Manual Wambeck.

OIL PALM PROCESS SYNOPSIS By Noel Wambeck. - June, 1999

V

Volume I – OIL PALM MILL, SYSTEMS AND PROCESS

OIL PALM PROCESS SYNOPSIS By Noel Wambeck - June 1999 2nd Edition - Update 3rd March 2001

Volume 1 - OIL PALM MILL SYSTEMS AND PROCESS. 1.0 INTRODUCTION 2.0 A BRIEF OF THE WRITER's EXPERIENCE 3.0 BRIEF HISTORY OF OIL PALM * Palm Oil Processing Flow Chart * Picture of Palm Fruit & Fruit Bunches * Uses of Palm Oil * Oil Palm Tree Matrix * Apparent Density of oils at various temperatures * Malaysia Palm Oil Products Export Procedure. 4.0 HISTORY OF OIL PALM PLANTATIONS IN INDONESIA 5.0 OIL PALM MILL, SYSTEMS AND PROCESS * Palm oil mill schematic process flow chart * Matrix Oil Palm Mill Process * Pictures of sections the oil palm milling process * Process Mass Flow and Losses During Production * Typical Empty bunch Incinerator. * Typical Effluent ( Ponding ) Treatment system of Anaerobic & Aerobic process. * Matrix of Oil Palm Mill Process & Waste Water Effluent Ponding System. 6.0 AN ENVIRONMENTAL CONTROL PLAN (ECP) * Potential Hazards and Control Plan. * Oil Palm Mill Environment Control and Waste Disposal Flow Chart. * Placement Avenue for empty bunch, fonds and treated effluent for land application. * POME Sludge process with the Decanter & Dryer - Schematic flow diagram. * Schematic diagram for Boiler three element control and scrubber system. * General layout of Anaerobic & Aerobic ETS. * Typical Layout of an Oil Palm Mill with the ECP effluent treatment plant. * Typical Furrow Layout. 7.0 OIL PALM MILL PROCESS MONITORING & CONTROL (PMC) SYSTEM. 8.0 THE DEVELOPMENT OF OIL PALM IN MALAYSIA. 9.0 THE OIL PALM EXTRACTION PROCESS MATCHING WITH TYPE OF FFB. 10.0 OILPALM EMPTY BUNCH DISPOSAL BY INTEGRATED INCINERATION. 11.0 FAO- FEEDING PIGS IN THE TROPICS : CHAPTER 4 - AFRICAN OIL PALM. 12.0 PREPARATION OF AN OIL PALM MILL PROJECT * Matrix for oil palm mill project. * Project manager's checklist. * Typical project monthly report

13.0 OIL PALM MILL DESIGN BASIS * Specific Gravities and Densities of Oil Palm Components & Substance. 14.0 A PALM KERNEL OIL EXTRACTION MILL PROJECT * Matrix for Palm Kernel Oil ( Expeller Press ) Extraction * Proposed Palm Kernel Oil Mill - Typical General Layout * Photors of a Palm Kernel Oil Mill * General arrangement drawing. 15.0 REFINING PROCESS FOR PALM OIL AND OTHER DOWNSTREAM PROCESSES * Introduction to Refining process for palm oil and other downstream processes. * Rationale of an integrated oil palm mill and refinery complex project. 16.0 USEFUL INFORMATION * Palm Oil Registration & Licensing Authority Activities. * PORLA Fresh Fruit Bunch Grading Manual * PORLA Fresh Fruit Bunch Grading Form * PORLA Basic Extraction Rate for Oil & Kernel based on year planted. 17.0 ABBREVIATIONS & GLOSSARY USED IN THE OIL PALM INDUSTRY

The complete Oil Palm Process Synopsis set includes the following: Vol.2 - TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL Vol.3 - OIL PALM MILL MAINTENANCE MANUAL

Revised 3rd March 2001

OIL PALM PROCESS SYNOPSIS Volume 2. TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL 2 nd Edition - 3nd March 2001

1.0

INTRODUCTION

2.0

A BRIEF OF THE WRITER's EXPERIENCE

3.0 A B C D E F

TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL Introduction Preparation Test procedures. Finalization Taking over and certification test. Training and Manpower

4.0 A. B C D E

APPENDICES Master list of machinery Checklist of oil palm mill. Electric motor list Palm Oil Mill Schematic Process Flow Matrix oil palm mill process.

5.0

SPECIFICATION FOR MACHINERY

6.0

MECHANICAL & ELECTRICAL DRAWINGS The complete Oil Palm Process Synopsis set includes the following: Vol.1 - OIL PALM MILL, SYSTEMS & PROCESS Vol.3 - OIL PALM MILL MAINTENANCE MANUAL

Noel Wambeck June 1999. Revised 3nd March 2001

OIL PALM PROCESS SYNOPSIS Volume 3. - OIL PALM MILL MAINTENANCE MANUAL 2nd Edition - Update 3rd March 2001.

1.0

INTRODUCTION

2.0

A BRIEF OF THE WRITER's EXPERIENCE

3.0

WELCOME TO PRODUCTIVE MAINTENANCE

4.0

STORE AND PARTS MAINTENANCE

5.0

MAINTENANCE OF HYDRAULIC SYSTEMS

6.0

DIGESTER USE AND MAINTENANCE Effective use of the Digester. Digester operating instructions and spare parts.

7.0

TWIN SCREW PRESS USE AND MAINTENANCE Operating instructions & spare parts manual. Effective use of the screwpress.

8.0

MULTI-HYDROCYCLONE SYSTEM Use of the Multi-Hydrocyclone system Automatic Triplex Multi-Cyclone Desanding System - Westfalia type ADP-100-3

9.0

DECANTER FOR CLARIFICATION SYSTEM. Alfa Laval Westfalia

10

CENTRIFUGE OIL PURIFIER Alfa Laval Westfalia China

11

SLUDGE CENTRIFUGE SEPARATOR Alfa Laval Westfalia Star Bowl Type - Local

12

NUT CRACKING MACHINE UDW rotor ring type - use and maintenance Ripple mill type - use and maintenance

Contents ……….

13

HYDRO CLAYBATH USE AND MAINTENANCE

14

STEAM BOILER ( Generator )

15

GEARBOX & GEARMOTOR USE AND MAINTENANCE

16

MAINTENANCE GLOSSARY & TERMINOLOGY

17

GLOSSARY OF BEARINGS

18

COMPRESSED AIR TERMINOLOGY AND SYSTEMS

19

PIPE FITTING AND VALVE GLOSSARY & TERMINOLOGY

20

PUMP MAINTENANCE Pump maintenance programs pay. Pump maintenance. Why Seals Fail. Pump performance checklist. Pump seal maintenance. Troubleshooting Electro-Hydraulic Pumps.

21

ROLLER CHAIN DRIVES Roller chain drives installation. Roller chain maintenance. Roller chain drives maintenance. Roller chain drives lubrication. Roller chain drives - Troubleshooting Guide.

22

V-BELT INSTALLATION AND MAINTENANCE.

23

USEFUL TABLES.

The complete Oil Palm Process Synopsis set includes the following: Vol.1 - OIL PALM MILL, SYSTEMS & PROCESS. Vol.2 - TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL.

Noel Wambeck June 1999. Revised 2nd March 2001

OIL PA LM PRO CE SS SYNO PSIS - Oil Palm Process Handbook By Noel Wambeck. - June, 1999

This oil palm process synopsis or handbook intents to be a series of reference books to the recipient, Manager, Engineer and people who are involved in the oil palm industry, it contains information such as the function, activities, the milling process and systems, specification of products, byproducts, processing mill and plant design basis, the operation, commissioning, maintenance, useful data, flow charts and graphs etc…. The handbook also hopes to encourage the expansion of product development and improved oil palm processing facilities, which can lead to greater commercialisation of oil palm, its products and to the betterment of the manager, engineer and all who seek knowledge. The Oil Palm Process Synopsis handbook is in three volumes, which are: Volume 1.

Oil Palm Mill, Systems and Process including the Preparation of an oil palm mill project and enclosures.

Volume 2.

Testing and Commissioning manual including specifications & drawings

Volume 3.

Oil palm mill maintenance manual including proprietary equipment installation and operation manuals.

The handbooks sized A4 with retractable binder hinged for flexibility in terms of being expandable whereby, occasional periodical in an update manner and series distribution can be filed into this handbook for continuous usage. The contents of this handbook are also available in CD-ROM The writer acknowledges with sincere appreciation the generous assistance given him by colleagues and friends who made many valuable suggestions. Any error or omissions are regrettable.

 June 1999 Noel Wambeck.

A Brief on the writer’s experience. Noel Wambeck @ Nurehsan born in Penang during the Japanese occupation to James Godfry Wambeck and Dorothy Symons of Dutch descendents. Educated at St. Xavier’s Institution in Penang with an engineering diploma from Gurney Technical Institute, Kuala Lumpur in the year 1969. Married to Fadilah A. Hamid in 1990 a Singaporean and fathered four children, two boys and twin girls. 30 years experience in the Agro-based engineering field of project management, project study, appraisal, market development of equipment, plant, system design and its implementation in such areas as edible oils industry, food processing plants, Rubber processing, Co-generation systems, pollution, effluent treatment and control systems. Some of the projects commissioned, are Padang Piol Oil palm Mill (Felda), Sarawak Oil palm mill (CDC), Fuji Oil refinery project ( Singapore) Ghana Rubber processing plant (Ghana), World bank projects PNP X Bekri, Betung PNP III Aek Raso Oil Palm Mills ( Indonesia ) Nalfico Premier for Palm kernel oil solvent extraction plant ( Malaysia) Indopalma extraction & refining of edible oils project ( Czech & Slovak) Coconut milk production for S&P Coconut Sdn Bhd (Malaysia) Rotary Dryer for Tioxide project (ICI Malaysia) Study on Pricing and distribution policies for Veg.Oils in Indonesia (ADB) Study on EB treatment / co-generation & PK crushing mill for Higaturu POM. ( CDC / PNG ) Study of production capabilities and marketing potential for coconut oil by products in Chuuk ( Fed.States of Micronesia) OPIL Oil palm Mill (India) PORIM Oil palm Mill ( Guthrie / PORIM) Kunak & Lumadan Oil palm mills ( Project manager with Konsultan Proses for Borneo Samudera Sdn Bhd. Sabah). He has consulted for commercial clients such as United Brands U.S.A., Cargill, Experience Inc., GFA International Management Consulting GMBH as well as donor agencies such as World Bank, KFW Bank (Germany), ADB, IBRD, UNIDP, CDC in Central America, Africa and Asia, including Malaysia and Indonesia. Noel Wambeck is at present an associate partner of Perunding AME – Consulting Engineers with on going assignments for consultancy services. The assignments are for oil palm mills for Borneo Samudera Sdn Bhd, Sabah, project study for PT. Kebun Ganda Prima in Kalimantan, Indonesia, project study for Low Yat Group in Sabah and detail engineering for the M&E works for a dry mixed cement plant for Chuan Cement Industries of Singapore.

June, 1999.

Brief History of Oil Palm ( Its

development in Malaysia).

by Noel Wambeck. - 8th November 1993. (Revised)

The oil palm ELAEIS GUINEENSIS grows around the globe in a zone of 10 degrees latitude to the north and south of the equator. Its utilization as basic nourishment had always been of vital importance to the inhabitants of this equatorial regions and its existence is reported as long as 3000 BC, when palm oil was known to the Egyptians under Pharaoh’s reign. The Oil Palm originates from Africa where there is a wealth of oil palm genetic material. The natives of Guinea coast who had made a living by raiding for slaves, were induced to find a new occupation in processing and selling the oil for export; for through the trade in palm oil firmly established before 1850. It has been selected by the Africans over the ages to provide palms with a high proportion of kernels and palm with a high yield of palm oil. The first planting of oil palm of the Deli type, brought from Africa and planted in the Buiterzorg botanical garden, Java, Indonesia in 1848, four plants being received, two from Bourbon and two from Holland and during the ten years of experimental observation, showed very good growth, and fruited. Their progeny was distributed from 1853 forwards and the stock in the Dutch Indies, in general, came from them. The palm was brought to Singapore about 1870, probably from Java. These seeds was soon distributed to various places, chiefly to gardens of those who cared to grow it as an ornamental tree. In 1879 Buitenzorg gardens in Java had sent seeds to Sumatra and the palm grew well; so that Sumatra appears to have received its first two supplies of the palm from Buitenzorg stock, one direct and the other through Singapore. Some of the oldest palms on the St. Cyr tobacco estate in Sumatra, figured by Rutgers are recorded as from seed from the botanical gardens of Singapore; and these trees, in turn, supplied material to many other places in Sumatra. The idea of a common origin is supported by and large the characters which all the old trees have in-common.

