, the
need for operators supervision is greatly minimised
and hence permits the labour cost to be reduced and
optimising the repeatability and efficiency of the
process done by the system. Thus, the operator may
readily and effcientty take real time action on the flow
of the process permitting the latter to have an upper
hand on the system as the latter may decide his own
desirable set points at critical intervals during the
sugar boiling process. Using Function Block Diagrams
(FBD) and Sequential Function Chart (SFC) as the
main programming languages for the PLC and with the
appropriate interfacing of the designed system on the
SCADA as per the Conductor NT manual, a complete
centralised control of the automated system for batch
vacuum pans is proposed.
Keywords: Automation, control, PL C, SCADA, sugar
boiling process.
1 Introduction
2 Overview of Cane Sugar Manufacture
The different processes involved with the cane stalks are
discussed. Prior to extraction, the cane should be converted
to strands of thread-like fibre with pith (ff ufTy in form), for
an optimum juice extraction. Afier juice is extracted it is
screened, heated, defecated, decanted, filtered to remove
dirt and clay. After filtration, the juice passes through a
series of evaporators in order to remove maximum water.
As water is removed, the juice becomes more viscous and
the brix (dissolved substance in solution) rises rapidly and
this viscous liquid is called syrup. The syrup is hrther
heated in a vacuum pan until it reaches the point of
saturation, then seedling can be initiated by the addition of
slurry (mixture of ethanol and icing sugar). The boiling
process continues and the icing sugar crystal grows and the
mixture becomes more viscous. The resulting viscous
mother liquor is termed as massecuita. Finally, the
massecuite is sent to centrifugal where the sugar crystals
and the moIasses are separated. The process continues
until sugar of type A, B and C are manufactured. Further
processing is done to the crystals and stored in silos for
ease of transportation. The processed sugar is now ready
for domestic and commercial uses.

Nowadays to maximise profit we need to minimise the cost
of production. The sugar industry [ 1,2] will definitely need
decrease the cost of production, which can be achieved by
reducing labour or by displacing labour into another sector.
Furthermore, energy consumption will have to be used in
an optimum way without any unnecessary wastage.
Centralisation will be the next target, that is, small
industries might have to close down and their activities
taken up by major industries. After considering these
suggestions, the best way to sustain these ideas is
automation. In fact, through innovation and upgrading the
machineries, the costs of production, as well as the harvest
will be more promising to back the above ideas.
The aim of this project is the automation of type batch
vacuum pans. The boiling process that is undergone in the
batch vacuum pans is very compkx and lengthy. To
develop the control statement the modular technique has
been used and this is enhanced by the use of the Sequential
Function Chart. The compIete automation design is
proposed for the batch vacuum pans.
2.1 Steps invoked in a sugar boiling cycle
The flowchart in Fig. 1 shows the complete sequences
involved in a sugar boiling cycle. For ease of programming
the sequences have been defined into discreet steps. All the
actions that follows within a particular step have been
fiather defined in complete details so as to define the states
of all the input and output devices of the proposed system
in the control statement of the system,
3 Design for the New Automated System of
the Pans
After considering the various requirements of the new
system and considering its economic feasibility, a
proposed design has been brought forward. It should be
noted that the developed system should be very user
fiiendly so as the operators can hlly interact with the
system. To accomplish this an easily interpreted GUI
(Graphical User interface) should be developed.

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 3.1 Functional Decomposition of Proposed Design

Fig. 2 shows the detailed design of the batch vacuum pans

1 and 2. Tags have been labelled in the design and are
defined completely in Table 3.1 and Table 3.2 that follow.
1 As it can be seen in the design, the lines in red show the
input signals from the transmitters namely the pressure,
resistivity, vacuum and level transmitters. Lines in blue
show the processed output signals to actuate the regulation
valves to achieve desired conditions. Control is achieved
by using PID (Proportional Integral And Derivative)
Controller [6], which is a block function in the PLC that is
the algorithm of the PID ,exists in software in the PLC

5.0 el application program. In calandria of the pan, a pressure

transmitter is placed which will be used to sense pressure
and send feedback to a PID block, which will regulate the
pressure valve in order to reach the desired setpoint.
Likewise, the other closed loops in the system perform
respective control actions. -Moreover, the real-time values
NO
from the transmitters will be used for monitoring, hence
the need for these to be displayed with appropriate units on

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the SCADA. The proposed system also contains ON/OFF
valves, which can operate in only two modes, which is
either opened or closed position. The states of these valves
also need to be displayed on the SCADA for monitoring
purposes.

