Internship Report 2k23

Shri B.V.V.
Sangha’s
BASAVESHWAR ENGINEERING COLLEGE (AUTONOMOUS)
BAGALKOTE - 587102
Report
on
Internship
carried out at
Bilagi Sugars Limited, Badagandi

Submitted in partial fulfillment of the requirement for the degree of
Bachelor of Engineering
in
Electronics and Communication Engineering
Submitted by
Pallavi Babu Halki 2BA21EC049
Under the Guidance of
Internship Co-ordinators Internal Guide External Guide

Dr. Vijayalaxmi Jigaginni Dr.Anand H U. Mr.Raju Tubaki
Dr.Ajay C .Katageri
DEPARTMENT OF ELECTONICS AND COMMUNICATION ENGINEERING

2022-23
DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING
2022-2023
CERTIFICATE
This is to certify that the Internship work carried out at Bilagi Sugars Limited,
Bilagi by Pallavi Babu Halki at bearing USN 2BA21EC049 in partial
fulfillment for the award of degree of Bachelor of Engineering in Electronics
and Communication Engineering, from Basaveshwar Engineering College
(Autonomous), Bagalkote, affiliated to VisvesvarayaTechnological University,
Belagavi during the academic year 2022-2023. Theinternship report has been
approved as it satisfies the academic requirements in respect of Internship
prescribed for the award of Bachelor of Engineering Degree.
Dr.Vijayalaxmi Jigajinni Dr.Anand H U Dr. Shridhar K.

Dr.Ajay C . Katageri
Internship Co-ordinators Guide
HOD
Name of Examiners: Signature with Date
1.
2.
3.
1
Department of Electronics and Communication Engineering
Basaveshwar Engineering College (A), Bagalkote
CERTIFICATE:
2
ACKNOWLEDGEMENT
Everything we do should be a result of gratitude for what people has done for us
First, I would like to thank R S Patil, Vice president, Bilagi Sugars Limited, Bilagi, for giving me the
opportunity to do an internship within the organization.
I sincerely thank Raju Tubaki, Head of instrumentation forhis careful and precious guidance
which would be extremely valuable for my study, both theoretically and practically.
I also express my gratitude to the officials and staff members who rendered their help during my
internship.
I also would like all the people that worked along with me with their patience and openness they
createdan enjoyable working environment.
It is indeed with a great sense of pleasure and immense sense of gratitude that I acknowledge the help
ofthese individuals.
I am highly indebted to Principal Dr. S.S. Injaganeri for the facilities provided to accomplish this
internship.
I would like to thank my Head of the Department Dr. Shridhar k, for his constructive criticism
throughout my internship.
I would like to thank my Internal Guide Dr.Anand H U
I would like to thank Dr. Vijayalaxmi Jigajinni and Dr. Ajay C Katageri
internship coordinator Department of ECE for their support and advices to get and complete
internshipin above said organization.
I am extremely great full to my department staff members and friends who helped me
In successful completion of this internship
Name of the student: Pallavi Babu Halki

.USN: 2BA21EC049
3
Abstract
Indian sugar industry, second largest agro -based processing industry after the cotton
textiles industry in country, has a lion's share in accelerating industrialization process and bringing
socio-economic changes in under developed rural areas. Sugar industry covers around 7.5% of total rural
population and provides employment to 5 lakh rural people. About 4.5 crore farmers are engaged in
sugarcane cultivation in India. Sugar mills (cooperative, private, and public) have been instrumentalin
initiating a number of entrepreneurial activities in rural India. This paper is an attempt as to review
progress of sugar industry in India, understand it's problems and challenges in context of ongoing
liberalization process. Indian sugar industry can be a global leader provided it comes out of the vicious
cycle of shortage and surplus of sugarcane, lower sugarcane yield, lower sugar recovery, ever increasing
production costs and mounting losses. It needs quality management at all levels of activity to enhance
productivity and production. Attention is required on cost minimization and undertaking by product
processing activities.
4
Contents
Chapter 1. Company Introduction 6
Company profile 7
specifications 8
Chapter 2. Task performed and learnings 10
PLC 11
DCS control systems 13
Boiler 16
Turbine 17
Chapter 3. Key learnings
Process of Sugar Industry 20
PLC Components 21
Chapter 4. Learning Outcomes 22
Conclusion 23
Chapter 5. Reference 25
5
List of Figures
Fig No. Description
1.1 Company Logo
2.1.1 PLC Block diagram
2.2.1
Diagram of Distributed Control System
2.2.2 Computerized control hierarchy model
2.3.1 Boiler diagram