Rutgers thinks that the actual trees of 1879 were subsequently removed to make room for the town of Medan as this tree race is the old Deli type. The material bred from these palms is referred to as DURA DELI. It is very stable and uniform in oil and kernel contents. The vernacular names for the palm in Java are “ salak minyak’’, ‘’klapa sawit’’ and ‘’klapa sewu.’’ The tree was then freely distributed in that island, and about 1906 interest in the oil palm was aroused among Malayan planters, who planted a few trees on their estates by way of experiment. The new era of advancing communications and transport, fueled the growth of liberalism in Europe as telegraph system was introduced in 1856, the postal system in 1862 and the opening of the Suez canal in 1869. The fast growth of plantations in the Golden era of plantation companies, before the first world war saw the expansion in acreage, productivity and diversification of crops. In 1903, the department of Agriculture made several importation of seeds to Batu Tiga experimental plantation and the public gardens in Kuala Lumpur. The foundation of the Industry is generally attributed to M. Adrien Hallet, a Belgian with some knowledge of the oil palm in Africa, who planted palms of Deli origin in 1911 in the first large commercial plantation in Sumatra. Hallet’s plantings on Sungei Liput, Atjeh and Pulu Radja, Asahan estates are recorded as being contemporary with the establishment of 2,000 palms by K. Schadt, on his Tanah Itam Ulu concession in Deli. He also recognised that the avenue palms growing in Deli were not only more productive than palms in Africa, but had a fruit composition superior to the ordinary Dura palms of the west coast. A potential oil content of 30% in the fruit was recongnised in the early 90’s. The climate of Malay Peninsula and Eastern Sumatra has proven ideal for growing Elaeis or Oil Palm trees. In the meantime, a Frenchman M. H. Fauconnier, who had been associated with Hallet, had established during 1911 and 1912 some palms of Deli origin at Rantau Panjang in Kuala Selangor. These palms were in full bearing by 1917 and in that year the first seedlings were planted on an area later to be known as Tannamaram estate.

It was during this period that the DURA palm and Pisifera palm were cross to produce a hybrid progeny, that all modern planting and milling systems are designed. Thus the birth of the Malayan Hybrid palm “ TENERA” was introduced to the Oil Palm Industry. The second commercial oil palm plantation, also in the Kuala Selangor district, was developed at “Elimina” Barlow’s estate ( Sungei Buluh ) Selangor in 1919 and the first 40 acres planted in 1920. In 1922, selected seeds from the experimental plantation were planted at the new experiment plantation in Serdang, Selangor. During this period the boost in prices of major commodities before the first world war, was the main factor in the expansion of plantations in Malaya. The number of plantations increased from 1925 to 1930 with an expansion in the development in the Palm Oil processing Mills which began only at the beginning of the nineteenth century when its possibilities were realized, alike in Europe and America. There are two oils in the fruit, one in the fruit wall ; the other is in the kernel. The methods of manufacture, then employed was badly, often abominably prepared, if the working be quoted from a letter from Accra, Gold coast, in 1877 and printed in the Kew bulletin ( 1889 p 263 ) whereby the writer describes the bunches of fruit as cut down from the tree and heaped in the open air for 7 to 10 days, during which the pedicels become weak and the fruit easy to detached. The dry fruit bunch is then shaken off and fruitlets gathered together. A hole about a meter deep is dug in the ground and lined with banana leaves; into this hole the fruitlets are put and left for a period between three weeks and three months for decomposition to set in, and the pericarp to become quite soft. Part of the accumulation of fruitlets, if not decomposed enough, will next be boiled in an iron or earthware pot and returned to the heap, and the entire quantity transferred to another hole, which is lined with rough stones, where it is pounded until the pericarp and kernel are separated. The pericarp are folded into a coarse cloth, and by twisting the ends, the oil is extracted and the nuts are collected manually.

Another method, which was used in Portuguese West Africa; describes that the fruit, after they have been detached from the pedicels are put into baskets and submerged in swamps to ferment, before they are beaten in order to detach the fruit from the kernel and are again left to ferment for a few days before the oil is extracted. Off course, oil so crudely process is full of fatty acids, even up to 80% FFA or sometimes called a “ Hard oil “. At first the Africans offered in trade the oil of the kernel mixed into the oil of the pericarp; and as they commonly cracked the shell by heat, the addition imparted a peculiar smell to the mixture; but, about 1870 the market began to offer a price for the kernel, which activated the interest of the locals to collect and sell the whole kernels to the trading stations, who than bagged them for export. Primitive methods of processing palm oil with crude machines during the course of the development of the extraction process, saw changes such as the hand press, centrifugal basket, hydraulic press and the present day screw press, which also changed the process system, flow and Mill layout design.

The method in winning the oil in the early 1900’s was that the bunches were transported from the field to a convenient place, where they remain for the fruit bunch to soften, so that the fruitlets may be removed. Next the detached fruitlets are sterilized by heat; and this kills the enzymes, which would otherwise spoil the oil by leading to the production of fatty acids. Keeping in mine that most of the equipment, machinery and plants were designed to handle Dura type material in the early 1900’s and not until 1960’s did the change in the Mill design take place, when Tenera type material made its prominent appearance in Malaya, when most of the further developments took place in the Mill layout and selection of processing equipment. Modern Palm Oil Mills with screw presses were first introduced into Mongana ( Zaire ) in the early 1950’s and soon after, about 1956 in Malaya at Jendarata Mill ( United Plantations ) and Limablas, Slim river Mill ( Socfin ) henceforth to process Malayan Tenera type material ( D X P ) fresh fruit bunches. The search for new process and the development of oil palm extraction plants, equipment and machinery continues ..................... End.

Kernel Shell Mesocarp

OIL PALM TREE MATRIX

OIL PALM COMPONENTS, BIOMASS AND ANALYSIS

by Noel Wambeck UNIT MEASURE

WEIGHT

BASIC DATA Type of Palm tree Planting density Growth of fronds per year Tree growth rate per year Inflorescence Number of fruit bunch produced per hectare / year

ELAEIS GUINEENSIS Tenera ( D x P ) Number of trees per hectare New leaves per year Vertical trunk height full production at every number of fruit bunch

Trees per hectare Nr. Of Fronds mm / year days per cycle Nr / year

143 21 - 25 1000 15 1250

7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9

COMPOSITION OF FFB Weight of Fresh fruit bunch (FFB) Empty Bunch (EB) Nos in EB Water in EB Oil in EB Fruitlets in each bunch Weight of each fruitlet Nuts in Bunch Pericarp

average weight average weight average weight average weight average weight Individual fruitlet Individual fruitlet average weight average weight

kg kg kg kg kg Nr grammes kg kg

20 5 1.4 3.2 0.4 1500 8 to 10 3 10

8 8.1 8.2 8.3

YIELDS FFB yield per year Crude oil yield per year Palm Kernel yield per year

average weight per hectare in a year average weight per hectare in a year average weight per hectare in a year

mt / year mt / year mt / year

25 6.25 1.5

9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14

BIOMASS Biomass of fronds pruned annually Biomass of Fibre Biomass of Shell Biomass of Empty bunch Moisture in bunch Solid matter in bunch Biomass of spears Biomass of cabbage Biomass of inflorescences Biomass of Leaflets ( average 40 fronds ) Biomass of Rachies ( average 40 fronds) Biomass of frond bases ( average 40 fronds) Biomass of Trunk ( 6-9 m length ) Biomass of matured palm tree in total weight

average weight per year / hectare average weight per mt FFB average weight per mt FFB average weight per mt FFB average weight per mt FFB average weight per mt FFB average dry weight of spears / palm average dry weight of cabbage / palm average dry weight of inflorescences / palm average dry weight of leaflets / palm average dry weight of Rachies / palm average dry weight of frond bases / palm average dry weight of Trunk / palm average fresh weight of palm tree 6-9 m

mt / year / ha kg kg kg kg kg kg / palm / dry kg / palm / dry kg / palm / dry kg / palm / dry kg / palm / dry kg / palm / dry kg / palm / dry kg / palm tree

10 120 80 240 200 40 9.4 4.5 6.3 58 118 130 302 2200

1 2 3 4 5 6

10 10.1 10.2 10.3 10.4 10.5 10.6 10.7

ENERGY Energy value for Oil palm products Fibre Shell Empty Bunch Crude Palm Oil Input energy per ha /year Output energy per ha /year

10.8 10.8.1 10.8.2 10.8.3 10.8.4 10.9

Energy consumption in oil palm plantation

10.10

Gas liberated by anaerobic digester contain

11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20

BULK DENSITIES Air Ash Bunch Cracked mixture Crude Palm Oil Diluted crude oil Fibre Fresh Fruit Bunch Fruitlets Palm Kernel Oil Palm Nuts Palm Olein Palm Stearin Press expelled cake Pure water without air at 30degC Shell Sludge Sterilized Fruit Vegetable oils Water at 4 deg.C max

Methane yield of kg mill effluent dry matter

3/3/01 23:56 Percentage

100% 25% 7% 16% 2% 65% 15% 50%

25% oil 6% Palm kernel

12% 8% 24% 20% 4%

9% 19% 21% 48% kcal

Net Calorific Value of FIBRE Net Calorific Value of SHELL Net Calorific Value of EMPTY BUNCH Net Calorific Value of CRUDE PALM OIL Annual energy values - INPUT Annual energy values - OUTPUT Energy values

kcal / kg kcal / kg kcal / kg kcal / kg GJ / ha / year GJ / ha / year Ratio

2,700 4,000 2,000 10,300 19.2 182.1 9.5

INPUT Fertilizers GJ / ha / year Pesticides, herbicides, rat baits GJ / ha / year Machinery GJ / ha / year other GJ / ha / year average yield of methane is litres per kg dry matterl / kg

11.2 0.8 5.14 2.06 230

methane percentage 60% carbon dioxide percntage 35% other gas percentage 5%

230 135 19

average weight in kg per m3 average weight in mt per m3 same same same same same same same same same same same same same same same same same same

l / kg l / kg l / kg kg / m3 mt / m3 same same same same same same same same same same same same same same same same same same

1.177 0.437 0.550 0.653 0.890 0.900 0.350 0.480 0.680 0.890 0.653 0.900 0.880 0.650 0.990 0.750 0.900 0.660 0.950 1

Kernel 6%

2420 3640 1600

Moist. % oil % 30 - 45 7 10 0 33 - 45 2

12 12.1 12.2 12.3

AIR ABSORPTION / EMISSIONS OF PALM TREE Absorption of Carbon Dioxide Carbon Dioxide emission to produce kw Oxygen emmissions per hectare

tonnes of carbon dioxide per hectare tonnes displacement of fossal fuel / tons carbon dioxide per kwtonnes tonnes of oxygen per hectare tonnes

5

13 13.1

Soil enrichment contribution Carbon contribution of root biomass at

contributes carbon per hectare at replanting

mt / ha

8

13.2

Nutrient stocks of above ground biomass for replanting cycle

N P K Mg Ca

kg / ha kg / ha kg / ha kg / ha kg / ha

577 50 1255 141 258

POME application

3 rounds a year or equivalent to twice rate of Nitrogen

kg N/ ha/ year

pH BOD COD Total solids Suspended solids Volatile solids Ammoniacal Nitrogen Total Nitrogen Oil & Grease

mean mg / Liter mg / Liter mg / Liter mg / Liter mg / Liter mg / Liter mg / Liter mg / Liter

14 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 15 15.1 15.2 15.3 15.4 15.5 15.6 16

Process waste water from th oil palm mill Properties of raw effluent (POME)

Page 2.

