Document ID: BO-Temp/CSW/NA/066

Control Philosophy
Molasses Storage

Reference: BO-Temp/CSW/NA/066
Revision:01

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 Document ID: BO-Temp/CSW/NA/066

Review and Approval

Prepared by:
Name: Divyendu Mishra
Position: Control Engineer
Signed:
Date:

Reviewed by:
Name: Ashwani Mahajan
Position: Technical Project Manager
Signed:
Date:

Reviewed by:
Name: Murli. V
Position: Semac Consultants
Signed:
Date:

Approved by:
Name: Rajat Guharoy
Position: Semac Consultants
Signed:
Date:

Revision History
Revision Date Change Summary
01 15/04/2022 Issued for approval

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Contents
1. Purpose and Scope .......................................................................................................................... 4
1.1 References ............................................................................................................................... 4
1.2 Abbreviations .......................................................................................................................... 4
2. The Process ..................................................................................................................................... 5
2.1 Filtration Tank ........................................................................................................................ 5
2.2 Unloading/Circulation Pump .................................................................................................. 6
2.3 Molasses tank .......................................................................................................................... 7
2.4 Transfer/Cooling Pump ........................................................................................................... 8
2.5 Existing Molasses Tank ........................................................................................................ 10
2.6 PHE/Surface Condenser........................................................................................................ 11
2.7 Heat Tracing Circuits ............................................................................................................ 12

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1. Purpose and Scope

This document defines and explains the Control philosophy for storing, loading and unloading of
Molasses. The document explains the philosophy beginning from the Filtration tank, unloading
pumps, 2000 MT molasses tank, transfer pumps, Surface Condenser and ending at existing 400
KL molasses tank. The document focuses on the Automation part and excludes mechanical and
electrical system. The requirement from mechanical and electrical to automate the process is
established and covered in the philosophy.

1.1 References
Ref. ID Title Rev Remarks
IO List Rev 03
BS/SS/CSD-001 Control Schematic Rev 02
Pin Chart Rev 02
BS/SS/CAS-001 Architecture Diagram Rev 01

1.2 Abbreviations

FM Mass Flow Meter

H Level High
HH Level very High
HT Heat Tracing
KL Kilo Litre
L Level Low
LL Level Very Low
LS Limit Switch
MT Metric Ton
NB Natural Bore
SOV Solenoid Operated Valve
TT Temperature Transmitter

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2. The Process
This section explains the process logic and operating sequences. Following shall be noted:

1. Four Sequences are provided – Unloading, Recirculation, Transfer and Cooling. Each can
be operated either in “Auto”, “Manual” mode.
2. Local mode is from the MCC and bypasses the PLC.
3. Unloading and Recirculation pumping is accomplished by the same set of pumps.
4. Transfer and Cooling pumping is accomplished by the same set of pumps.

2.1 Filtration Tank

A 2 KL Filtration tank is provided to receive the molasses, as shown in the figure below. It is
fitted with high-level (HL) limit switch to stop the receiving by closing the SOV - 1, if HL is
active.

Auto Sequence:

1. The operator puts the Local – Remote switch of SOV-1 and SOV-2 in “Remote” position.
2. The Auto sequence opens the SOV-1, if the HL switch is inactive and closes SOV -1 in
case the HL is active to avoid the overflow from the tank.
3. An alarm is generated on the HMI for LS01-HL to alert the Operator.

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Manual Sequence:

1. The operator puts the Local – Remote switch of SOV-1 “Remote” position.
2. In Manual sequence the Operator can open and close the SOV-1 valve manually from HMI.
In case of active HL, only alarm is generated to alert the operator. It may result in overflow
in case the Operator do not respond to the alarm.

Local Sequence:

1. The operator puts the Local – Remote switch of SOV-1 in “Local” position.
2. In Local operation the Operator can open and close the SOV-1 from MCC. There is no
interlock from the PLC, except generating the alarms.

2.2 Unloading/Circulation Pump

Two numbers of pumps in working and standby configuration, each with 20 CMH capacity are
provided to either unload the molasses from the Filtration tank or to recirculate the molasses in
the 2000 MT molasses tank as shown below.