Fig. 1 showing the various steps involved in a sugar

boiling cycle

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.... ..

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UAVO29

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llAVO13

BATCH VACUUM PAN TWO

-
RSTO:
BATCH VACUUM PAN ONE
I SUAVKlB

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Fig. 2: Detailed design of the batch vacuum pans

854
3.2 Control Principtes Used to Control the Parameters
in the New System
1. Regulation of vacuum (0 inch mercury to 29.2 inches
of mercury) is achieved by controlling the entry of
finely sprayed cold water in the barometric condenser,
since vapour evolving kom the juice being heated in
the batch vacuum pans enters the barometric
condenser, which is a closed chamber. So this can be
used to create vacuum by direct contact of cold water
with the evolved vapour. Obviously, there will be
condensation of the vapour and hence leading to
volume contraction in the condenser. This will lead to
the creation of vacuum.
2. Regulation of pressure (- 1.0 bar to + 0.6 bar) in the
caIandria can be achieved by varying flow of steam
into the calandria. To control the flow rate a regulation
valve can be used. By increasing the opening of the
valve, flow rate of steam can be increased and hence
leading to an increase in pressure. Likewise, a
decrease in pressure can be achieved by gradually
closing the valve.
3. Regulation of the hot water valve (0-100%) and
syrup/molasses valve (0-100%) will be used to control
the desired slope (variation of concentration with
time) set by the operator especially during the feed
crystal growth stage. Increasing the opening of the
valve will lead to increase in flow rate and vice-versa.
4. The water valves, syrup valves, pressure valves, cold
water inlet valve in the barometric condenser are
expected to be controlled automatically according to
the IeveUpercent opening of water valve,
resistivity/percent opening of syrup valve, actual
pressure in cahndridpercent opening of pressure
valve, actual vacuum in pansipercent opening of cold
water inlet valve in the barometric condenser. These
control valves are supposed to response according to
the instruction given by the controller.
5. The remaining valves are the ON/OFF valves. These
valves have only two states, either they are opened or
closed. So, a signal from the Programmable Logic
Controller is sufficient to either activate or deactivate
the solenoid of the valve .which turn opens or closes
the valves by positioning the controller of the valves
to allow flow of compressed air in the correct
direction.
6. As it can be seen in Figure 2, lines in red shows input
analogue signals kom the transmitters involved.
However, lines in blue shows the controlled output
signals from the controller to the corresponding
rcgulation valves.
7. It should be noted in the proposed design, an or
condition is defined for the inputs from the two
vacuum transmitters. This is done so that each pan can
work independently of each other. Secondly, an
averaging function has also been used to average the
two incoming signals from the two transmitters, so as
to give priority to the pan with the lowest vacuum.
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3.3 Identification of Inputs and Outputs for the Batch
Vacuum Pans
After analysing the proposed design (Figure 2), first a list
for all the inputs and outputs were identified. Moreover, all
tag5 used in the proposed design have been defined. It
should be noted that the states of all ONlOFF valves are
being monitored; to accomphsh this feedback fiom the
position of the valves will be used. This signal will be
obtained from the inbuilt limit switches in the valves.
Moreover, the state of the discharge valve will not be
monitored, since this valve shall normally be closed in the
process, hence no need to monitor its state. A visual alarm
consisting of a lamp will also be used. The lamp will be
placed near the pan, and will be used to signal for the
satisfaction of preset parameters (setpoint) set by the
operator. For example if the operator sets a setpoint for the
brix, the moment the setpoint has been attained the lamp
shall light up to catch the attention of the operator. The
latter can then take appropriate Iocal action that is opening
or closing valves. This will be used more frequently when
the system will operate in the manual mode, or is
controIled manually, that is, the operators intervention to
confirm that the next step can be started.
4 Description of Equipment Used
A brief overview of the hardware and software that will be
used for the realisation of the project is given. Then, the
details and technical specification of the hardware used
will be elaborated further. After the selection of the
materials, selected quotations for the equipment will be
analysed in details for the selection of the cost-effective
components.
4.1 Understandingthe Working Principles of the ABB-
PLC (AC SOOF) [10,12]
After considering the working principles of this PLC, for
instance a proper understanding of the communication
protocols that have been used namely the Profibus DP
protocol and the Ethernet protocol. The input and.output .
addressing techniques of this PLC has been mastered, as
this will be useful in the control development,
4.2 Ethernet Protocol
Ethemet is quite a rapid medium of communication
especially when dealing with bulky softwares like the
SCADA, which consists of synoptic views. That is why