650 4.1 25,000 53,630 43,635 19,020 36,515 35 770 8,370

ANALYSIS of dried sludge (POME) Moisture Ash Silica Ether extract Crude fibre Crude protein

5 - 15 % 15 - 22 % 7 - 10 % 11 - 13 % 11 - 14 % 11 - 13 %

N 1.8 - 2.3 % P 0.3 - 0.4 % K 2.5 - 3.2 % Mg 0.6 - 0.8 % Ca 0.6 - 0.8 %

B 20 ppm Cu 20-50 ppm Fe 3000-5000 ppm Mn 50-70 ppm Zn 20-100 ppm

kg / m3 Mpa Mpa Mpa (N)

220 - 550 800 -8,000 8 to 45 5 to 25 350 - 2,450

OIL PALM STEM ( Trunk )

16.1

Properties

Density ( Oven dry ) MOE MOR Compr // to grain Hardness

16.2

Chemical Composition

Alcohol benzene Hot water solubes Alkali ( 1% NaOH ) soluble Holocellulose Alpha - cellulose Acid- insoluble lignin Pentosans Ash

16.3

Sugar Contents ( after acid hydrolysis )

% of O.D. original fibre Glucose Xylose Galactose Arabinose Mannose Rhamnose

9.8 14.2 40.2 45.7 29.2 18.8 18.8 2.3 Persentage

Average % 35 14.,47 0.5 1 0.83 0.2

APPARENT DENSITY OF OILS AT VARIOUS TEMPERATURES (3) (Decimal point omitted)

RECOMMENDED VALUES FOR (CRUDE) PALM OIL PRODUCTS Palm Oil MS814:1983, Rel density 50/25 deg.C AOCS, Spec.grav. 37.8/25 deg.C Equivalent 50/25 deg.C Codex Aliment. Rel density 50/20 deg.C Equivalent 50/25 deg.C

Range 0.8919 0.888 0.880 0.891 0.892

to to to to to

0.8932 0.901 0.893 0.899 0.900

0.9001

to

0.9028

0.8816

to

0.8915

Palm Olein MS816:1983, Rel density 40/25 deg.C

Palm Stearin MS815: 1983, Rel density 60/25 deg.C

Source: Porim technology No.12 Aug 1985 “ The Density of oils in the liquid state.” 16th August 1997./ NW

MALAYSIA PALM OIL PRODUCTS EXPORT PROCEDURE 1. The buyer and the seller sign a sales contract in accordance to products and standard contract forms for PORAM, FOSFA, MEOMA, MOPGC, GAFTA 2. PORLA licensees are required to register the contracts with PORLA within 24 hours after the contracts are concluded, A copy of the contract must be submitted to PORLA within 30 days. 3. The seller fills in the Exchange Control Form (KPW 3) and submits it to the bank for approval of foreign exchange. 4. The buyer instructs his bank to Issue a credit in favour of the seller. 5. The buyer’s bank advises or confirms the credit to the seller’s bank. 6. The seller’s bank informs the seller that the credit has been issued. 7. The seller is in a position to load the goods and dispatch them to the buyer 8. The following documents are required for the exports. a. b. c. d. e. f. g. h. i. j. k. l.

Commercial Invoice. Bill Of Lading. Packing List. Marine Insurance Policy (CIF) Customs Declaration Form (CD 2) Exchange Control Form (KWP 3) Survey report. Analysis Certificate. Ship Masters Authorisation Letter for shipping agent to sign Bill Of Lading. IASC Heating Instructions. Masters Certificate For The Last Three Cargoes. Masters Certificate certifying vessel tank, heating oil, manifold pipe and pipelines, valves and fittings do not contain copper or copper alloy. m. Cargo Shipped Under The Appropriate FOSFA Contract n. Other document as and when required, may include: § § § §

Phyto Sanitary Certificate Radiation- free Certificate Lard-free Certificate Certificate Of Origin

9.

The seller then remits to the seller’s bank the documents evidencing the shipment as follows:

a. b. c. d. c. d. e.

Commercial Invoice Packing List Certificate of Origin Bill Of Lading Marine Insurance Policy Original Letter of Credit Survey/Analysis Certificate

10. After checking the documents against the credit, the bank will pay, accept or negotiate according to the terms of the credit to the seller. 14th September 2000./ NW

THE HISTORY OF PLANTATIONS IN INDONESIA.

THE HISTORY OF PLANTATIONS IN INDONESIA Noel Wambeck June 21st 1992 ( Revised )

To appreciate the present developments in the Indonesian Oil palm industry, one has to look back into the history of plantations in Indonesia. Large plantations were first established 170 years ago by the Dutch colonial administration, and term what was known as Cultuur Stelsel ( forced cultivation ) . Oil Palm Plantations today are not only divided into large and small holding plantation, but also Nucleus Estates Schemes or ( PIR ) which constitutes a form of cooperation between large plantation companies and small holders. Development of the plantations since 1830 to present day operations are as follows:

Period I. ( 1830 to 1870 ) During this period, plantation consist of camps established by the Government, then the Dutch Government on the cultuur stelsel system with forced labour. But prior to this period, trade went on in the normal way between the VOC a Dutch trading company and with Indonesian growers with chosen agents who were important to the Dutch. The agents were mostly ethnic Chinese, officials of the Indonesian Kingdoms or Dutch nationals. The VOC set up a number of warehouses in areas near a port to facilitate the trade. The commodities were the products grown by the Indonesian farmers which were controlled and managed by VOC who later on handed over the monopolized trade to the Dutch Government which brought about the start of the Dutch colonial power in Java. The process of domination of the country was hampered by the situation in Europe for a period, when the Netherlands was under the French Napoleon rule. The Napoleon war from 1800 - 1816 and then the Diponegoro war from 1825 to 1830, caused financial problems, which prom the Dutch Governor Daendles at that point of time to surrender Indonesia to Britain for a period, and after the defeat of Napoleon, the Dutch regained a foothold and power in Indonesia. The Dutch Government with the lack of funds, took on a program to cope with the budget deficit, whereby the cultuur stelsel was introduced which started the forced cultivation in 1830 the farmers were forced to set aside one fifth of their land to grow export crops and further to work 60 days per year, without pay for the Government. The cultuur stelsel system earned the Dutch Government 18 million guilders a year or 60% of the Dutch budget revenue.

1


The first crops to be grown were, sugar and indigo, but later the crops range were diversified to include coffee, tea, tobacco, pepper, cinnamon and cotton of which coffee grew to become the main crop. Plantation were established in West Java for Sugar, coffee and pepper whereas indigo was stopped after it turned out to be not profitable as a synthetic substitute was discovered. The first plantation of palms of the Deli type was made in Java in 1859, and during the ten years of experimental observation, showed very good growth, and fruited. It was brought to Singapore about 1870, probably from Java, seed was soon distributed to various places, chiefly to gardens of those who cared to grow it as an ornamental tree. In 1879 Buitenzorg had sent seed to Sumatra and the palms grew well; so that Sumatra appears to have received its two first supplies of the palm from the Buitenzorg stock, one direct and the other through Singapore. Some of the oldest palms in Sumatra, those on the St Cyr tobacco estate, figured by Rutgers are recorded as from seed from the Botanic gardens of Singapore; and these trees, in turn, supplied offsprings to many other places in Sumatra. The idea of a common origin is supported by the characters which all the old trees have in common. Rutgers thinks that the actual trees of 1879 were subsequently removed to make room for the town of Medan as this tree race is the old Deli type. The vernacular names for the palm in Java are ' salak minyak ', ' klapa sawit and ' klapa sewu'. The tree was then freely distributed in that island, and about 1906 interest in the oil palm was aroused among Malayan planters, who planted a few trees on their estates by way of experiment.

Period II ( 1870 to 1900 ) Liberalism in Europe in 1850 opposed the cultuur stelsel system enforced by the colonial countries which marked the begaining of the privatisation of plantations in Indonesia. The new era of advancing communications and transport, fuel the growth of liberalism in Europe as telegraph system was introduced in 1856, the postal system in 1862 and the opening of the Suez canal in 1869.

The Agrarian law in 1870 made it possible for private companies to secure land title for 75 years, which were considered long enough for plantations. Dutch ownership of plantations companies, mushroomed with the support of Dutch Government, banks, trading houses, communications and transport facilities. The Dutch built railways to facilitate transport of the plantation commodities and irrigation systems for the crops.

2


In Deli north Sumatra, investors were allowed to lease the land owned by the Sultan for 75 years and growing of the reknowned Deli tobacco was established and later on orther plantations were opened to include Rubber, Coffee and Oil Palm estates.

Period III. ( 1900 to 1930 ) The fast growth of plantations in the Golden era of plantation companies, before the first world war saw the expansion in acreage, productivity and diversification of crops. The first rubber plantation was established in 1905 and followed by Oil palm plantation in 1911. The importance of Chinese tea was changed for Assam tea and Arabica coffee for Robusta. The Indonesian Kings or Sultans had their powers reduced in 1915 and the Dutch authorities began collecting tax on land. During this period the boost in prices of major commodities before the first world war, was the main factor in the expansion of plantations in Indonesia. The number of plantations increased from 2130 in 1925 to 2467 in 1930 with an expansion in the acreage from 2.6 million hectares to 2.8 million.

Period IV ( 1930 to 1940 ) The depression period which began with the crisis in 1929 resulted with a steep fall in prices, whereby the supply exceeded the demand for most commodities including plantation crops in the world market which hit rock bottom in 1933. According to the Javasche Ban, exports in 1933 were worth only 40% of the export prices for the same commodities in 1929. The global recession forced the Government to impose restriction on production and exports through a quota system on tea, rubber, sugar and copra in 1933. Farmers were even prohibited to tap rubber, under what was called ' rubber restrictie' whereby the Dutch government offered cash compensation for rubber plantations. A team was set up to supervise the distribution of the compensation of which the government charged levies on certain plantation crops to finance research and marketing promotions. The number of plantations and acreage is shown in the table below: Details 1930 1933 1938 --------------------------------------------------------------------------------------------------------------------------Plantations. 2467 2395 2402 Acreage held under HGU ( Ha) 2,876,000 2,410,000 2,485,000 Acreage cultivated (Ha) 1,048,000 1,089,000 1,171,000 source ; Institute of Asian Studies.

Many sugar mills were forced to shut down operations as a result of the recession; leasing of small holder's lands declined by 51% where many concession holders with land title (HGU) returned the land to the government, resulting in a sharp shrinkage in the acreage of plantations.

3


Period V. ( 1940 to 1950 ) The advent of world war II in 1941, communication with the Netherlands ceased and in March 1942, Japanese forces landed on Java and the occupation of Indonesia. All development hauled as many foreign planters and owners left the country or were arrested by the Japanese; leaving the larger plantations without proper management, however the small holders of local Indonesian farmers increased in numbers as they had to be self-sufficient; resulting in the expansion of small holding plantations. The Japanese authorities took over the management of plantations and reinstated forced cultivation of the land. The Dutch which returned to resume colonial administration in Indonesia, after Japan surrendered, relied mainly on plantations for finance. Rehabilitation of some of the plantations, where it was possible under the tense situation as the during this time, were the plans made by the locals for the war of independence of Indonesia. The original foreign owners of the plantations could only regain and operate their plantations in the areas where the Dutch military could effectively maintain authority.

Period VI. ( 1950 to 1970 ) This period marked by the consolidation and fostering of plantations which were still productive; pre and post independence of Indonesia. The process of transferring ownership was made between Indonesian private companies and the colonial or foreign owners which took place from 1959 to 1962 during the campaign to free Irian Jaya from the Dutch colonial rule. The number of plantations, continued to decline and the acreage reduced from 1,819,000 Ha in 1950 to 841,800 Ha in 1970. The plantations were managed and operated by state-owned companies in 1962 which were gradually changed into limited companies. The Indonesian Government took direct control over British, Malayan and Singapore plantations in Indonesia; following the campaign against the establishment of the new Malaysia which was later returned to its original owners, when the control was lifted towards the end of the 60's.when Indionesia and Malaysia resume a relationship. The implementation of the Agrarian law No. 5 in 1960, replaced a similar Dutch law the Agrarische Wet of 1870. The law maintained the controlling rights by the state over land. The law regulated the land title as follows: a. The land title for exploitation was for 25 years and could be extended to 35 years. b. Concession rights was lifted and replaced with HGU. c. HGU for land wider than 25 hectares was available only for a company based in Indonesia.

4


d. A HGU land was at least 5 hectares and no wider than 25 hectares could be held by an individual A concession holder was required to convert its land title to HGU and in the process the holder is required to hand over part of the land to the state to be given to a new private company which resulted an increase in the number of private plantation companies.

Period VII. ( 1970 to date ) The new order period, called the ' Repelita' ( five year development plan.) marked the start of the phase development of the plantation sector, with the focused on improvement of productivity and efficiency. The main commodities were given greater attention for development are sugar, rubber and oil palm as a number of state owned plantation companies received credit aid from the world bank to improve productivity and efficiency. The Government's prime concern was for the farmer, and in the middle of the 1970's introduced a new system for development of plantations for the small holder which is known as the " small holder nucleus pattern ( PIR ); A state plantation company ( PTP ) planning to expand its acreage must use the PIR pattern whereby under the system, PTP act as an agent of development of the tree crop projects. Private companies could use the National Private Plantation (PBSN) scheme without having to use the PIR pattern. Working relations between small holders and the large plantations companies were maintained through the selling of crop by the small holder and purchase by the PTPs who is responsible for the processing and marketing of finished products. The Government have adopted two systems in the development of the plantation sector, such as in the intensification and diversification programs; One is based on the initiative of the farmer with government guidance and the other is program oriented, based on the government program with partial or integrated approaches. The partial approach is assistance to plantation companies by providing part of production, usually in the form of seedlings and guidance, while the integrated approach, the government provides all production factors which includes fund, management, operation and marketing. Great progress has been made in Indonesia in recent years to improve the lot of its citizens. The Indonesian oil palm industry have also advanced and are poised for a major leap forward; this has been made possible by an enlightened Government and by the efficient implementation of the government directives.

BIBLIOGRAPHY. Selected documents, data, studies and books available in the project file are :

• •

Economic Products of the Malay Peninsula by I.H. Burkill dated 1935. Indonesia tree crop processing project 6949-IND dated 11th Jan 1988.

