Sugar Manufacturing – Retrofitting of Dalmia Chini Sugar Mills automation system

Sugar Manufacturing – Retrofitting of Dalmia Chini Sugar Mills automation system

Retrofitting of  Sugar Mills automation system with HollySys MACS System

(Photo: HollySys Asia Pacific)

HollySys retrofitted obsolete DCS system for one of Dalmia Bharat’s major sugar plant in Uttar Pradesh, India with MACS-K DCS system – a safe and efficient operation for boilers, turbines, generators and other auxiliaries.

Project summary

Industry(s): Sugar Manufacturing
Customer: Dalmia Bharat Sugar and Industries Limited
Products: MACS-K DCS System
Site Location:  Uttar Pradesh, India

The Company

Dalmia Bharat Sugar and Industries Limited is a sugar company. The Company is engaged in manufacturing of sugar, generation of power, manufacturing of industrial alcohol and manufacturing of refractory products. The Company’s cane crushing capacity is 29,250 tons crushed per day (TCD). Its operations are integrated with a 140 kiloliters per day distillery and a renewable energy capacity of 119 megawatts. Its sugar plants are located in Uttar Pradesh (Ramgarh, Jawaharpur and Nigohi) and Maharashtra (Kolhapur and Sangli).

About Dalmia Ramgarh Sugar Mills

The Dalmia Ramgarh sugar mills has a cane crushing capacity of 7500 TCD. The plant produces bagasse, final molasses and filter cake as by-products. Bagasse is burnt in the high pressure boiler of 120 MT/Hr to produce steam and consequently electricity for in house use and export of surplus power to the Grid. The final molasses is used at distilleries.

The Scope

The Ramgarh sugar plant’s existing DCS system for its bagasse cogeneration facility was running on Windows XP OS, it was aging and costly to operate. When Windows XP OS was discontinued in India, there was no service support readily available. The 1 x 23MW bagasse cogeneration facility needed a new system to provide highly reliable control of operational functions within their sugar mill. They also need to ensure that the new system is customizable to accommodate software upgrades in the near future. Our team of engineers were required to  dismantle the existing DCS system and reintegrate without shifting existing field cables position from location.

(Photo: HollySys Asia Pacific)

The Solution

As sugar plant present a complex operating environment with many specific functions that must be controlled and coordinated, HollySys team of engineers have the monumental task of redesigning, re engineering, reintegration and dismantling the existing DCS system. A total of about 3500 I/Os was commissioned by HollySys for this project. We have also supplied 4 set of MACS K- Series controller, in which 3 set of Controllers for power generation and 1 controller set for sugar mill operation with 6 x operator stations and 2 x engineering stations. The operator stations are placed respectively in the sugar mill house, boiling facility & co-gen control room for control and monitoring.

(Photo: HollySys Asia Pacific)

(Photo: HollySys Asia Pacific)

We managed to commission the DCS system ahead of projected timeline, much to the satisfaction of our customer.  We will also like to congratulate the engineers involved for working round the clock and providing such professional services to ensure plant operations reliability.