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Instrumentation & Control of Continuous Vacuum Pans: by M.A. Getaz

This document discusses control philosophies and instrumentation for continuous vacuum pans (CVPs). It describes: 1) Standard control uses 14 loops including one for each compartment to regulate feed flow and one for vacuum and steam pressure control. 2) Newer options include predictive control using mass balance calculations and flow meters, and using radio frequency probes or hydrotrac probes to measure brix and temperature. 3) Choosing the right control philosophy and instrumentation is important as it impacts costs and performance. The choice should be based on an evaluation of the specific factory's needs.

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Javier Manuel Ibanez
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584 views

Instrumentation & Control of Continuous Vacuum Pans: by M.A. Getaz

This document discusses control philosophies and instrumentation for continuous vacuum pans (CVPs). It describes: 1) Standard control uses 14 loops including one for each compartment to regulate feed flow and one for vacuum and steam pressure control. 2) Newer options include predictive control using mass balance calculations and flow meters, and using radio frequency probes or hydrotrac probes to measure brix and temperature. 3) Choosing the right control philosophy and instrumentation is important as it impacts costs and performance. The choice should be based on an evaluation of the specific factory's needs.

Uploaded by

Javier Manuel Ibanez
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Instrumentation & Control of

Continuous Vacuum Pans

by M.A. Getaz
Standard Control Philosophy
(for a 12 cell CVP)
 Consists of 14 control loops;
➢One for each compartment, using an RF probe signal to regulate feed flow.
➢One for calandria steam pressure control.
➢One for absolute pressure control of the pan vacuum.

 Also included are;


➢A flow meter for measuring the condensate flow (to assess the CVP’s
production rate.
➢An inverter drive unit for controlling the speed of the seed pump.
Typical Process & Instrumentation Diagram
(for Standard Direct Control)
Radio Frequency Probes

Originally conductivity probes were used. They gave good control for low grade
massecuite, but were found to be too sensitive to;
➢Scale and encrustation build up.
➢Variations in ash content in high purity products like A-massecuite.

The need for better control and reliability, for A-massecuite boiling particularly,
led to the development of the RF probes.

FS now recommends:-


Monotrac probes for products with purities less than 90.
Duotrac probes for high puritty products.
Hydrotrac probes for direct brix and temperature measurements.
Monotrac, Duotrac and Hydrotrac Probe
Photographs
RF Probe Cleaning
In a continuous pan a gradual build up of encrustation eventually results in
reduced sensitivity of the probes. Therefore they need to be periodically cleaned.

The monotrac and duotrac probes are supplied with quick-release connectors
which enable;
➢Quick and easy cleaning with the operations typically lasting;
➢ 2½ minutes per probe.
➢ 14 minutes for 4 probes.
➢ For a cleaning schedule of each probe once a day, the operation requires4% of an operators
time.

In-situ cleaning with steam or hot water may also be used as an option.
Predictive Control of a CVP
Uses a mass balance calculation to determine and control the
quantity of feed to be added, based on;

➢Condensate flow measurement.

➢Some feedback obtained by measuring the brix of the massecuite leaving the
CVP.

➢Feed to each compartment (or group of 2 or 3) being set as a ratio of the


total and monitored by means of flow meters.

➢Throughput adjustments being accomplished by changing a set-point of


either calandria steam pressure of condensate flow.
A Process and Instrumentation Diagram
for Predictive Control
Advantages & Disadvantages of Predictive Control of
a CVP

It avoids the use of probes (& associated scaling problems, and drifting
of output due to product quality changes).

It cannot fully adjust for variations resulting from;


➢Inaccuracies in condensate flow.
➢Compartment to compartment changes in evaporation rate arising from brix
variations, encrustation, circulation etc.
➢Sudden sever disturbances, such as vacuum changes, loss of seed feed etc.

It cannot ensure as tight control of the massecuite condition in each


cell.
CVP Control System Examples
•Raceland ‘A’ CVP SCADA System •Puunene ‘A’ & ‘C’ CVP DCS System
Control of the FS Continuous Vacuum Pan
Brix Profile Establishment

TYPICAL GROWTH PROFILE FOR a MULTI CELLED PAN

Forward Boiling Back Boiling


Cells Cells

Discharge Brix
Line A
M
Base Line
X

Growth Brixing Up
Seed Brix Condition Area
N Area
Area

Travel – Cell No.


Cell Set Point Curves for RF Probes
Magdalena 'C' CVP Cell RF Set-Points Curve
50

45

40

35
RF Probe Values
30

25

20

15

10

0
1 2 3 4 5 6 7 8 9 10 11 12

Cell Number

New RF Probe Setpoints (SPs) RF Probe Recommendedl SP


RF Probe Min RF Probe Max
AN A-CVP SCADA SYSTEM OVERVIEW SCREEN
A B-CVP SCADA SYSTEM OVERVIEW SCREEN
A C-CVP SCADA SYSTEM OVERVIEW SCREEN
Process Parameter Trending – A Vital Management Tool

An Introduction to the FF CVP

16
A-CVP Vacuum & Steam Trends
Mitr Phu Viang Thailand
A-CVP Calandria Vacuum & Steam Pressure – Poor Control
New Developments in CVP Control
The use of liquor feed, water and condensate flow meters for on-
line determination of specific evaporation and product production
rates, amongst other details.

The use of a Hydrotrac probe for simultaneous massecuite brix and


temperature measurement.

This facility can then be used for;

➢Calculating the massecuite boiling point elevation.

➢The on-line determination of heat transfer coefficients.


A Hydrotrac Microwave Probe in Cell 12 of an A-CVP
(for measuring massecuite brix and temperature)
Hydrotrac Probe

DP Cell for Level


Indication
‘A’ CVP - Cell 12 Brix, Temperature & Vacuum Measurement
On-Line Determination of Massecuite Brix,
Temperature, Flow and of CVP Specific Evaporation
Rate & HTC
A CVP SCADA Trend Screen
Showing Evaporation Rate, HTC, and Product Flows
Conclusions

The choice of a CVP control philosophy and the instrumentation and control
package is important as;

➢It has a significant impact on the capital and operating (production, performance and
utility requirements) costs of the CVP.

The choice for a particular installation should be based on;

➢An informed evaluation of the options.

➢A specific evaluation of the circumstances and requirements of the factory.

➢Sourcing from a reputable, reliable and experienced supplier.

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