5


• • •

Study on Indonesian plantations and market of Palm Oil 1990 Book by PT. Capricorn Indonesia Consult Inc. Progress and development of Oil palm industry in Indonesia by Adlin U Lubis dated Sept.1991. Notes from the Institute of Asian Studies.

6

0

OIL PALM MILL SYSTEMS & PROCESS

OIL PALM MILL, SYSTEMS AND PROCESS. By Noe l Wambe ck ( Re vi sed June, 1999 )

&INTRODUCTION The aim of the writer of this paper is to provide an overall brief description of the Oil Palm Mill flow process and its systems employed based on concept and collective experience of the firm. Any errors in intention are regrettable

The synopsis of the Malaysian Oil Palm Industry success is basically due to the following factors: •

Commercially sound investment with state encouragement.

•

Practical Project Study Preparation.

•

Good management of the plantation who will provide for and ensure good genetical planting material, soil conditioning, harvesting, collection standards, handling and transportation of FFB to the mill and let nature do the rest.

•

Proper selection of the process system, machinery equipment and plant ( eg. Process matching with type of FFB ) for high extraction yield, quality palm oil and palm kernel.

•

Efficient transportation of the finished production to the bulking station or refinery.

•

Good shipping facilities for loading and discharge of the finished products for the export market.

•

And last but not the least, a dedicated and loyal workforce whose ambition is filled with grit.

Malaysian engineers can to-day provide Oil Palm Mill and process systems designs to achieve lower production cost, train and organize a stable work force, which will maintain the oil palm mill effectively and produce the best quality product at maximum yield extraction for the minimum cost.


2

&THE REQUIREMENT OF A MODERN OIL PALM MILL. The requirements of a modern oil palm mill shall be with consideration for and incorporation of the latest technology available in the Industry and to include the following : a)

To be suitable in every respect for processing fruit from Tenera palms;

b)

To recovery with the minimum loss the palm oil and the kernels;

c)

To produce oil and kernels of the highest quality;

d)

To facilitate the disposal of the shell, fibre; and empty bunches;

e)

To incinerate the empty bunches for the recovery of the potash for fertilizer or to treat the empty bunch to recover 0.25% additional oil and used as fuel to produce steam for more valuable electrical power generation.

f)

The plant and process shall be Environmentally friendly and to dispose of waste water (sludge) in such as a way as not pollute local rivers and waters;

g)

To be reliable and suitable for local conditions of labour supervision and maintenance.

h)

Consideration and the incorporation of safety aspects that comply with Occupational Safety and Health act, such as to provide for good ventilation, working space, dust free and noise levels within permissible limits.

i)

The incorporation of operating procedures, equipment, plant and process systems to meet the ecological, hygienic and cleanliness of the plant on par with good food manufacturing industrial plant standards.

j)

Designed for cost effectiveness for operation and maintenance.

&THE PALM. Practically all the oil palm planted in the Far East are directly related to one, two or four oil palms which were brought from Africa and planted in the Buiterzorg botanical gardens in Java in 1848. The material bred from these palms is referred to as Dura Deli. It is very stable and uniform in Oil and kernel content. An average content of the fresh fruit bunch ( FFB ) is 25% oil, 5.5% kernel, 6% shell, 9% fibre, 25% empty bunch ( EB ) and the balance is moisture. In recent years another parent has been introduced to produce the material referred to as Tenera. The same Dura Dali palm is used to produce the Tenera palm seed but it is pollinated with pollen from a selected Pisifera palm ( the selected Pisifera when self pollinated produce fruit with a small kernel and little shell ). The resultant Tenera material produces fruit with more oil than Dura material, the same kernels as Dura but less shell than Dura.

3


For this reason, it is now always planted in preference to the straight Dura Deli and it is for Tenera material that all modern oil palm mill systems should be designed. The quality of the palm oil and kernels is at its highest just before harvesting, collection and milling. The extent to which the oil is degraded depends on the system used and the care with which is executed.

&TENERA BUNCH COMPOSITION. The bunch composition will very from bunch to bunch and from tree to tree particularly in respect of shell thickness but the average bunch content for Tenara material (D x P) with an assumed average composition of Fresh Fruit Bunch ( FFB ) or now called Palm Fruit Bunch ( PFB ) from matured palms having a maximum 2.5 ffa for the extraction of Crude Palm Oil and Palm Kernel. TENERA MATERIAL COMPOSITION ( PORLA STD ) Empty bunch

25%

Evaporation

10%

Fruitlets

65%

Total PFB

= = =

Nos 7% water 16% Oil 2%

=

ash 0.5%

= =

nuts 15% pericarp 50%

= = = =

kernel 6% NOS 7.5% water 19.5% Oil 23%

100% ==== Total Oil Plus FFA =

25% to Palm Fruit Bunch

&HARVESTING. Harvesting is normally a 6 to 8 day cycle. It is important that the fruit must not be harvested before it is ripe, that is until the process of photosynthesis, which converts the carbohydrates into fat, is well in advance. The oil content of unripe mesocarp may be in the order of 35% whereas the oil content of ripe mesocarp is usually between 50% and 55%. The harvesting of under ripe fruit can cause losses in the order of 8% of the possible yield.


4

&FREE FATTY ACID ( FFA) The FFA content of the oil in the bunch before harvesting may be in the order of 0.1% whilst the FFA of the oil in the same bunch when it is received at the mill will never be less than 1%, normally in the order of 3%, and is frequently above 3% under bad conditions. A low FFA content is the first characteristic to which edible oil refiners pay attention. A premium of 1% of the sale price is paid for every one percent, should the FFA content be below 5% and the Refining loss will be 1.25% to 1.80% per 1% of FFA. The rise in the FFA content from harvest to mill will make possible the harvesting of riper fruit with higher oil content and recovery of higher quality oil with a lower FFA. The riper the fruit the more vulnerable it is to damage during transport and handling. Of all different stages of processing, the harvesting of the palm tree and the transport of fruit to the edible oil refiner has the most effect on quality.

&FRUIT COLLECTION AND TRANSPORT. There are two basic systems used for fruit transport. One is the collection of fruit directly into the sterilizer cages and the other is the collection of the fruit in trucks or trailers and then transferred into sterilizer cages at the oil palm mill. The transfer system is less costly but results in some loss of oil and a higher FFA content due to the extra handling and damage to the fruit. The other system requires that the sterilizer cages be taken to the field for direct loading from the collection points. At such points the harvester’s place the fruit on nets which are lifted by crane to load gently into the sterilizer cages. At the time when the fruit is lifted in the nets it is convenient to weigh, using a weighing cell. This is particularly important for the collection of small holder crops.

5


OIL PALM PROCESSING. The flow diagram and matrix relating to the processing of fruit from Tenera palms is shown in the appendix enclosed.

1.0

FFB Reception.

The FFB bunches loaded on trucks, cages or trailer are weighed on arrival at the mill and on departure when empty by weighbridge of 50 ton capacity and automatically recorded, that is computerised. After weighing-in process of the truck, cage or trailer, the PFB are dumped into the inclined hopper at the ramp that will hold 900 mt PFB ( 2 lines of 15 bays x 30 mt PFB ). Modern mills in Malaysia are equipped with the following in the reception area of the mill: A. Load cell ( pitless ) 50 tons weigh bridge of 3.3m W x 15m L and computerised. B. Larger loading ramp with double door hoppers of 30mt capacity per bay. C. FFB Cage and bogie with capacities of 5, 7 and 10 mt of wheel spanned of 800mm gauge. D. FFB loading into cages by conveyor system E.

Straight line railway system with Cage transfer carriage located at both ends of the railtrack system to facilitate easier operation of the 2-door sterilizer and shunting of the cages can be handled easily with the capstan and Bollard.

On opening the hopper door ( 2 doors to a bay ) the bunches drop into the 7mt cages with bogies placed beneath it. The loaded PFB cages are then conveyed by the transfer carriage on the rail track and pushed into the sterilizer, by a winch and ballard system for sterilization.

2.0

Sterilization.

The sterilizer process is done in 5, 7 and today 10 tons capacity FFB cages which are pushed into long cylindrical steel vassel with special doors and subjected to steam at approximately 3 BAR. One of the effects of sterilisation is to inactivate the fruit enzyme. inactivated the rise of the FFA is virtually stopped.

Once this enzyme has been

The objective after harvesting is to sterilize the fruit as quickly as possible with the minimum of handling and damage. In addition to arresting the development of the FFA content, the sterilizing of the fruit also facilitates: a.

The purification of the palm oil by coagulating nitrogenous and mucilaginous matter and thus preventing the formation of emulsions during verification of the crude oil.


b.

6

The extraction of the crude palm oil by freeing the fruits from the bunch stalks and by breaking the oil cells in the mesocarp.

Majority of mills today has programmable automatic control systems to cater for proper sterilization of 90-minute cycle. Sterilisation is a simple process but it is essential, for the proper operation of the mill so that it is done correctly. This operation is the largest user of steam in the mill.

A STERILISER STATION WITH SINGLE DOOR STERILISERS

3.0

Stripping.

After the sterilisation the sterilised fruit in 3.5 mt PFB Cages are then winched out of the steriliser vassal by the arrangement of Bollard & winch and then placed in position for the remote control overhead hoist, for the activity of emptying the FFB into the threshing machine which will separate the empty bunches from fruit. Or for larger capacity mill with 5 mt FFB cages and above, into the cage Tippler machine a ring structure for emptying the contents of FFB onto a scraper type conveyor and transported to the thresher machine for stripping of the fruitlets from bunch. The fruit is then conveyed by screw conveyors and bucket elevators to the Pressing or Extraction station. New mills have included in their design bunch crusher and secondary thresher system for recovery of fruitlets of large or poorly sterilised bunches which are difficult to strip.


4.0

7

Empty Bunches.

Empty bunches from 25% of the total weight of the ffb. They are then returned to the field as fertilizer after incineration for the recovery of resultant potash, in conventional mills. They have no food value and have a high silica content. When properly incinerated they yield 0.3 to 0.5% of potash. Utilisation of empty bunche for field application as fertiliser supplement is found to be cost effective by some plantation groups and to the others justification of logistics, other constrains or practical experience? seems to be the objection for use of EFB in the field. In recent years a system has been introduced in Malaysia for the Treatment of Empty Bunches which recovers a further 0.25% of the oil on ffb from the empty bunches and at the same time reduces the moisture content to approximately 35% so that they can be used as additional solid waste fuel for steam and power generation, required for other down stream process.

5.0

Oil Extraction.

The efficient extraction of the crude oil from Tenera fruit has presented problems but these have been overcome by the development of the continuous screw press, which is now used in all modern factories. The fruit from the stripper passes to digesters, which complete the breaking of the oil cells with slow moving arms. Digesters have a capacity of above 3 cubic metres.

TYPICAL SIDE VIEW OF THE EXTRACTION STATION


8

The fruit mash then passes to the screw presses (capacities of 10–16Mt FFB per hour) which press the crude oil out through holes in the side of the press cage. The ‘press cake’, which is discharged from the end of the press, contains the ‘fibre’ and the ‘nuts’. The three products separated in this section are : a)

The crude oil which consists of water, dirt and palm oil. This is passed to the purification section;

b)

Nuts: 15% of the ffb. Is separated by the depericarper and kernel plant for the recovery of the kernels;

c)

Fibre: Approximately 15% of the ffb weight with moisture content of 37%. The residual oil content should be between 6% and 8% of oil to dry fibre. The fibre should also retain as far as possible the phophatides and other non-glycerides impurities. The fibre separated in the deparicarper winnowing system is conveyed to the boiler as fuel.

The proper design of the extraction section is important. Unsatisfactory practices such as excessive drainage of the crude oil before the extraction press leads not only to purification problems and losses but also to the higher absorption of iron by the palm oil. The importance of reducing the absorption of heavy metal, copper and iron is indicated by the totox value. For the production of superior quality palm oil, stainless steel moving the wearing parts should be used for extraction units (such as the digester and screwpress).

6.0

Kernel Recovery

The conditioning of the nuts starts in the sterilizer and the separation starts in the screw presses. After the screw press the nuts and the fibre traverse a heated breaker conveyor which further separates them and removes moisture from the fibre. The fibre and nuts then pass into a pneumatic separating column, called the “winnowing column” fitted with IC damper in operation, depending on the number of presses in operation. The fibre is blown into a cyclone close to the boiler and the nuts pass down a polishing drum, designed to handle a verity of nuts which removes any attached dirt or fibres and tramp iron.