2.4.1 Turbine diagram
3.1 Flow graph Of Sugar Indrustry
List of Tables
Table No. Description
1.1 Profile of the Company
1.2 Specifications
6
Company Introduction:
Fig 1.1 company logo
Established in 1995, MRN group is a successful business conglomerate with headquartered presence at
Mudhol, Karnataka. Under the visionary of Founder Mr. Murugesh R. Nirani, the group has been
striking the balance between reimagining & advancing industrialization and improving people's lives
not only across Karnataka state but various parts of India. At MRN Group, we constantly work to make
the future a reality by staying connected to our roots of rich resources and combining integrity, creativity
and smart innovation with the utmost consideration for our people, their families, the local communities
around us, our valued customers and the country at large.
A conglomerate of successful industries which have been playing crucial role in transforming
Karnataka state as well as rest parts of the India through bringing economic sustainability, MRN (Nirani)
Group boasts with its success stories.
This Group has witnessed dynamic growth by setting up many industries in various niches in a
record time period of mere two decades. By doing so, this Group fulfils a dream to bring balanced
economic development in this region for social uplift and to empower the common masses with fast
industrialization.
7
Profile Of The Company
Sl. No. Description Particulars

Bilagi Sugars mill limited, Badagandi
Name & Address of Tq :Bilagi near Bilagi Cross, Dist :Bagalkot
1
the company Karnataka 587116
Registered under companies act 1956

2 Constitution of the firm
bilagi Group,9th Floor,world tradecenter brigade

3 Corporate Office gateway campus,26/1,Malleshwaram Rajajinagar,
Bangalore Karnataka 560055
4 E-Mail bilagisugarmill@yahoo.co.in
5 Status of Company Public limited company
6 Bankers of the Company Axis Bank
7 Nearest railway station Bagalkot
8 Nearest Airport Belgaum & Hubli
9 Nearest Village Badagandi
10 Nearest Town Bagalkote
11 Nearest major city Bagalkot and Vijayapura
12 Products Sugar and power, by product molasses
8
Specifications
Cane Crushing capacity: 6500 TCD
Installed components:
Weighing Bridge : 2no, Make: Essae, Capacity: 60 Ton Mill :5 no
Cane carrier : Type: Slat, Make: SS Engineer,
Juice flow meter : Type: Electromagnetic, Make; Endress & Huser,
Capacity:350 TPH,
Imbibition water flow meter : Electromagnetic, Make; Manas, , Capacity: 250 TPH,
Imbibition control valve: : Type : Pneumatic, Make: RK controls,
DCS control system :DCS Based Make: SpinCo India Private ltd.
Boiler
Make : SS Engineer
Working pressure : 87 kg/cm2 Working temperature: 505°C
Capacity : 110 TPH
Turbine -1
Make : Siemens
Working pressure : 84 kg/cm2Working temperature: 505°C
Capacity : 8 MW
Type : Back pressure
Turbine -2
Make : SNM
Working pressure : 84 kg/cm2Working temperature : 505°C
Capacity : 10 MW
Type : condensate cum Extraction
Control system : DCS Based Make: SpinCo India Private ltd.
Juice Boiling House
Juice Heater : 4 no
Sulphur burner : 3 no
Juice sulphation : 1 no
Evaporation Body : 8 no
Pan Body : 5 no, Make: SS Engineers, Capacity: 60 Ton-3 & 40
Ton-2
Batch Centrifugal M/C : 5 no Make: ss Engineers & Thyson Krupp,
Capacity : 1750kg/cycle
Continuous Centrifugal M/C : 9 no Make: ss Engineers.Sugar Grader :2 no
Sugar silo : 3 no
Automatic sugar weighing M/C : 3 no, Make: Hitech, Capacity :50 kg, speed 14 bag/min
Sugar Bag printing M/C : 1 no
9
CHAPTER-2
TASK PERFORMED AND LEARNINGS
PROGRAMMABLE LOGIC CONTROLLER:

A PLC is an industrial computer control system that continuously monitors the input devices and decides
upon the output devices based on the custom program designed. It canbe used as a substitute for
components like relays, counters, timers etc.
At some hostile circumstances the intricacy and complication of the newly developed
processing techniques cannot be solved by relays and timers in order to overcome these difficulties PLC
can be used. To accomplish certain roles, the relays must be hardwired and the wiring must be
personalized to take up new challenges.
A programmable logic controller (PLC) is a special form of microprocessor-based
controller that uses programmable memory to store instructions and to implement functions such as
logic, sequencing, timing, counting, and arithmetic in order to control machines andprocesses (Fig. 2).
It is designed to be operated by engineers with perhaps a limited knowledge of computers and computing
languages. They are not designed so that only computer programmers can set up or change the programs.
Thus, the designers of the PLC have preprogrammed it so that the control program can be entered using
a simple, rather intuitive form of language.
The term logic is used because programming is primarily concerned with implementing logic
and switching operations; for example, if A or B occurs, switch on C; if A and B occurs, switch on D.
Input devices (that is, sensors such as switches) and output devices (motors, valves, etc.) in the system
being controlled are connected to the PLC. The operator then enters a sequence of instructions, a
program, into the memory of the PLC. The controller then monitors the inputs and outputs according to
this program and carries out thecontrol rules for which it has been programmed.
PLCs are optimized for control tasks and the industrial environment. Thus PLCs:
• Are rugged and designed to withstand vibrations, temperature, humidity, and noise
• Have interfacing for inputs and outputs already inside the controller
• Are easily programmed and have an easily understood programming language that is primarily
concerned with logic and switching operations
• PLCs are now widely used and extend from small, self-contained units for use with perhaps
20 digital inputs/outputs to modular systems that can be used for large numbers of inputs/outputs,
handle digital or analog inputs/outputs, and carry out proportional-integral-derivative control modes.
10
PR RA
M
R ORY
Fig. 2.1.1 PLC Block diagram