Auto Sequence:

1. The operator puts the Local – Remote switch of Pump-A and Pump-B in “Remote”
position.
2. The Operator selects Unloading/Recirculation mode from HMI
3. In case of unloading, Auto sequence starts the pump with lesser running hours only if SOV-
11/12, 22 open feedbacks are active and molasses tank very high level (HH) is not active. It
will generate the alarm in case any of these are not permissive. Any of these getting non
permissive during running of the unloading process will trip the pump with an alarm to the
operator. In case the selected pump is not available or trips during the running process, the
standby pump is started automatically. An alarm is generated for the tripped pump for
operator information and necessary action.
4. In case of Recirculation, Auto sequence starts the pump with lesser running hours only if
molasses tank low level is inactive, SOV – 24, 11/12 and 21 open feedbacks are active. It
will generate the alarm in case any of these are not permissive. Any of these getting non
permissive during running of the recirculation process will trip the pump with an alarm to
the operator. In case the selected pump is not available or trips during the running process,

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the standby pump is started. An alarm is generated for the tripped pump for operator
information and necessary action.

Manual Sequence:

1. The operator puts the Local – Remote switch of Pump-A and Pump-B in “Remote”
position.
2. In Manual sequence the Operator can run any pump from HMI. However, the permissive
signals will remain in interlock as explained in the “Auto sequence”, above to safeguard the
pumps.

Local Sequence:

1. The operator puts the Local – Remote switch of Pump-A and Pump-B in “Local” position.
2. In Local operation the Operator can start any pump from MCC feeder. There is no interlock
from the PLC, except generating the alarms.

2.3 Molasses tank

A 2000 MT tank is provided to hold the molasses as shown in the figure below. It is fitted with
the following elements:

1. Recirculation inlet valve – SOV 21,

2. Recirculation outlet valve – SOV 24,
3. Unloading inlet valve – SOV 22,
4. Limit switch for very high level, high level and low level – LS02
5. Mass flow meter to show the flow rate and keep totalizer for record – FM20.
6. Temperature transmitter – TT20 to activate the cooling sequence, in case transfer sequence
in not running.

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Auto Sequence:

1. The operator puts the Local – Remote switch of SOV-21, SOV-22 and SOV-24 in
“Remote” position.
2. The Auto sequence opens the SOV-22 in case Operator selects the “Unloading” sequence
from HMI. It closes the SOV-22 and stops running the unloading pump in case the tank
level LS02-HH is active.
3. The Auto sequence opens the SOV-21 and SOV-24 in case Operator selects the
“Recirculation” sequence from HMI. It closes the SOV-21, SOV-24 and stops running the
recirculation pump in case the tank level LS02-L is active.

Manual Sequence:

1. The operator puts the Local – Remote switch of SOV-21, SOV-22 and SOV-24 in
“Remote” position.
2. In Manual sequence the Operator can open and close any of the above valves from HMI.
However, the Unloading/Recirculation pump and Transfer/Cooling pump will trip if any
permissive condition is not met, as explained in the “Auto” sequence above.

Local Sequence:

1. The operator puts the Local – Remote switch of SOV-21, SOV-22 and SOV-24 in “Local ”
position.
2. In Local operation the Operator can open and close SOV-21, SOV-22 and SOV-24 from
MCC. There is no interlock from the PLC, except generating the alarms.

2.4 Transfer/Cooling Pump

Two numbers of pumps in working and standby configuration, each with 5 CMH capacity are
provided to either transfer the molasses from the 2000 MT tank to 400 KL tank or to cool the
molasses in 2000 MT tank by circulating the molasses through PHE/ Surface Condenser, as
shown below.

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Auto Sequence:

1. The operator puts the Local – Remote switch of SOV – 31, 32, 41, 51, 52, Pump-A and
Pump-B in “Remote” position.
2. The Operator selects Transfer/Cooling mode from HMI.
3. In case of Transfer, Auto sequence starts the pump with lesser running hours only if 2000
MT tank low level (LS02-L) is inactive, SOV – 31/32, 41 open feedbacks are active and 400
KL molasses tank very high level (LS04-HH) is not active. It will generate the alarm in case
any of these are not permissive. Any of these getting non permissive during running of the
transfer process will trip the pump with an alarm to the operator. In case the selected pump
is not available or trips during the running process, the standby pump is started automatically.
An alarm is generated for the tripped pump for operator information and necessary action.
4. In case of Cooling, Auto sequence starts the pump with lesser running hours only if 2000 MT
molasses tank low level (LS02-L) is inactive, SOV – 31/32, 51 and 52 open feedbacks are
active. It will generate the alarm in case any of these is not permissive. Any of these getting
non permissive during running of the cooling process will trip the pump with an alarm to the
operator. In case the selected pump is not available or trips during the running process, the
standby pump is started. An alarm is generated for the tripped pump for operator information
and necessary action.