9


A. Press cake to winnowing B. Ejection of Nuts C. Fibre to cyclone D. Removal of dirt & tramp iron

A DEPARICARPER, WINNOWING COLUMN AND POLISHING DRUM STATION FOR FIBRE & NUTS SEPARATION

The nuts are conditioned in nut silos before being cracked in centrifugal nutcrackers or / and in present day Rippler mills. After cracking, the cracked mixture is separated in the double winnowing separating column for dry separating system or separated in hydrocyclones or clay baths. These processes are wet. A modern Hydroclay bath separator is more efficient than a hydrocyclone separator when processing more than 15% Dura material in the cracked mixture. A supply of suitable clay at the rate of approximately 450 kg to 100 tons of ffb is necessary for the clay separator system. Both systems depend upon the density of the shell being greater then the density of the kernels. The higher yield of PK compensates the addition cost of clay or kaolin required for the Hydro-clay bath separator process. The shell and kernels are washed and the kernels are passed to a kernel dryer to normalize the moisture content of 7% so as to minimize the development of FFA during storage and shipment. It is also advantages to sterilizer the kernels before shipment or storage with steam at atmospheric pressure. Kernel plants designed for Dura derived nuts are not suitable for the processing of Tenera derived nuts. There have been a number of experimental designs, which have proved failures. Caution and a wide experience are required in selecting the proper equipment and design for kernel recovery plant.

7.0

Palm Oil Purification

The modern purification or oil classification station is designed to recover and purify the crude oil as quickly as possible with the minimum heating and exposure to air. This is to minimize the damage by oxidation, which is caused by the exposure of crude oil to air at high temperature.


10

The process begin at the crude oil tank of the extraction station and ends at oil cooler as finished CPO with dirt contents of 0.009% and moisture contents of 0.09%. The major effluent problem is eliminated by the decanter system, which removes the semi-solid sludge for treatment, by the sludge dryer, which reduces the moisture of the sludge from 45% to 10%. Adequate heat for drying of the sludge is obtained from the boiler exhaust flue gasses. The composition of the dryer decanter cake is shown in Appendix. The major contributor to poor quality oil is oxidation. Oxidation measured by the totox value, starts when the oil is above 60ºC and exposed to air During processing, storage and shipment.

8.0

Steam and Power Generation.

Utilization of existing energy resources is indispensable not only for large industrial processes but also for small production plant and in particular oil palm mills where the balance between heat and power are required for production process which are pre-condition for a “ combined heat and power ( CHP ) scheme.” Or commonly referred to as C0-GENERATION SYSTEM. Solid waste fuel in the form of shell, fibre and empty bunches which are by-products of the process are utilized as fuel for the boiler. Steam is required for processing at the approximate rate of 500kg per hour per ton ffb. This steam can be easily raised in a reasonably efficient water tube boiler with fuel available from the Fibre, shell and empty bunch. Power is required at the approximate rate of 15 to 25 Kw per ton ffb. This can be easily be provided by placing a back-pressure single stage steam turbine between the boiler and the header of the mill processing system. Steam is generated from the boiler at a pressure of say 20 Bar.g and into the steam turbo alternator at 18.5 Bar.g at 260ºC with back pressure of 3.16 Bar.g for the mill process which is convenient and effective for process Heating. The additional power generated in this system is made possible by burning of the empty bunches as shown in the enclosed Fuel /Steam /Power balance and Steam Production from 1 Ton Solid Waste Fuel for a Oil Palm Mill. Every ton of FFB can produce 733 kg steam and 30kw power shown, in the diagram below : A system has been introduced for the treatment and disposal of empty bunches and recovery of palm oil and at the same instance reduces the moisture contents of the empty bunches to approx. 45 % so that they can be used as solid waste fuel for the boiler and production of additional steam and electrical power.


11

Every ton of FFB can produce 733 kg steam and 30kw power shown, in the diagram below :

Steam is produced by water tube boilers at pressures and temperatures higher ( 20 bar.g 207 deg. C ) than required for the process. First it is expanded in steam turbines, and then led into the process where the latent heat contained in the exhaust steam ( 3.16 bar.g ) is utilized for sterilisation of FFB and heating systems in the process. The diagram below show a typical CHP scheme of a modern oil palm mill.

The energy released during the expansion of steam is converted by the turbine into mechanical power to drive an alternator.


12

There is a direct relationship between the number of palms cultivated and the corresponding harvest yield of a given plantation area processed by the mill, the primary energy available in the by product fuel, and power / heat requirement of the mill A properly design Oil Palm Mill will not only provide sufficient steam and electrical power for its operation requirement but will provide an additional 17 to 33 % more power for other planned integrated down stream processes, domestic use or sold to other consumers of power.

9.0

Effluent Control.

SOURCE OF SOLID WASTE, EFFLUENT & POLLUTION

Effluent discharge quantities in Oil palm mills is dependent on the extent of design of the milling process systems, in -plant process control, equipment maintenance and good house-keeping. The solid waste or by-products in the oil palm milling process, consist of :

• • • • • •

Empty bunches Shell and fibers Decanted solids Sludge centrifuge solids Boiler ash De-sludging of ponds.

Solid waste such as treated empty bunches ( de-water ) of approximately 25% to FFB and recovered dryed sludge of approximately 3% to FFB are by products that will be utilized in the plantation and sold as produces. The shell and fiber are sources of solid waste fuel for co-power generation in the oil palm mill. Waste water from the sterilizer condensate, clarificatio n effluent and hydro-cyclone or claybath discharges are sufficiently contaminated and require treatment. Some of the sources waste water discharged from the steam turbine condensate / cooling system and boiler blow down are relatively clean and can be put to good use in the process such as for the dilution system, screw press, oil gutter spraying and for the factory floor cleaning requirements. The liquid effluent total quantity of 0.6 to 1 mt per ton of FFB between the generating sources being as follows :

• • • •

Sterilizer condensate Calrification station Hydrocyclone / Claybath. Other waste water

13


The table below presents the typical physical and chemical properties of raw effluent from Oil palm milling process. PARAMETER

MEAN

pH BOD COD Total Solids Suspended Solids Volatile Solids Ammoniacal Nitrogen Total Nitrogen Oil and Grease

4.1 25,000 53,630 43,635 19,020 36,515 35 770 8,370

* All values except pH are in milligrams per liter ( mg / L) Source : PORIM

The total liquid effluent could well increase if mill process wash water is included. The effluent is not toxic but it has a biochemical oxygen demand of above 25,000 (BOD) which makes it objectionable to fish life when introduced in relatively large quantities in waterways and rivers. The objective is to treat the oil palm mill effluent discharge so as to comply with conditions imposed by the Department of Environment (DOE) for disposal in accordance to standards as follows: Standard A. - For discharge to rivers shall be less than Standard B – For discharge to waterways shall be less than Standard C – For discharge to land & field shall be less than

– BOD 20 mg / l - BOD 50 mg / l - BOD 500 mg / l

A system to treat affluent by ponding or “ Oxidation ponds” is commonly adopted in Malaysia. The system of Anaerobic and Aerobic process in general conform to regulations which require a sizeable area of 65 to 75 days retention time for the ponds, proper monitoring, cost for power for circulation pumps and aerators, de-sludging of ponds, maintenance and supervision but at times are unstable as a result of a reduction of ponding volume due to silting with sludge, weather conditions and by contamination. Many systems are being tried but no generally accepted system has yet emerged. The systems tried including centrifuges, fitters, sun bed drying, air flotation / coagulation and mechanical extended aeration plants. Some pilot systems include Methane production units and “Effluent free system” or Zero discharge by means of a multi-Stage condensing unit and Thermal Oxidation plant to produce dry sludge in the finish product as POME which is sold as fertiliser and filler for animal feed. The search for new designs and systems continues…….. q q q

Oil Palm Mill Schematic Process Flow Oil Palm Process Matrix Process Mass flow and losses during Production

 Noel Wambeck / October. 1997 / Revised June 23, 1999.

ALTERNATIVE CAGE TIPPLER SYSTEM

EMPTY BUNCH DISPOSAL BY INCINERATION FIELD APPLICATION OR OIL RECOVERY

DECANTER FOR SOLIDS REMOVAL

CRUDE PALM OIL 0.09% moist. 0.009% dirt.

DRY KERNEL 7% moisture 4.6% dirt.

Designed by Noel Wambeck - 25th. July 1992

05b. Matrix OPM Process.xls

MATRIX OIL PALM MILL PROCESS. POINT

BASED ON MALAYSIA TENERA MATERIAL WITH 25% OIL CONTENT

Mill Capacity: mt FFB / Hr >

SAMPLE AT POINT % / FFB

OIL

WATER

SOLID

OTHER

3

5

10

20

30

45

60

90

120

1,000

3,000

5,000

10,000

20,000

30,000

45,000

60,000

90,000

120,000

A

Fresh fruit bunches

100

25

48.5

26.5

B B1 B2

Empty bunches Liquid from EB Press Potash ( Bunch ash )

25 8.3 0.5

0.75 0.249

18 7.387

6.25 0.664

0 0 0.5

250 83 5

750 249 15

1,250 415 25

2,500 830 50

5,000 1,660 100

7,500 2,490 150

11,250 3,735 225

15,000 4,980 300

22,500 7,470 450

30,000 9,960 600

C C1

Fruitlets on bunch Fruitlets in Empty bunch loss

66 2

24.25 0.735

37 1.121

7 0.212

0 0

660 20

1,980 60

3,300 100

6,600 200

13,200 400

19,800 600

29,700 900

39,600 1,200

59,400 1,800

79,200 2,400

D D1 D2

Digested mash Press Cake Extraction CPO & water ex-press

64 26 38

23.52 1.56 21.96

35.88 10.9 15.2

6.79 14.0 0.84

0 0 0

640 260 380

1,920 780 1,140

3,200 1,300 1,900

6,400 2,600 3,800

12,800 5,200 7,600

19,200 7,800 11,400

28,800 11,700 17,100

38,400 15,600 22,800

57,600 23,400 34,200

76,800 31,200 45,600

E E1 E2

Wet Fibre & Nuts to depericarper Wet Fibre to boiler Wet Nut Ex- winnowing

25.75 12.0 13.75

1.55 1.08 0.47

10.82 3.60 0.76

13.39 6.48 12.53

0 0 0

257 120 137

771 360 411

1,285 600 685

2,570 1,200 1,370

5,140 2,400 2,740

7,710 3,600 4,110

11,565 5,400 6,165

15,420 7,200 8,220

23,130 10,800 12,330

30,840 14,400 16,440

F F1 F2 F3 F4

Cracked Mixture Kernel Shell Water for Hydrocyclone Clay for Claybath system

G G1 G2

Crude oil diluated with water Clarified crude oil to Purifier Sludge to Separator

53.2 25.00 42.31

21.96 21.96 21.74

30.4 2.20 19.81

H H1

Clean oil to Oil dryer Clean & dry CPO to stoarge tank

23.91 21.52

21.74 21.50

2.17 0.01

J J1 J2 J3

Raw water Boiler feed water Precess water Domestic water

1000 700 120 180

K K1 K2 K3 K4

Solid waste fuel to boiler ( 30% moist.) Fibre Shell Light particals De-oiled empty bunches

43 12 8 0.5 22.5

L L1 L2 L3

Boiler steam generation ( kg / ton FFB ) Turbine steam requirement Sterilisation steam requirement Process heating steam requirement

660 600 540 120

660kg 600kg 540 kg 120 kg

M M1 M2 M3 M4 M5

Wast water Effluent ( kg / ton FFB ) From Clarification From Steriliser condensate From PK recovery plant Boiler blow down From OTHERS & cleaning

1000 550 150 80 120 100

1000kg

N N1 N2 N3

Power generation ( kw / ton FFB / hr ) Process Mill lighting & grounds Domestic

Perunding AME / POMProMatrix / 16th November 1998 /nw.

