Specialized Instruments for Sugar Industry Instruments for Sugar Industry.pdf · Complete Sugar Process Automation with Loops like Evaporator, Pans, Continuous Pans, Melters Conditioners,

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

E: [email protected]

W: www.yutech.in

Serving the Sugar Industry since 1978

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


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


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


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


YUTECH also undertakes Turnkey Automation Projects:


YUTECH Presence:

Pan India and

SAARC Region

ASEAN

Countries

West Asia

South

America

African

Continent

Screen Shot of YUTECH Mill Automation using

Mill Instruments


Centralized Sugar Plant Automation Pictures:


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


� 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


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


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



� 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



� More than 400 Sugar Mills use YUTECH CBLS Sensors in India, Asia


YUTECH Hall’s Effect Type Cane Blanket Level

Sensor Features


Top Roller Lift Indicator

Cum Transmitter

Product Code: ASD-HE-TRLIT-1005-1-2

YUTECH Hall’s Effect Type Top Roller Lift


Hall’s Effect Type Top Roller Lift Sensor

Product Code: ASD-HE-TRLS-10


� 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



� More than 300 Sugar Mills use YUTECH TRL Sensors in India, Asia


YUTECH Hall’s Effect Type Top Roller Lift




Assembly Diagram


Sensor Mounting Assembly

Extension to rest on Mill Pressure Plate



Picture of YUTECH Continuous Vacuum Pan Automation using YUTECH Brix Analyzers:

YUTECH Sugar Process Automation Screen Shots

Systems using YUTECH Brix Analyzers:


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


YUTECH Brix Sensor

Self Cleaning Auto Retractable Brix Sensor in Operation

Auto Retracting Self Cleaning Brix Sensor

installed on Continuous Vacuum Pan


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


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


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.


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.


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.


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



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



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



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



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.


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


Concentric Split Diaphragm Control Valve:


• 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:


• 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


Sugar Refineries:


• 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


Sugar Refineries:


• 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


HEAD

MOUNTED RTD


ISOLATING THERMO-COUPLE TEMPERATURE TRANSMITTER


Sugar Refineries:


• 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


Sugar Refineries:


• 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


SAVE FUEL

REDUCE CARBON FOOTPRINT

MAKE THE WORLD GREENER

AND YET, MAKE MONEY

Specialized Instruments for Sugar Industry Instruments for Sugar Industry.pdf · Complete Sugar Process Automation with Loops like Evaporator, Pans, Continuous Pans, Melters Conditioners,

Documents