Ethemet has been used to communicate with the SCADA
instead of Profibus-DP. The use of Erhernet also permits
several computers to be connected to the network at
different locations in the plant for control and monitoring.
It should be noted that Ethernet assign a unique address to
each hardware connected to the network, that is, it uses the
TCP/IP protocol (Internet Protocol).
4.3 Profibus DP Protocol
Profibus specifies the functional and technical
characteristics of a serial fieldbus. This bus interconnects
digital and analogue field devices in the low
(sensor/actuator level) up to medium (all level)
performance range. The system contains master and slave
devices. Masters are called active stations. Slave devices
are simple devices such as valves, actuators and sensors.
For the actual case, the PLC with the profibus module is
the master and the data logger modules are the slaves,
which supply .data (serial form) to the PLC. One main
advantage of using profibus-DP is to minimise the cost of
wiring, Instead of using many wires for taking signals from
isolated field devices, a single twisted pair cable, which
transmits all the data into a serial communication [4] can
be used instcad to minimise the cost of Wiring.
4.4 The SCADA (Supervisory Control And Data
Acquisition) System
The SCADA system communicates With specific
controllers to retrieve data. SCADA was traditionally used
for data collection from PLCs and plant floor controllers.
SCADA systems were also used for monitoring and
supervisory control of processes. The role of SCADA
systems has expanded. SCADA systems [3] are a vital part
of many manufacturers information systems. The
manufacturing data, real-time values of parameters being
monitored can also he used to program dynamic attributes
(visual alarm like flashing and so on). Furthermore they
can also be used to program database for parameters of
interest and collected data are clearly visible in the form of
graphs, this is normally known as historical trending. As a
whole the SCADA is use to develop user-fiiendly
graphical intcrface. The main advantage of using SCADA
is that graphical user interface (GUI) can be developed in
an easiIy programmable way.
4.5 Selection of Sensors 171
In selecting a sensor for a particular application, there are a
number of factors that need to be considered:
Identify the nature of the measurement required
that is factors like the variable to be measured, its
nominal value, the range of values for
measurements, the required speed of
measurement, the reliability required, the
environmental conditions under which the
measurement is to be made.
0 Identify the nature of the output required from the
sensor; this determines the signal conditioning
requirements in order to give suitable output
signals fkom the measurement.
Possible seiisors should be identified taking into
account factors like range of operation, accuracy,
linearity, speed of response, reliability,
856
maintainability, power supply requirements,
ruggedness, availability, cost and so on.
4.6 Selection of Components
For this project, the sensors were obtained from the
suppliers and they also have their inbuilt signal
conditioning circuit. That is, standard output like 4-20 mA
was readily obtained from the ordered transmitters. The
various transmitters that were required for this project are
as follows:
Resistivity transmitters (Radio frequency probe)
PI
0 Pressure transmitters [9]
Vacuum transmitters
Level transmitters
4.7 Criteria for the Selection of Valves
Control valves are called to handle all kinds of fluids at
broad range of temperatures. So selection of a control
valve body assembly requires particular consideration to
provide the best available Combination of valve body style,
material and trim construction design for the intended
service. In order to select the control valve best suited for
the existing service conditions the following application
guidelines should be considered.
Type of fluid to be controlled.
Temperature range of fluid.
Viscosity range of fluid.
Minimum and maximum flow required.
Minimum and maximum inlet pressure at the
control valve.
Minimum and maximum outlet pressure at the
control valve.
Pressure drop across the valve expected during
normal flow conditions.
lnlet and outlet pipeline size and schedule of pipe.
After considering the specifications of all the components,
these components have been ordered so as to complete the
proposed design.
5 Understanding the Software for the
Control Statement I
The selected languages used are namely (1) The Function
Block Diagram (FBD) and (2) The Sequential Function
Chart (SFC). Some basic function blocks used for the
software development with the FBD are discussed in
details. The rules of thumb of the SFC are also explained
as per the AC-800F manual. As per the requirements of the
control statements, approximately 20 function blocks were
used to develop the control statement. So, a deep
understanding of these fbnction blocks is needed.
5.1 Programming the PLC
The control statement was developed into different folders
with specific task that is using the modular technique. This
simplifies our task in the testing stage. During the
programming stage, some compulsory limits of the
function blocks were not defined and these have to be
entered by the operator. Hence, parameters for pan one was
deveIoped so as to simplify the task of operator so that the
latter can easily enter the setpoint from the GUI. This