12.5 5.5 7 80 5

25 20 2 3

kg

1 Weight in kg.

0 0 0 0

125 55 70 80 5

375 165 210 240 15

625 275 350 400 25

1,250 550 700 800 50

2,500 1,100 1,400 1,600 100

3,750 1,650 2,100 2,400 150

5,625 2,475 3,150 3,600 225

7,500 3,300 4,200 4,800 300

11,250 4,950 6,300 7,200 450

15,000 6,600 8,400 9,600 600

0.84 0.84 0.8

0 0 0

532 250 423

1,596 750 1,269

2,660 1,250 2,115

5,320 2,500 4,230

10,640 5,000 8,460

15,960 7,500 12,690

23,940 11,250 19,035

31,920 15,000 25,380

47,880 22,500 38,070

63,840 30,000 50,760

0.009

0 0

239 215

717 645

1,195 1,075

2,390 2,150

4,780 4,300

7,170 6,450

10,755 9,675

14,340 12,900

21,510 19,350

28,680 25,800

1,000 700 120 180

3,000 2,100 360 540

5,000 3,500 600 900

10,000 7,000 1,200 1,800

20,000 14,000 2,400 3,600

30,000 21,000 3,600 5,400

45,000 31,500 5,400 8,100

60,000 42,000 7,200 10,800

90,000 63,000 10,800 16,200

120,000 84,000 14,400 21,600

430 120 80 5 225

1,290 360 240 15 675

2,150 600 400 25 1,125

4,300 1,200 800 50 2,250

8,600 2,400 1,600 100 4,500

12,900 3,600 2,400 150 6,750

19,350 5,400 3,600 225 10,125

25,800 7,200 4,800 300 13,500

38,700 10,800 7,200 450 20,250

51,600 14,400 9,600 600 27,000

660 600 540 120

1,980 1,800 1,620 360

3,300 3,000 2,700 600

6,600 6,000 5,400 1,200

13,200 12,000 10,800 2,400

19,800 18,000 16,200 3,600

29,700 27,000 24,300 5,400

39,600 36,000 32,400 7,200

59,400 54,000 48,600 10,800

79,200 72,000 64,800 14,400

1,000 550 150 80 120 100

3,000 1,650 450 240 360 300

5,000 2,750 750 400 600 500

10,000 5,500 1,500 800 1,200 1,000

20,000 11,000 3,000 1,600 2,400 2,000

30,000 16,500 4,500 2,400 3,600 3,000

45,000 24,750 6,750 3,600 5,400 4,500

60,000 33,000 9,000 4,800 7,200 6,000

90,000 49,500 13,500 7,200 10,800 9,000

120,000 66,000 18,000 9,600 14,400 12,000

25 20 2 3

75 60 6 9

125 100 10 15

250 200 20 30

500 400 40 60

750 600 60 90

1,125 900 90 135

1,500 1,200 120 180

2,250 1,800 180 270

3,000 2,400 240 360

80kg 5kg

1000kg 700 kg 120kg 180kg 0.01 0.016 0.008 0.0005 0.008

12.9 3.6 1.2 0.025 6.75

kg kg kg kg 30.09 8.384 6.792 0.4745 15.742

kg kg kg kg kg KW KW KW KW

5/10/00

PROCESS MASS FLOW AND LOSSES DURING PRODUCTION Based on Tenera material Oil content FFA

FFB input in kg STERILISER 100 kg

Out Flow 12.3

STRIPPING 87.7 kg

25

EXTRACTION 62.7 kg

31.14 31.56

24% 2.5% max

LOSS

kg

kg

Evaporation Oil Loss

12 0.3

Empty bunches Oil Loss

24.5 0.5

Solids Liquids

6.56 2

Oil Loss Oil

16.19

KERNEL RECOVERY 14.95 kg NUTS 5.4

TOTAL in kg CPO Yield

WASTE

kg

Water Non-oily solids

OIL CLARIFICATION 31.56 kg

DEPERICARPER 31.14 kg

PRODUCT

0.75 22.25

Evaporation Oil Loss Fibre Kernel Loss

3.84

Evaporation Oil Loss Kernel Loss Shell Kernel

1.7

0.1 12 0.25

0.1 0.15 8 5

100 22.25

27.25

70.6

2.15

92.7%

Total OIL loss in kg

1.75

92.6%

Total kernel loss in kg

0.4

( Including FFA as Oil )

Palm Kernel Yield

QUALITY

Noel Wambeck Feb.1999

5

Moisture % Dirt % FFA %

0.09 0.009 3.5

Moisture % Dirt % FFA %

7 5 2.5

Empt y b unch Incinera tor for Oil Palm Mill ( c ap : 6,000 kg / hr )

TYPICAL FLOW DIAGRAM OF AN EFFLUENT TREATMENT PONDING SYSTEM FOR A 30 MT FFB PER HOUR OIL PALM MILL.

FAT PIT EFFLUENT OIL RECOVERY STATION WASTE WATER FROM : Steriliser Condensate, Clarification Station Kernel recovery station and wash water

Cooling Pond No 1 12 x 15 x 2.5

RAW EFFLUENT INPUT 432 m3 /day BOD 25,000 ppm.

302 m3 each Pond 1 day HRT

Cooling Pond No 2

Recycle Activated Sludge

Acidification Pond No.1 12 x 15 x 2.5

302 m3 each Pond 1 day HRT

Anaerobic Pond No.1 16 x 160 x 6

( 100%) 18m3 per hour

Acidification Pond No.2

Anaerobic Pond No.2 6629 m3 each Pond 61days HRT

Anaerobic Pond No.3

Anaerobic Pond No.4

RECYCLE PIPE LINE

RECYCLE PUMP

Facultative Pond 932m3 2 days HRT 16 x 30 x 2.5

Aerobic Pond No.1 16 x 80 x 2.5

2,611 m3 each 12 days HRT

Aerobic Pond No.2

Pipeline / Tanker

FINAL DISCHARGE TO PLANTATION FLOW RATE OF > 432 m3 / Day BOD REDUCTION = 99.6 % > LESS THAN 100 PPM BOD

Perunding AME/ ETP Flow Diagram

05g. MatrixPOMEffluent.xls

MATRIX OF AN OIL PALM MILL PROCESS & WASTE WATER EFFLUENT PONDING SYSTEM. Item

Details

1

Milling capacity

MT FFB / hr

2

Effluent Generation Rate a. FFB moisture b. Sterilizer condensiate c. Clarification station d. Kernel Plant e. Other & washwater Total per hour in kg.

kg kg kg kg kg kg

200 140 600 150 110 1,000

6,000 4,200 18,000 4,500 3,300 30,000

9,000 6,300 27,000 6,750 4,950 45,000

12,000 8,400 36,000 9,000 6,600 60,000

18,000 12,600 54,000 13,500 9,900 90,000

24,000 16,800 72,000 18,000 13,200 120,000

Flow rate of Effluent Per Hour Per Day ( 24 hours ) HRT of 75 days

m3 m3 m3

1 24 1,800

30 720 54,000

45 1,080 81,000

60 1,440 108,000

90 2,160 162,000

120 2,880 216,000

Suspended Solids at Fat / Sludge pit ( 22,000 mg/L ) at Final discharge ( 200 mg/L ) Rate of aerobic Biosolids produced

kg kg kg

39.6 0.36 39.24

1188 10.80 1177.2

1782 16.20 1765.8

2376 21.60 2354.4

3564 32.40 3531.6

4752 43.20 4708.8

5

Organic loading Rate ( 0.3 kg BOD/m3/Day )

kg

7.2

216

324

432

648

864

6

Rate of Re-circulation of Anaerobic effluent Anaerobic - HRT 5 days return to seeding pond ( 50 % ) Pump size number of pumpsets

m3 m3 / hr KW unit

120 0.5 0.33 1

3600 15 3 1

5400 22.5 4.5 1

7200 30 6 1

10800 45 9 1

14400 60 12 1

BOD of Effluent at Sludge pit - 25,000 mg / L at Anaerobic pond discharge - 5,000 mg /L at Aeration pond discharge - 50 mg /L at Stabilisation pond discharge - 20 mg / L

kg kg kg kg

4.5 0.90 0.009 0.0036

135 27.00 0.27 0.108

202.5 40.50 0.405 0.162

270 54.00 0.54 0.216

405 81.00 0.81 0.324

540 108.00 1.08 0.432

Aeration pumpsets Flow rate Drive motor Number required

m3 / hr at TDH 20 kw units

2

45 5.625

67.5 8.4375

90 11.25

135 16.875

180 22.5

3

4

7

8

1

30

1 x 7.5

45

2 x 5.5

60

2 x 7.5

90

2 x 10

120

4 x 5.5

PERUNDING AME – Consulting Engineers

1

AN ENVIRONMENTAL CONTROL PLAN (ECP) By Noel Wambeck April 1999.

FOR THE PROPOSED OIL PALM MILL WITH AN INTEGRATED EFFLUENT TREATMENT AND DISPOSAL SYSTEM, AIR POLLUTION AND SOLID WASTE DISPOSAL SYSTEM.

01. INTRODUCTION. The proposed Environmental Control Plan (ECP) will exploit every practical avenue to provide a complete effective system for Effluent treatment, solid waste disposal, air pollution control and minimising of the environmental impact, to the requirements and expectations of DOE, local authorities and inhabitant indemnity. The Department of Environment has set a target for Oil palm mills to achieve 100 percent compliance by the year 2000 in terms of meeting emission and effluent discharge standards, which are :

• Environmental Quality ( Licensing ) regulations 1977. • Environmental Quality ( Prescribed Premises) (Crude Palm Oil ) Regulations 1977 (Amendment) 1982.

• Environmental Quality ( Clean Air ) Regulations 1978. The overall objective of this project report is to determine and advise the client on the following : 1

Proposed project needs in terms of design, cost, capacity, manpower requirements and project schedule.

2

Selection of the Oil Palm Mill complex location.

3

Provide detail design and specification, supervision, commissioning, training of personnel and guarantee performance for the proposed project.

4

Care in the implementation of the project, and not to endanger the environment by providing the proper process, system and method for the treatment of effluent for 100 % land application, solid waste disposal and the control of noise and air pollution.


2

02. PROJECT SALIENT DATA. The following salient data is used in the design calculations:2.1

Milling capacity ( MT / FFB per hour. )

:

30 mt per hour 720 mt FFB per day

2.2

Amount of Empty Bunches for disposal (mt / hr.) Based on the ratio of 25% Empty bunches to FFB

:

7. 5 mt per hour 180 mt per day

Empty bunch decomposing period Area required for mulching ( 2333m3 / Ha )

: :

90 days 26 Ha

2.3

Ratio of raw effluent (POME) to FFB

:

60 %

2.4

B.O.D. level of raw effluent (POME)

:

25,000 mg/l

2.5

Processing hours – based on peak operation

:

24 hours.

2.6

Average flow rate of effluent (POME )

:

18 m3 / hr or 432 m3 / day

2.7

Effluent ( waste water ) treatment system : 1 No. Sterilizer condensate oil recovery tank 1 No. Sludge oil recovery tank 2 Nos Fat pits : 20m3 volume 2 Nos Cooling Ponds : 256m3 each 1 No. Mixing Pond 461m3 3 Nos Digesting Tanks : 3720m3 each 4 Nos Aeration reactor : 2000m3 each 1 No. Sludge drying bed : 6 x 30 m 1 No. Sludge Clarifier : 225.6.m3 1 No. Treated effluent holding tank

: : : : : : : : :

120 m3 120 m3 40 m3 461m3 / hr HRT 2.13 days 461m3/ hr HRT 1.07 days 11,160 m3 HRT 25.8 days 8000 m3 HRT 4 days 180 m2 225.6m3 HRT 12.5 hr

B.O.D. level of Final discharge Total BOD reduction 2.10 Proposed site area

:

< 20 mg/l 99.9 %

: :

122 ha

Area allocated for Oil palm mill complex

:

12 ha

Percolation Rate of liquid Effluent on proposed land

:

560m3 / day / ha

Area allocated for field / Land disposal of final effluent : in trenches / furrows ( based on 90 days cycle )

69 ha

2.11 Boiler Gas Volume

:

30 m3/ s

2.13 Dust load

:

4000mg/ NM3 max.

2.14 Boiler Air Emission

:

< 0.4g / NM3


3

03. SOURCE OF SOLID WASTE, EFFLUENT & POLLUTION Effluent discharge quantities in Oil palm mills is dependent on the extent of design of the milling process systems, in -plant process control, equipment maintenance and good house-keeping. The solid waste or by-products in the oil palm milling process, consist of :

• • • • • •

Empty bunches Shell and fibers Decanted solids Sludge centrifuge solids Boiler ash De-sludging of ponds.

Solid waste such as treated empty bunches ( de-water ) of approximately 25% to FFB and recovered dryed sludge of approximately 3% to FFB are by products that will be utilized in the plantation and sold as produces. The shell and fiber are sources of solid waste fuel for co-power generation in the oil palm mill. Waste water from the sterilizer condensate, clarification effluent and hydro-cyclone or claybath discharges are sufficiently contaminated and require treatment. Some of the sources waste water discharged from the steam turbine condensate / cooling system and boiler blow down are relatively clean and can be put to good use in the process suc h as for the dilution system, screw press, oil gutter spraying and for the factory floor cleaning requirements. The liquid effluent total quantity of 0.6 m≥ to 1m≥ per ton of FFB between the generating sources being as follows :

• • • •

Sterilizer condensate Calrification station Hydrocyclone / Claybath. Other waste water

The table below presents the typical physical and chemical properties of raw effluent from Oil palm milling process. PARAMETER

MEAN

pH BOD COD Total Solids Suspended Solids Volatile Solids Ammoniacal Nitrogen Total Nitrogen Oil and Grease

4.1 25,000 53,630 43,635 19,020 36,515 35 770 8,370

* All values except pH are in milligrams per liter ( mg / L) Source : PORIM


4

04. POLLUTION CONTROL SYSTEM. The proposed Pollution control and treatment systems are : 4.1 THE DISPOSAL OF EMPTY BUNCH. 4.2 THE PROCESS OF THE INTEGRATED DECANTER – DRIER SYSTEM 4.3 THE ANAEROBIC & AEROBIC EFFLUENT TREATMENT SYSTEM. 4.4 DISPOSAL OF TREATED EFFLUENT FOR LAND APPLICATION. 4.5 CONTROL OF AIR EMISSIONS.