Manual Sequence:

1. The operator puts the Local – Remote switch of SOV – 31, 32, 41, 51, 52, Pump-A and
Pump-B in “Remote” position.
2. In Manual sequence the Operator can run any pump and SOV from HMI. However, the
permissive signals will remain in interlock as explained in the “Auto sequence”, above to
safeguard the pumps.

Local Sequence:

1. The operator puts the Local – Remote switch of SOV – 31, 32, 41, 51, 52, Pump-A and
Pump-B in “Local” position.
2. In Local operation the Operator can start any pump and valve from MCC feeder. There is
no interlock from the PLC, except generating the alarms.

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2.5 Existing Molasses Tank

A molasses tank with 400 KL is provided for the process requirement of the plant, as shown
below.

Auto Sequence:

1. The operator puts the Local – Remote switch of SOV-41 in “Remote” position.
2. The Auto sequence opens the SOV-41 in case Operator selects the “Transfer” sequence
from HMI. It closes the SOV-41 and stops running the transfer pump in case the tank level
LS04-HH is active to avoid the overflow.

Manual Sequence:

1. The operator puts the Local – Remote switch of SOV-41 in “Remote” position.
2. In Manual sequence the Operator can open and close SOV - 41 from HMI. However, the
Transfer pump will trip if any permissive condition is not met, as explained in the “Auto”
sequence above.

Local Sequence:

1. The operator puts the Local – Remote switch of SOV-41 in “Local” position.
2. In Local operation the Operator can open and close SOV-41 from MCC. There is no
interlock from the PLC, except generating the alarms.

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2.6 PHE/Surface Condenser

A surface condenser is provided to keep the temperature of the molasses within the limit of 41 +
2 degree Celsius by exchanging the heat with cool water circulating in the PHE/Surface
Condenser as shown below.

Auto Sequence:

1. The operator puts the Local – Remote switch of SOV- 51 and 52 in “Remote” position.
2. The Auto sequence opens the SOV- 51 and 52 in case Operator selects the “Cooling”
sequence from HMI. It closes the SOV- 51 and 52 in case Transfer is selected from the
HMI or tank level is low (LS02-L).
3. Once the sequence is activated, it will keep running for a predetermined period.
4. A time-based operation can also be selected to run the cooling based on a timer.
5. The Cooling sequence stops in case the transfer sequence is operated.

Manual Sequence:

1. The operator puts the Local – Remote switch of SOV- 51 and 52 in “Remote” position.
2. In Manual sequence the Operator can open and close SOV – 51 and 52 from HMI.
However, the cooling pump will trip if any permissive condition is not met, as explained in
the “Auto” sequence above.

Local Sequence:

1. The operator puts the Local – Remote switch of SOV- 51 and 52 in “Local” position.
2. In Local operation the Operator can open and close SOV-23, 51 and 52 from MCC. There
is no interlock from the PLC, except generating the alarms.

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2.7 Heat Tracing Circuits

Heat tracing lines with insulation are provided, partially on the 2000 MT tank and on the pipe
lines to keep the molasses line clear and choke free. Temperature of each heat tracing circuit is
each line are monitored by installing a RTD in each circuit.

Auto Sequence:

1. The operator puts the Local – Remote switch of individual HT in “Remote” position.
2. The Operator sets the setpoint for the temperature to be maintained with permissible dead
band.
3. The Auto sequence switches ON/OFF the circuit depending on the temperature reading
going below or above the dead band, automatically.

Manual Sequence:

1. The operator puts the Local – Remote switch of individual HT in “Remote” position.
2. In Manual sequence the Operator can switch ON/OFF individual circuit.

Local Sequence:

1. The operator puts the Local – Remote switch of individual HT in “Local” position.
2. In Local operation the Operator can switch ON/OFF HT circuit from the MCC.

END OF DOCUMENT

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