Evaporator Control System Update
The challenge
A sugar factory had automated its evaporator station using its own resources to improve process efficiency and ensure reliable control.
However, despite the substantial investment in equipment, the results were not as expected, and the evaporator station operated almost entirely in manual mode, with all the drawbacks that this entailed.
The solution
Comprehensive control strategy.
PAC
HMI
A comprehensive control strategy was designed and implemented, using a process model and controlling flows and levels, in accordance with the balance calculated in real time.
The project included:
- Complete review of functional, electrical, and mechanical design specifications.
- Validation of operating and maintenance manuals and SAT testing criteria.
- Programming of changes in PLC and improvement of control logic.
- Optimization of the HMI, with new screens, menus, and intuitive navigation.
- Support during on-site acceptance testing (SAT) and commissioning.
- Updating of system documentation.
The benefits
Reducing the cost of restructuring the control process by leveraging the configuration flexibility and scalability of existing equipment
- Greater efficiency and operational reliability in the evaporator station.
- Greater control stability and lower operational risk.
- Modern, user-friendly interface that facilitates operation and monitoring.
- Successful commissioning with specialized field support.
- Clear and comprehensive documentation, useful for maintenance and future expansions.
Impact on the plant
Increased safety, efficiency, and productivity. Target brix stabilized and process interruptions minimized.
The upgrade provided the factory with a modern, safe, and future-proof evaporator control system, ensuring continuity of the production process and more efficient operation.
Process interruptions due to full tanks of clear juice and molasses were reduced, and the time lost by the evaporation station was significantly reduced.
2024 Evaporator Control System Upgrade