Case Study – Distillery Segment Boiler Automation & Electrical Systems 25 TPH Cogeneration Boiler

Project Overview

End User: Ashoka Distillers & Chemicals Pvt.Ltd.

Project: 25 TPH Cogeneration Boiler Automation

Industry Segment: Distillery & Chemical Manufacturing

Location: India

Client / EPC Contractor: M/s Cogent Engineers Pvt. Ltd.

Automation & Electrical Partner: CABISOL

Background & Requirement

Ashoka Distillers & Chemicals Pvt. Ltd. required a highly reliable and energy-efficient automation solution for its 25 TPH boiler, which is a critical utility for continuous distillery operations.

Key requirements included:

• Safe and stable boiler operation

  
  

• Accurate steam, water, air and flue gas control

  
  

• Energy optimization using VFDs

  
  

• Centralized monitoring through PLC & HMI

• Integration-ready architecture for future expansion

Scope of Work by CABISOL

CABISOL executed the project on a turnkey instrumentation, VFD, and control system basis.

Instrumentation Scope

• Pressure, temperature & draft gauges

• Thermocouples with thermowells

• Flow elements (orifice plates, flow nozzles)

• Pressure & DP transmitters

• Drum level & deaerator level measurement

  
  

Control valves for:

• Feed water

• Superheater temperature

• Deaerator pressure & level

• Minimum recirculation

Variable Frequency Drives & Soft Starters

Supplied and engineered ABB VFD & Soft Starter Panels for critical boiler auxiliaries:

ID Fans -150 HP

FD Fans - 270 HP

Boiler Feed Water Pumps - 190 HP with COS

Pocket Feeders & Screw Feeders

Key benefits:

• Energy savings

• Smooth motor starting

• Reduced mechanical stress

• Improved process control

Control System Architecture

PLC Platform

ABB AC500 Series

I/O System

ABB S500 Distributed I/O

HMI

ABB CP400 Touch Panels

Programming Software

PS501 (IEC 61131-3 compliant)

Control system covered:

• Boiler steam & water circuit

• Air & flue gas system

• Fan control & interlocks

• Alarm, trip & safety logic

• Manual / Auto / Remote operation modes

Control Room Engineering

• CABISOL also delivered control room layout engineering, ensuring:

• Ergonomic operator access

• Clear segregation of PLC, VFD, and power panels

• Provision for UPS and future expansion

Engineering Highlights

• Designed for continuous distillery operation

• High reliability for 24×7 boiler service

• Energy-efficient fan & pump control

• Modular PLC architecture for scalability

• Easy maintenance with clear diagnostics

• Future-ready communication (Profibus / Modbus / Ethernet)

Project Challenges & Solutions

Challenge	Solution
High thermal & dusty environment	Industrial-grade instruments & IP-rated panels
Variable steam demand	VFD-based fan & pump control
Operational safety	Interlocks, alarms & fail-safe logic
Limited shutdown window	Pre-engineered panels & structured commissioning

Results & Benefits to Client

• Stable boiler operation

• Improved steam quality & control

• Reduced power consumption

• Enhanced equipment life

• Centralized monitoring & diagnostics

• Compliance with industrial safety standards

Conclusion

The successful execution of the 25 TPH Boiler Automation Project at Ashoka Distillers & Chemicals Pvt. Ltd. demonstrates CABISOL's strong capability in delivering integrated automation solutions for the distillery sector.

This project stands as a reference installation for:

• Distilleries

• Ethanol plants

• Cogeneration utilities

• Process & utility automation