The brief process description of the above systems are as follows:

4.1 THE DISPOSAL OF EMPTY BUNCH. Empty bunch a solid waste product of the Oil Palm Milling process has a high moisture content of approximately 55 – 65% and high in silica content , form 25% of the total weight of Palm Fruit Bunch. The treated Empty bunch are mechanically crushed ( de-watered and de-oiled ) in the process but are rich in major nutrients and contain reasonable amounts of trace elements. They have a value when returned to the field as mulch for the enrichment of soil. The use of empty bunch for field application as mulching material is preferred by the client, therefore we shall confine to this method of disposal of empty bunch for the proposed oil palm plantation. The land application .mulching system is said to have a cost savings of RM 250 per ha annually in place of fertiliser supplement. In Perak state, several estates have this system of land application of empty bunch mulching, including Seri Pelangi, Nova Scotia, Jendarata Estate, since 1973 on a commercial scale. Other mills that used the same method of disposal are; Ulu Basir, UIE, Southern Perak, Changkat Chermin, Topaz Emas, Foong Lee etc To do this, adequate hopper and conveyor system will be provided at the oil palm mill site for storage and an arrangement of tractor & trailer with a capacity of 5 -10 mt EFB shall be deployed for the transportation of the treated empty bunches ( de-watered ) to the field for disposal. On arrival at the estate, the train of two or more trailers are parked on the road adjacent to the inter row to be mulched and with the aid of the extended draw-bar, the trailers are unhitched one from the other. The trailers are towed one at a time into the inter rows and tipped while slowly moving forward. The empty trailers are then hitched back one to the other by lifting with the tractor draw-bar and pins put into position, they than return to the mill to repeat the process.


5

The drainage pattern in most fields is four palm rows to a drain, to ensure that all palms benefit from mulching, the empty bunches are applied in the avenue between row 2 and 3, and between palm points in the two outer drain side rows ( see the diagram of the Placement of empty bunches in the appendix.) In the latter, the side-tipping trailers are particularly useful. Manual labour is used to make minor improvements where leveling may be required. The rate of application ranges between 75 to 100 tons empty bunches per hectare.

In conclusion, bunch mulching of oil palms on a commercial scale is recommended as a viable proposition in plantation where the terrain and ground conditions allow mechanisation of the operation.

4.2 THE PROCESS OF THE INTEGRATED DECANTER – DRIER SYSTEM ( FOR THE PRODUCTION OF SOLID WASTE SLUDGE ( POME ) AS ANIMAL FEED OR FERTILISER. )

The Decanter – Drier integrated system reduces the volume and handling of oil palm mill effluent discharge of about 75% of the total BOD load discharge from the mill. The system also provide a means of a dust collecting system for the boiler flue gas with the advantage of being able to produce an added value by product of dried sludge ( POME ) for animal feed or fertiliser, resulting in better returns on investment of the project. The source of solid waste effluent are : 1. 2. 3. 4. 5. 6.

Decanter solids Steriliser condensate sludge Clarification station sludge Boiler ash De-sludging of the effluent treatment system De-sludging of all process tanks

The use of the Decanter in the oil clarification station for the removal of solid matter, reduces the load on the separator and static clarification settling tank by about 50 – 75% while there is not change in the load on the other machinery of the clarification station process. Process dried sludge has certain properties:

• • •

Releases nutrients slowly It supplies trace elements And it improves water retention.

The system proposed has been developed and in operation over 20 years at United Plantations Mills, Keck Seng and several other mills in Malaysia and Indonesia.


6

The proposed system details are as follows : A. Multi cyclone separator. The multi cyclone will remove coarse sand and other solid matters with a particle size of more than 50 microns or about 50% of the solid matter from the crude oil. B. The Decanter system. The decanter will remove approximately 90% of all suspended solids from the crude oil. C. Rotary Drum drier. Solid sludge is conveyed by the screw conveyor and fed to the Rotary Drum Drier located close to the boiler house for heating by the Boiler flue gas. The rotary drum drier in which the flue gas from the boiler, is in direct contact with the wet solids discharged from the decanter, multi cyclone and oil pit – effluent recovery system. Flow of the flue gas and solids is con-current. The flue gas is tapped from the chimney above the boiler fan. The ducting size would be the same size of the chimney and the portion of the chimney above the ducting is closed with a damper for flue gas control. The diamension of the rotary drum drier is 2 meter in diameter and about 15 meter in length. D. Dried sludge clarification screen. The dried sludge material with a moisture content of 10% is discharged at the end of the rotary drum drier and conveyed by a screw conveyor and fed to the vibrating screen. A circular vibrating screen will screen the dust and sludge grains before the mixing and packing in polybags for storage as the finished product and sold to buyer. The product POME ( Palm Oil Mill Effluent Dried sludge ) The best prospects for POME as an animal feed because of its ability to substitute some of the expensive imported components of feed meals and as a fertiliser, POME is a good source of major and minor nutrients. Commercial value of POME fertiliser is about RM 500 per ton and sold to plantations, flower gardens, golf club application to turf etc. A comprehensive analysis of dried sludge is given in the table below:

Moisture Ash Silica Ether extract Crude Fibre Crude Protein

% 5 – 15 15 – 22 7 – 10 11 – 13 11 – 14 11 – 13

N P K Mg Ca

% 1.8 – 2.3 0.3 – 0.4 2.5 – 3.2 0.6 – 0.8 0.6 – 0.8

B Cu Fe Mn Zn

p.p.m. 20 20 – 50 3000-5000 50 – 70 20 – 100


7

In conclusion, we can say that dried sludge or POME improves the water availability, carbon and nitrogen content, a provider for microbial activities in soil and a useful source of plant nutrients for crops grown on normal or degraded land. An added attraction of the system that is of growing importance, is the reduction in air pollution brought about by scrubbing of the boiler flue gas in the drier and finally its yields an income as waste by-product.

4.3 THE ANAEROBIC & AEROBIC EFFLUENT TREATMENT SYSTEM. The effluent is not toxic but it has a biochemical oxygen demand of above 25,000 (BOD) which makes it objectionable to fish life when introduced in relatively large quantities in waterways and rivers. The effluent treatment system developed for use in this project shall be of a modern biological system, characterised by the anaerobic and aerobic process phases. The total effluent from the proposed Oil palm mill process is approximately 0.6 tons per ton ffb. which is made up of : 1. 2. 3. 4. 5.

Sterilizer condensate Classification station dicharge of effluent Hydrocyclone / Claybath waste water Boiler blow down. Wash water, make up the balance.

The proposed Anaerobic & Aerobic effluent treatment system, shall be located within the oil palm mill complex, that will require an area of approximately 100 m x 100m ( 1 ha ) and will consist of :

• • • • • • • • • • • • •

Sterilizer and Sludge oil recovery tank Fat trap pits Compressed air flotation unit. Cooling & Mixing tanks Anaerobic digesting tanks Aeration reactors Solids removal clarifer Effluent metering. Drying bed. Final effluent holding tank Monitoring & control system Pumps and Air compressor Inter-connecting piping, valves and fittings.

A schematic flow diagram and system calculations are enclosed in the appendix.


8

The system will be monitored on site for pH, volatile fatty acids (VFA), total alkalinity (TA) and solids contents whereas the more complex tests for BOD, COD, ammoniacal nitrogen (AN) and total organic nitrogen (TKN) analysis will be sent out to reputable laboratory for samples test. The proposed effluent treatment system shall be procured from experience environmental control equipment and system vendor who will guarantee its performance. Full advantage is to be made of the “ decanter “ and the “ decanter solids “ dryer, design to dry all of the wet solid sludge removed from the system. To this end part of the sludge outlet water is to be used at the screwpress, in place of the existing dilution water, to assist the transport of the crude oil to the clarification plant.

THE PROCESS The effluent treatment system will include two main parts, the anaerobic section and aerobic stabilisation process before the final discharge of treated palm oil mill effluent onto the plantation for palm tree irrigation. The condensate discharge from the sterilizers is pumped to the post static clarifier an oil recovery system tank. The oil skimmers removes the highly contaminated oil from both the clarifier and sludge decanter tank which is isolated in a special drumming holding tank. The sludge will than pass through a CAF unit for the removal of disolved oils, grease by flotation process etc,… before being fed to the cooling pond. Every precaution is to be taken to ensure that this oil cannot and does not contaminate the crude oil system. The objective is to reduce the loading of the effluent treatment system by the removal of the oil and solid matter in sterilizer condensate at an early stage. The deoiled sterilizer condensate is then discharged in to its own isolated effluent collection pit And overflow to the effluent treatment sys tem. The sludge slurry which are drained from the static clarifier and sludge decanter tank are discharged to the drying bed or conveyed to the rotary sludge dryer for the drying process. The anaerobic phase is favoured by higher temperature and the absence of air. The influent from the sterilizer sludge pit and the clarification pit is to be pumped to the cooling pond and than to the mixing pond. The anaerobic process start to take place in the first pond and end at the digester tanks. There the complex organic materials are first solubilized by the extra cellular enzymes and then converted to volatile acids by acid producing bacteria.


9

In the last methane fermentation phase the volatile acids are transformed to methane and carbon dioxide. The process is to be accelerated by the circulation of the bacteria laden sludge into the mixing pond of the material from the last digester tank. The acidification process will have an HRT of 1 day. Effluent from the mixing pond is pumped from the collecting sump and into the digesters with a total HRT of more than 20 days. The discharge from the overflow of the final anaerobic tank is to be discharge into an open pit and pumped into the aerobic reactor tanks for the extended aeration process equipped with over powered mechanical aerators. The overflow of the aerobic reactor tank, operating in tandem with a total HRT of 4 days will be pumped to the clarifier tank for the removal of solids. The sludge scum is to be held back and removed from the ample sized “sludge clarification tank”. Sludge accumulated at the bottom of the clarifier, and drying bed, are to be removed by the auto programmed system provided for the sludge removal process. The separated sludge cake can be dried in rotary dryer and used as plant nutrient in compound form as a by product. The treated effluent is now pumped to the final effluent holding tank. A finish effluent holding tank will hold the effluent waste water with a BOD of 20 ppm for displacement into furrows in the plantation disposal area. The system is to be stable and is to be capable of with standing reasonable shock loads. The efficiency of the system is facilitated by a monitoring and programmable control system design which requires only simple maintenance and operational skills.

4.4 DISPOSAL OF TREATED EFFLUENT FOR LAND APPLICATION. The recycling of POME in plantations is now widely accepted as an economically viable and environmentally acceptable waste management technique. Treated Effluent are pumped or discharged by gravity to the pre-selected area as a good source of plant nutrients and a value added ( RM 350 per ha / year ) cost effective organic fertilizer. The disposal of treated effluent for land application require an area of approximately 69 hectares in the plantation, have been marked in the vicinity of the proposed oil palm mill to receive the effluent in loaded furrows. A typical furrow layout is shown in the report drawing section. Field drains on the sides of each plot which act as trenches to prevent poaching.


10

a. Methods of Land Application. The percolation through furrows or trenches method will be used in the land application of treated effluent of approximately 560m3 / day / ha for the given volume at an application cycle of mor e than 90 days, based on experience. b.

Factors for consideration.

The following factors effect the rate of application. • Soil characteristics such as porosity, water table, acidity of soil; • Characteristics of effluent, such as concentration of large solids; • Age of oil palms; • Vegetation in between the oil palms; Over application of the effluent must be avoided which may result in anaerobic conditions in the soil by formation of an impervious coat of organic matter on the soil surface. c.

The percolation through furrows or trenches system.

Waste Water Effluent is pumped or discharged by gravity to the high points of the pre-selected area and allowed to drain down the slopes in furrows or trenches shown in the appendix “ Typical Furrow layout”. The velocity of flow is given as a steady infiltration rate of 7 – 11 cm per hour, slow enough to enable percolation into the soil and also it prevents erosion. An area of approximately 110 hectares have been marked and allocated in the vicinity of the proposed oil palm mill, shown in the “ Soil suitability for land application of Palm Oil Mill Effluent Survey Report” enclosed. The furrows or trenches are about 90 cm / 60 width x 75 cm depth shown in the appendix and survey report. Field drains of each plot, which act as pits to prevent poaching and used as silt traps to contain sediments transported by surface erosion.

d. Effects of land application. Yields of oil palm increases with the use of oil palm mill effluent. The optimum rate of application is approximately 40 cm rainfall per year. The nutrient value of the soil also shows improvements with land application, especially the nitrogen, phosphorus, potassium and magnesium values. The effect on underground water and surface drainage, are negligible.