The processor unit or central processing unit (CPU) is the unit containing the microprocessor.
This unit interprets the input signal and carries out the control actions according to the program
stored in its memory, communicating the decisions as action signals to the outputs.
• The power supply unit is needed to convert the mains AC voltage to the low DC voltage (5V) necessary
for the processor and the circuits in the input and output interface modules.
• The programming device is used to enter the required program into the memory of the processor. The
program is developed in the device and then transferred to the memory unit of the PLC.
• The memory unit is where the program containing the control actions to be exercised by the
microprocessor is stored and where the data is stored from the input for processing and for the output.
• The input and output sections are where the processor receives information from external devices and
communicates information to external devices. The inputs might thus be from switches, Input and output
devices can be classified as giving signals that are discrete, digital or analog.
11
• Devices giving discrete or digital signals are ones where the signals are either off or on.
• Thus a switch is a device giving a discrete signal, either no voltage or a voltage. Digital devices can be
considered essentially as discrete devices that give a sequence of on/off signals. Fig. 3.1c analog devices
give signals of which the size is proportional to the size of the Variable being monitored. For example,
a temperature sensor may give a voltage Proportional to the temperature. The communications interface
is used to receive and transmit data on communication networks from or to other remote PLCs. It is
concerned with such actions as device verification, data acquisition, synchronization between user
applications, and connection management.
12
Distributed Control System (DCS):
A distributed control system (DCS) is a computerized control system for a process or plant usually with
many control loops, in which autonomous controllers are distributed throughout the system, but there is
no central operator supervisory control. This is in contrast to systems that use centralized controllers;
either discrete controllers located at a central control room or within a central computer. The DCS
concept increases reliability and reduces installation costs by localizing control functions near the
process plant, with remote monitoring and supervision.
Fig. 2.2.1 Diagram of Distributed Control System
Distributed control systems first emerged in large, high value, safety critical process industries, and
were attractive because the DCS manufacturer would supply both the localcontrol level and central
supervisory equipment as an integrated package, thus reducing design integration risk. Today the
functionality of Supervisory control and data acquisition (SCADA) and DCS systems are very similar,
but DCS tends to be used on large continuous process plants where high reliability and security is
important.
13
The key attribute of a DCS is its reliability due to the distribution of the control processing around nodes
in the system. This mitigates a single processor failure. If a processor fails, it will only affect one section
of the plant process, as opposed to a failure of a central computer which would affectthe whole process.
This distribution of computing power local to the field Input/Output (I/O) connectionracks also ensures
fast controller processing times by removing possible network and central processingdelays.
The accompanying diagram is a general model which shows functional manufacturing levels using
computerized control.
Fig. 2.2.2. Computerized control hierarchy model
14
Level 0 contains the field devices such as flow and temperature sensors, and final controlelements,
such as control valves
Level 1 contains the industrialized Input/Output (I/O) modules, and their associateddistributed
electronic processors.
Level 2 contains the supervisory computers, which collect information from processornodes on the
system, and provide the operator control screens.
Level 3 is the production control level, which does not directly control the process, but isconcerned
with monitoring production and monitoring targets
Level 4 is the production scheduling level.
Levels 1 and 2 are the functional levels of a traditional DCS, in which all equipment arepart of an
integrated system from a single manufacturer.
Levels 3 and 4 are not strictly process control in the traditional sense, but where productioncontrol
scheduling takes place.
15
BOILER:
The steam is the main energy source, used in the process of cane sugar production. Steam is generated
by burning bagasse. The advantage of using steam is, it is distributed and controlled easily. Another
special feature of steam production in sugar factories is the availability of renewable bio-mass fuel-
bagasse, a byproduct of cane after juice extraction. Modern boiler has one or two steam drums inter
connected with water and steam tubes. The bagasse is burnt in the furnace. Thus the heat produced is
passed through the passage of boiler tubes which gives its heat energy to water inside to convert in to
steam. The final gases which after giving maximum heat energy for producing steam are called flue
gases which are let out through chimney to atmosphere Ash after bagasse burning is collected, which
contains potash is used as fertilizer infield. Bagasse coming from mill has 50% moisture and grass
calorific value is around 2270 K. Cal/Kg. In a Sugar factory co- generation boiler pressure varies from
67 Kg/cm to110 Kg/cm2 and temperature ofsteamfrom480°Cto540°C. The air for combustion is
supplied by fans after heating air by flue gases. Feed water is treated in D.M. or R.O plant to maintain
its high quality.
Fig. 2.3.1. Boiler diagram
16
Turbine:
Surplus power helps to improve energy efficiency of the sugar factory enabling the plant to sell higher
quantum of surplus power to the state grid/other buyers. Energy efficiency and the sale of power is made
feasible by the employment of high pressure and temperature steam cycles and by the utilization of the
surplus bagasse to produce more steam and hence more electricity. Such a scheme, called the Maximum
Electricity Configuration, shall have to employ straight condensing or extraction cum condensing
Turbines for power Generation. The choice of the levelof the pressure and temperature for the cycle
depends on the level of confidence in the of benefits and cane availability etc. the steam received from
boilers passes through the rows of rotating blades of turbine. While passing through the blades steam
expands and give its energy to rotate the rotor. The turbine coupled to A.C. generator which converts
this rotating energy in to electricity
Fig. 2.4.1. Turbine diagram
17
Screenshot work:
18
CHAPTER – 3
Key Learnings
Process of Sugar Industry:
Fig 3.1.1 Flow diagram of Sugar Industry
19
PLC Components:
 Processor-Microprocessor based, may allow arithmetic operations, logic operators, block memory moves,
computer interface, local area network, functions, etc.
 Memory- Measured in words
1. ROM (Read only memory)
2. RAM (Random Access Memory)
3. PROM (Programmable Read Only Memory)
4. EEPROM (Electronically Erasable Programmable ROM)
5. EPROM (Erasable Programmable ROM)
 Power supply AC power
 I/O-Modular plug-in periphery
AC voltage input and output
DC voltage input and output Low level analog input
High level analog input and output
Special purpose modules, e.g.: high speed timers
Stepping motor controllers, etc. PID, Motion
 Peripheral-Handheld programmer (loader)
CRT programmer
Operator console
Printer
Simulator
EPROM loader
Network communication interface, MAP, LAN
20
LEARNING OUTCOMES:
1) I learnt about production, refinement and packaging of sugar from sugar cane.
2) To know the entrepreneurship and working skills of the industry.
3) Ability to communicate efficiently.
4) Generation of electricity from bagasse.
5) Importance of electronics in industry.
6) Utilization of byproducts produced during production.
7) Precautionary actions.
8) Time discipline.
9) To maintain clean and good environment.
10) To know the mechanism of power generation and electrical field involved in it.
11) To know the Co-generation plant works in sugar factory and what are different fuels can be supplied for
boiler and etc.
21
Conclusion:
Sugar industry is the second largest agro -based industry in India. Sugar factories, particularly
cooperative sugar factors in Maharashtra and other states have been instrumental in building confidence
among rural people and strengthening industrial base in rural India. In the era of globalization sugar
industry needs more competitive edge which can be given by way of modernization, enhancing
productivity, and manufacturing excellent quality sugar at competitive prices. It needs quality
management at every level of activity to enhance its performance. The need of the hour is to liberalize
industry from clutches of unprofessional people. Most of the sugar units do not have by-product
utilization plants. Projects based on bagasse’s and molasses should be initiated. Ethanol, alcohol, and
paper projects have tremendous scope for development in India. In future, 10-15% ethanol may be
allowed to be blended with petrol Bagasse’s based power generation projects installed adjacent to each
sugar factory would fulfil need of power.
This industrial training has helped me in gaining knowledge in multi dimension. The
training included understanding the processing at different stages, starting with the unloading machine
to processing of canes to produce the sugar of different qualities and remains used inthe boiling section
as well producing the power generation for self sufficiency as well as to distribute. This training has
provided me thorough working environment knowledge of an industry which includes functional as well
as technical aspects. It has helped us immensely in widening my theoretical based knowledge to
industries practical working environment knowledge by widening my knowledge horizon and same
thing will be utilized in teaching the academics and provide exact working nature and practical
requirements of the current industry.
• Bilagi SUGARS LTD, it is one of the leading sugar industries in north Karnataka,
whichproduce sugar & by products and supplied all over Karnataka and other states.
• All the departments play a vital role in every organization. A function of all the departments
provides material to the factory without wheel of machines cannot move.
• The overall study that emerge in this firm that has been maintained well (and efficient
department in the management) it’s all sections are working efficiently. The production capacity
of sugar has been improved.
22
References
• www.somaiya.com
• Automatic Process Control - W. F. Coxon
• Process Control 3rd Edition - BELA G. LIPTAK
• Process Measurement and Analysis - BELA G. LIPTAK
• Matthew Parker (2012). The sugar barons.
Windmill Books. ISBN 978-0099558453.
• Mosen Asadi (2006). Beet-Sugar Handbook.
John Wiley & Sons. ISBN 978-0471763475.
• Michael Moss (2014). Salt, Sugar, Fat: How the Food Giants Hooked
23
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Shri B.V.V.

