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Alvorada do Bebedouro Sugar and Alcohol Unit, located in the municipality of Guaranésia, Minas Gerais state in Brazil, started this year the production of VHP (Very High Polarization) sugar, a raw material for the food industry. With the goal of 106.250 tons of sugar exports up to 2009, it invested R$ 60 millions in the expansion of its Crushing, Steam Generation, Juice Treatment, Evaporation and Sugar Plant implementation.

Smar Application Engineering, coordinated by the Application Engineer Leonardo Mansur Pinheiro, jointly with the ABAA unit technical team chose the PROFIBUS industrial network for the job. The main factors leading to this choice were the high degree of acceptability and trustability of this protocol in the market, due to its open, interoperable communication standard that works with several suppliers, besides its easy installation, and simple configuration and architecture. The automation system chosen was the Smar System302-7, which combines connectivity flexibility and the integration with specialist administration, quality and maintenance systems like the MES (Manufacture Execution System) and the ERP (Enterprise Resource Planning).

Therefore, the administrative, production planning and industrial management sectors may access the information necessary to their needs and make possible to follow up, control and improve production and the support to the logistic chain, through more accurate decision making, and bring more efficiency and effectiveness to the implemented actions, while improving plant availability.

The architecture project included the implementation of PROFIBUS DP for the MCCs (Motor Control and Command), PROFIBUS PA for continuous field control equipments and AS-I for discreet field startup equipment distributed among master PROFIBUS DP controller. Horizontal communication between the controllers may be done by using an Ethernet 100 Mbits network providing control and supervision protocol.

All Smar field equipments are specially made to operate with PROFIBUS DP and PA protocols, such as FY303 series positioners for pneumatic valve actuators, series LD303 manometric and differential pressure transmitters, series TT303 temperature transmitters, series IF303, 4-20mA/PROFIBUS PA converters used to insert 4-20 output signal in the PROFIBUS PA network, and DF73 PROFIBUS DP-V1 master controllers.

These local operation stations make possible to operators supervise and command the plant through supervisory software with synoptic, tuning, graphs, alarms and history screens. The Maintenance and Management station, besides monitoring and making available process data for the via Web corporate network, has System302 tools necessary to configure the PROFIBUS DP/PA and AS-I networks (cyclic configuration), to access and alter parameters like field equipment calibration and diagnostic on the PROFIBUS PA network (acyclic configuration) and create the control logics. All field devices configuration on PA network was done using PROFIBUSView from Smar.

The System302 architecture makes possible the integration with corporate, quality and maintenance specialist systems, such as MES (Manufacture Execution System) and ERP (Enterprise Resource Planning). The administration, production planning and industrial management sectors may access the information they need to follow up, control and improve the production process and support the logistic chain, through better and well coordinated decision making, more efficient actions and higher plant availability.