Modernization of the Tandem #3 Control System
The challenge
Among the main challenges that an automatic cane feeding system must overcome are:
- Stable and continuous grinding control
- Protection of cane preparation equipment
- Speed synchronization of conveyors
- Safety, protections, and interlocks
The control panel had obsolete electrical wiring and pneumatic controls, causing recurring failures, lost operating time, and risks to system safety.
The challenge was clear: modernize the station's control system, eliminate obsolete equipment, and provide greater reliability, safety, and stability to the factory's juice supply.
The solution
New control architecture.
A new, modern, and reliable control architecture was designed and implemented.
This included:
- Advanced operating stations, replacing obsolete consoles with HMI and industrial PCs.
- Distributed control cabinets (remote I/O) for turbines, mashing, and juice to factory, integrated into a network via a redundant DLR ring..
- Automation of critical equipment:
- Replacement of manual pneumatic valves with solenoid valves.
- Turbine speed regulation with I/P converters.
- Automatic mill flotation control.
- Smart instrumentation:
- Hydrostatic level transmitters for mash and juice tanks.
- Electromagnetic flow meter for juice to the factory.
- CCM design with frequency converters for controlling mash and juice pumps.
- 20-port Ethernet switch, expanding system connectivity and linking to the rest of the plant.
The benefits
Elimination of recurring failures, reduction of risks, and increase in grinding capacity, greater diagnostic and information capabilities for system operation.
- Greater operational safety and reliability, eliminating risks from obsolete wiring and equipment.
- Stability in the supply of juice to the factory, improving process efficiency.
- Modern, user-friendly interface that facilitates operation and real-time monitoring.
- Robust, redundant control network, ready for future expansion.
- Better decision-making, thanks to the integration of level and flow instrumentation.
- Comprehensive support in all phases of the project: engineering, installation, programming, and commissioning.
Impact on the plant
Reliability, safety, productivity, and stability in process continuity.
With this modernization, the sugar mill now has an integrated, secure, and efficient control system that ensures the operational continuity of Tandem #3, optimizes production, and provides technical staff with better tools for operation and maintenance.
This project is a clear example of how intelligent automation drives productivity and reliability in the sugar industry..
2024 Tandem #3 Automation