Bilagi Sugars Limited, Badagandi

Under the Guidance of

Internship Co-ordinators Internal Guide External Guide

DEPARTMENT OF ELECTONICS AND COMMUNICATION ENGINEERING

Dr.Vijayalaxmi Jigajinni Dr.Anand H U Dr. Shridhar K.

Name of Examiners: Signature with Date

Name of the student: Pallavi Babu Halki

Chapter 1. Company Introduction 6

Chapter 2. Task performed and learnings 10

DCS control systems 13

Chapter 3. Key learnings

Process of Sugar Industry 20

Chapter 4. Learning Outcomes 22

2.3.1 Boiler diagram

Fig 1.1 company logo

Sl. No. Description Particulars

Registered under companies act 1956

bilagi Group,9th Floor,world tradecenter brigade

5 Status of Company Public limited company

6 Bankers of the Company Axis Bank

7 Nearest railway station Bagalkot

8 Nearest Airport Belgaum & Hubli

9 Nearest Village Badagandi

10 Nearest Town Bagalkote

11 Nearest major city Bagalkot and Vijayapura

12 Products Sugar and power, by product molasses

Cane Crushing capacity: 6500 TCD

PROGRAMMABLE LOGIC CONTROLLER:

Fig. 2.1.1 PLC Block diagram

Fig. 2.2.1 Diagram of Distributed Control System

Fig. 2.2.2. Computerized control hierarchy model

such as control valves

system, and provide the operator control screens.

with monitoring production and monitoring targets

Level 4 is the production scheduling level.

integrated system from a single manufacturer.

scheduling takes place.

Fig. 2.3.1. Boiler diagram

Fig. 2.4.1. Turbine diagram

Fig 3.1.1 Flow diagram of Sugar Industry

provides material to the factory without wheel of machines cannot move.

of sugar has been improved.

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