INVT GD200A VFD Enhances Water Injection System Efficiency at Indian Sugar Mill

Abstract: Water injection is a process used in sugar plants primarily to improve the efficiency of various operations, enhance the quality of the final product, and reduce energy consumption. In the context of sugar production, water injection is applied in different stages of the manufacturing process, such as during extraction, evaporation, and crystallization, as well as in cooling systems.

In the extraction phase, water is injected into the sugar cane or beet to facilitate the separation of sucrose from the fibrous material, improving the yield of juice. During the evaporation process, water injection can help control the temperature and pressure, ensuring optimal crystallization of sugar and preventing the formation of unwanted byproducts.

Keywords: GD200A

1. Introduction

System Procedure:
* Control System:
1.    Here provide variable frequency drive to control the motor rpm.
2.    Can achieve soft start, start time and start mode can be adjusted according to the site conditions.
3.    For better protection and to start stop power, provide power contactor on both side input as well as output side.
4.    System can operate remote and local.
5.    Motor speed can be adjusted via drive potentiometer, external potentiometer or Modbus communication.
6.    This system can run from 0-50Hz frequency like 0-990 rpm speed without any distraction.
7.    Acceleration and deceleration time can be set as per application so that system cannot go to generation mode and not shows any kind of error on drive. 

2.  Project information and Solution

1. Project information
Site information: Sugar Industry

 2. INVT solution

Table1. INVT suggested sugarcane mill VFD parameters

3. System Configuration:
Table2. Sugarcane mill motor parameters

4. System commissioning:

                                   Control panel

3.  Advantages and benefits

1    The sugarcane mill can be run smoothly with wide speed rang.
2.    The sugarcane mill is not running at full speed and power all the time.  When it runs at low speed, there is much energy saving.
3.    By gradually adjusting motor speeds instead of switching abruptly on and off, VFDs reduce mechanical vibrations and noise, which leads to lower maintenance costs and a quieter working environment.
4.    VFDs allow for soft starting and stopping of motors, reducing the mechanical stress on equipment. This helps prevent issues like motor burnout, bearing damage.
5.    The VFD control system adjusts the motor speed, which in turn controls the flow of water to the injection system. This allows for more precise water management, ensuring that the right amount of water is injected at the right time.
6.    The sugar production process has different stages that require varying water amounts (e.g., during evaporation or crystallization). The VFD system adjusts the motor speed dynamically to match the flow requirements of each stage.
7.    VFDs protect motors from overloads and excessive heat by controlling acceleration and deceleration speeds.
8.    Built-in fault detection capabilities, allowing operators to identify problems early, such as motor malfunctions, ensuring higher system reliability.
9.    VFDs can be integrated with a Supervisory Control and Data Acquisition (SCADA) system, allowing operators to monitor and control the entire water injection system remotely.

4. Conclusion

By optimizing the performance of motors and equipment, VFDs help sugar plants maintain higher levels of productivity, reliability, and profitability while reducing their overall environmental impact. INVT provide solutions against star delta starter and ABB drive.