characteristic of the program enable the operator to have
full control on the boiling process and makes the system
flexible and adaptive in the cases of poor yielding fiom the
sugar cane that is low purity syrup obtained. The
programming stage includes the development of the
allocation list that is representing the hardware used with a
corresponding PLC address. The control statement that has
been developed should be tested to make sure that it
contains no bug.
6 Graphical User Interface Development
The pan boiler operators should easily understand the GUI
developed so that they can interact fully with the system,
which pcrmits full control on the sugar boiling process as
per the operators choice.
6.1 Real-Time Aspect of the System
Most control rooms in industries require PC-based systems
that automatically acquire data and display the parameters
being monitored. The monitored parameters are relevant to
the current operating state of the plant, highlighting
potential problem areas to the control room staff and
engineering staff. The displays must be informative and
easily interpreted at a glance by the operators. The main
emphasis concerns the real-time aspect of the system, that
Fig. 4: Combined synoptic view for pan one and pan two
857
is, the speed and capacity at which the data is gathered
from the system being monitored (Fig. 3).
L ..,...
r
Fig. 3: Basic block diagram for the online data acquisition
system
6.2 Developed Synoptic Views for this Project
The synoptic view shown in Fig. 4 has been developed in
the Conductor NT SCADA [l 11, the synoptic view is very
informative as real time values and states of all the devices
used in this project is readily available by a simple glance.
6.3 Synaptic view for the parameters of pans
This synoptic view shown in Fig. 5 has been developed to
simplify the task of the operator so that the latter can easily
enter the setpoint. This permits the operator to have full
control on the process. The working principle of this
synoptic view is explained below.
6.4 Developed synoptic view for historical trending of
pans
A historical trending sub model was configured for each
pan respectively (Fig. 6). This sub model was configured
such that the variation of the five main analogue
parameters can be displayed with rea1 time fluctuations and
can store these fluctuations up to one week. The process
manager can thus have knowledge about these fluctuations
and the current yielding obtained from the sugar cane
being processed at the factory. A11 the synoptic views that
have been developed should be tested independently to
make sure that each sub models in the synoptic view has
been correctly interfaced on the SCADA.
 Fig. 5: Synoptic view for the parameters of pan one
Fig. 6: Historical display
6.5 Cost analysis
The idea behind this renovation was to reduce the cost of
production by decreasing energy consumption, labour and
also to optimise the sugar boiling process. We would have
to acknowledge the fact that large investments are needed
in any re-engineering shift and competitiveness and
increased profitability should trail the way. In a standard
economic analysis such as for this project, rough estimates
must be made. Art economic analysis can be performed on
the system together with an economic breakdown of the
main categories concerned. This can guide the company or
anybody in the assessment of the project feasibility in
terms of cost, selectivity and decision-making.
7 Conclusions
This automation project will definitely bring along with it
benefits which will enable the factory to make maximum
profit at minimum cost. Examples of some of the benefits
that will be witnessed after the implementation are
(1) A decrease in production time,
(2) Maximum sucrose yielding from the syrup, that
is, lower purity of the final molasses,
(3) A decrease in labour cost, and
(4) An efficient energy consumption.
Furthermore, the aims of increasing the profit, decreasing
the cost of production and optimising the production
capacity will be attained. This system will clear the need of
operators to be pennanently on site, next to the batch
vacuum pans and actuating parameters manually as
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of the SCADA
I
requested by the regulation process. This system will
provide the benefits of remote control and automatic
regulation fiom a centralised control room action.
References
J.V. PiIlay, Essential Sugar Technology by Sugur
MiIling Research Instjtute, University o f Natal, 4041
Durban, South Africa.
E. Hugot, Handbook Of Cane Sugar Engineering,
Elsevier Publishing Co., 1960.
John Stenerson, Fundumentals of Programmable
Logic Controllers, Sensors, And Communications,
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Second Edition, Prentice Hall New Jersey, 1999.
Jerry FitzGerald and Alan Dennis, Business Data
Communicdons and Nerworking, 6& Edition, Wiley
New York, 1999.
Douglas E. Comer, Internetworking with TCP/IP, 3rd
Edition, Prentice-Hall New Jersey, 1995.
W. Bolton, Electronic Conpol Systems in Mechanical
Engineering, Addisoq Westley Longman Limited, 3d
Edition, 1997.
Katsuhiko Ogata, Modern Control Engineering,
Prentice-Hall of India, New Delhi, 2000.
The FS Duotrac Radio Frequency Probe User
Manual.
Operation and Maintenance Instruction Manual for
Intelligent Pressure Transmitters (LD 300 series).
(1 01 AC S6OF Documentation Version-6.2, PLC Manual.
[l 11 Conductor NT (Version 4.0) Graphic Editor.
[12] hm://www.abb.com/control