11

4.5 CONTROL OF AIR EMISSIONS. The Environmental quality ( clean air ) regulation 1978 stipulate the permitted level of solids concentration in gases emitted from solid waste thermal plants to be not more than 0.4 g per cubit meter. Air emissions from oil palm mills are from the boilers and incinerators, being mainly gases with particulates such as tar and soot droplets of 20 – 100 microns and a dust load of about 3000 to 4000 mg. / NM3. Incomplete combustion of the boiler and incinerator produces dark smoke resulting from burning of a mixture of solid waste fuel such as shell, fibre and some times empty bunches. A good design and properly rated boiler capacity with a closed loop control over the fuel feed rate and air supply will ensure steady state combustion in tandem with steam demand. The introduction of the proposed system will alter the situation whereby the thermal plant such as the waste fuel boiler shall emit clean smoke in accordance to the DOE standard requirements.

The scrubber system. Flue gas from the boiler furnace with a temperature of approximately 288 deg. C flow through the ducting to the scrubber. Water is sprayed from the top of the scrubber, through a manifold and then mixed with the flue gas and dust particles where the proc ess of separation of the particles, gas and water droplets take placed. The spray water of 10 m3 per hour used in this system are from the steam turbine cooling system and heat exchange steam condensiate waste water. The cooled clean gas is conveyed by the ID fan that blows the exhausted gas to the chimney Slurry from the separator is collected in a seal tank via a trap sump and pump to the effluent treatment plant. The scrubber system consist of :

• • • • • •

Scrubber unit Fan Moisture separator Pump Inter-connecting piping, valves, fittings and duct works. Control , Instrumentation & wiring.

The above system vendor guarantee an emission at the chimney outlet of less than 400 mg./ NM3 and in accordance to the DOE allowed standard.


12

5.0 PROJECT COST. The project cost of establishing the proposed mill with a capacity of 30 mt FFB per hour is estimated at the total cost of approximately RM 30 million. This amount is made up of RM 25.6 million for the conventional oil palm mill and the additional investment of RM 4.4 million or 17.19% more for the systems required for the proposed Environmental Control Plan. The expenditure is spread over the mill constructional period of two years. The summary of the above costs are as follows : PACKAGE DETAILS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

INVESTMENT

PRELIMINARIES SITE FACILITIES EARTH WORKS QUARTERS BUILDING WORKS RAW WATER SUPPLY AND TREATMENT CIVIL & STRUCTURE WORKS MECHANICAL & PI STORAGE TANK FARM ELECTRICAL WORKS EFFLUENT TREATMENT PLANT

330,000 270,000 1,400,000 2,800,000 800,000 7,500,000 10,500,000 600,000 1,400,000

25,600,000 TOTAL PROJECT COST in RM

ADDITIONAL

400,000

1,700,000 300,000 2,000,000

4,400,000

30,000,000

Additional Investment for ECP in % is approximately : 17.19 %

Preliminary estimates can vary extensively depending on terrain, type of soil, accessibility, selection of quality of equipment and design factors applied. The above estimate have taken into consideration of the following : a). Best applied technology, innovation and development for a modern oil palm mill. b). Proven design of machinery, systems and plant layouts.

c) The site for locating the proposed oil palm mill has been selected on the basis of substantial cost savings in transportation, as being one of the factors for its selection. “ Our aim is to help shape our common future and to save us from being submerged in sludge.”  April 1999 Noel Wambeck

POTENTIAL HAZARDS AND CONTROL PLAN.

The potential hazards which could affect the public water supply and the proposed control plan in place, are as follows :

POTENTIAL HAZARDS.

CONTROL PLAN.

1.

Process wastewater

1.

Runs into process drains, fat pit collecting sump, effluent oil recovery and solid removal system before discharge to effluent pond system.

2.

System failure of mill during operation

2.

Shut down of operation for major problems or effect repairs immediately of equipment and plant for minor repairs, all runoffs into process drains.

3.

Wash water contaminated with oil.

3.

Runs into process drains, the Fat pit collecting sumps and effluent treatment.

4.

Oil tanks leakage, spillage during loading into oil Tankers.

4.

Runs into process drains and into collecting sump for recycling back to process.

5.

Fuel tanks spillage during unloading and pipe line Leakage

5.

Contained in bund storage area.

6.

Lubrication oils & Chemicals spillage

6.

Contained in bund storage area

7.

Boiler blow down waste water

7.

Runs into dedicated process drains

8.

Rain water flooding.

8.

Runs into dedicated storm drains.

9.

Oils and sludge in the sump

9.

Oil is skimmed and pumped into drums for sale, whereas the treated sludge and sterilizer condensate waste water will be treated in the effluent treatment system and than discharged of the effluent to the plantation with BOD of 20 ppm.

Fat pit collecting sumps. Ex- Oil room waste water, Sterilizer condensate water, Hydrocyclone / Claybath and wash water.

Perunding AME / 22 nd. February 1999.

OIL PALM MILL ENVIRONMENT CONTROL PLAN ( EPC System ) WASTE MATERIAL

REDUCTION Present system CONDENSATE SLUDGE TANK

STERILISER CONDENSATE

STATIC SEPARATION OIL RECOVERY

Liquid phase to Effluent ponds

CLARIFICATION STATION WASTE WATER

DECANTERED SLUDGE

EMPTY BUNCH FROM THRESHING STATION

INCINERATOR

Liquid phase to CAA system

STORAGE HOPPERS DEWATERING PROCESS

MULTI CYCLONE DUST SEPARATOR

WATER TUBE BOILER Subject to shock loads / unstable combustion

Discharge of air polluting dust to atmosphere

FINAL TREATMENT & DISPOSAL

CONTROL Anaerobic & Aerobic (CAA)system

TREATED EFFLUENT

EFFLUENT to Field

SLUDGE Drying System to produce Fertilizer products

Bag POME

POTASH production FIELD DISPOSAL Dewatered bunch for oil recovery and COGEN power production. FIBRE products

Full combustion for Reduction of dust particles to less than 0.2 mg / m3 in flue gas

POTASH

OIL and POWER

FIBRE products

CLEAN FLUE GAS

INSTALL SOUND DAMPERS TO HIGH SPEED MACHINERY.

PROCESS LINE & POWER ROOM MACHINERY NOISE

SOUND CANOPY PARTITIONED ROOM

MAINTAINED EQUIPMENT

Reduce to 50 dB / m sound Limits

NOISE CONTROL

ECONOMICS OF WASTE BUT WASTE NOT OF USEFUL VALUE ADDED PRODUCTS

SOLID WASTE

LIQUID EFFLUENT

© Noel Wambeck / 8th December 98.

& AIR POLLUTION

TREATMENT & CONTROL

ZERO HAZARDS DISPOSAL & PRODUCTION HAVE VALUE ADDED PRODUCTS

PROPOSED PLACEMENT AVENUE FOR EMPTY BUNCHES, FRONDS AND TREATED EFFLUENT FOR LAND APPLICATION.

PRESS STATION

CLARIFICATION STATION

BOILER HOUSE

STERILIZED FRUITLETS

WET SLUDGE FOR DRYING PROCESS

BAGGING OF DRIED POME

POME SLUDGE PROCESS WITH THE DECANTER & DRYER – SCHEMATIC FLOW DIAGRAM

HOLDING / DISTRIBUTING FURROW

FURROW

CONTIGENCY FURROW

EFFLUENT PIPE LINE – PUMPED FROM MILL

ESTATE RING ROAD FOR INSPECTION PURPOSE

Perunding AME / 20th April 99 / NW.

TYPICAL FURROW LAYOUT

PVC OVERFLOW PIPE

Oil palm mill process monitoring & control system

OIL PALM MILL PROCESS MONITORING & CONTROL (PMC) SYSTEM

CONTENTS. • • • • • •

Introduction. System description. Data Acquisition Features. Process Alarm. Interlocking Features. Systems for Individual Stations

1. 0 Sterilizer control system 2. 0 Crude oil dilution control system 3. 0 Depericarper control system 4. 0 Cracked Mixture Winnowing control system for kernel recovery plant 5. 0 Back-pressure vessel control system 6. 0 Boiler combustion control and scrubber system 7. 0 Specifications of hardware and software.

1


INTRODUCTION.

Spotting trouble before it strikes for most manufacturing plants, maintaining production equipment means keeping a process within well-defined parameters. Slight variance from those parameters introduces product defects, added machine wear, such as slipping belts, chattering chains and poorly meshing gears, resulting in equipment or system failure. To complicate the process further, critical signs or warning provided in the monitoring and control system are ignored and at times human errors in operation are the cause of total breakdown of the mill. When product defects or equipment failure occur, mill engineers must diagnose the situation and do so quickly to minimize production stoppage.

& Which component is out of specification ? & What is necessary to return the process to normal ? & What needs an adjustment ? & Replacement of new parts or an overhaul is required immediately ? Process monitoring and control (PMC) systems are the best available tools for the purpose. They record the process systems or equipment digitally, they allow instantaneous review, data measurement, and analysis of the data measured. Until now, mills seeking process monitoring systems that work properly had limited choices. The present availability of PMC systems, durable components and companies of reputation with full after sale service, makes rational sense in the investment of a good working process monitoring and control system for oil palm mills that are conducive to spotting trouble before it strikes.

2


SYSTEM DESCRIPTION. The Process and Monitoring Control (PMC) system shall be a user friendly PC based platform that is specifically designed for the monitoring of analog or digital inputs, graphic display, data logging and acquisition, trending and change of parameters of the network operation in the individual stations in an Oil Palm Mill The systems for the individual stations are : 01.

Sterilizer control system

02.

Crude oil dilution control system

03.

Depericarper control system

04.

Winnowing control system for kernel recovery plant

05.

Back-pressure vessel control system

06.

Boiler combustion control and scrubber system

There will be remote control panels with PLC cards, whereby each system will be linked to the control by their respective station. The remote control panels will be link to the Central Control Station that will be located inside the Central Control Room (CCR) through computer networking system. The proposed system shall be robust in construction, proven design, user friendly and widely used in oil palm mills. The Central Control Room which fully air conditioned shall contain the computer unit with screen, key board, mouse, backup battery unit and printer in a console work station. The PMC system shall provide a means for centralizing the tasks of monitoring, data recording, configuring and manipulating the process while using distributing processors to perform application, control and actual process interface functions. Further the system shall interface to printer, recorder and graphic annunciators for logging, alarming, the inter locking, trip override and real time trending of selected points.

3


DATA ACQUISITION FEATURES. The data acquisition features will include the following :

• Weighbridge data for FFB received, dispatched produce of CPO, Palm Kernel, Empty bunch, ash etc.

• Vehicle movements and registration numbers. • Sterilizer system operating status • Crude oil dilution system operating status • Depericarper system operating status • Winnowing system operating status • Clarification station operating status • Back-pressure vessel system operating status • Boiler operation operating status • Pressure and temperature of all salient equipment, machinery and plant. • KW recording of all salient equipment, machinery and plant. • Hour meter recording of all salient stations and plant. PROCESS ALARM. Data captured shall be monitored and information generated will be computed to rise the alarm when any of the parameters exceed the normal condition.

INTERLOCKING FEATURE. The system shall be wired for safety interlocking of the operating process as an example when the fibre cyclone airlock trips, the interlocking system will trip the upstream process line equipment such as the screw presses, the cake breaker conveyor etc.

4


SYSTEMS FOR INDIVIDUAL STATIONS.

0.1 STERILISER CONTROL SYSTEM. The system shall be designed to achieve the optimum utilization of steam for the sterilisation process in a continuous and balance mode. The steriliser programmable control system will regulate the sequence for sterilisation of the FFB for process with the objective of conditioning the FFB before the stripping of the fruitlets from the bunches. The system is designed to operate in the following modes :

• Automated operation controlled by PLC • Semi automatic operation by manual activation of pushbuttons. • Manual operation.

The Sterilizer Control System Features are : The system will start with a batch sequencing control where the sterilizer will start in sequence automatically and shall incorporate safety features whereby the steam inlet valves will operate if the following conditions are fulfilled :

• When the sterilizer doors are in closed position and that the safety lock is in placed. • The steam feed to the sterilizer can start on Auto mode or on the ready push button mode and on manual override by manually operating the sterilizer valves. The modulating valves will control the steam inlet valves based on the balanced pressure of the sterilizer, the back pressure vessel and boiler which are linked to Central Control Station via the PLC and network computer. The sterilisation cycle can be set or modified via user- friendly keypad, text and graphic display without interrupting the program or the process. The system shall be flexible and can be expandable to cater for future sterilizer units.

5


0.2 CRUDE OIL DILUTION CONTROL SYSTEM Crude oil mixture does vary in composition and therefore hot water dilution is a means of stabilisation to provide an accurate consistency of the crude oil mixture before the clarification process. The auto dilution control is to cater for the monitoring and regulating the amount of water dilution required for the stabilisation of the crude oil . The aim is to provide a dilution of 50% oil and 50% water plus NOS maintained at 95°C as the set point that is based on a variance of 40-60 % oil and 60-40% water including NOS of between 12 – 16% discharged from the extraction process. The set point of the unit can be adjusted to the operation requirements but over dilution must be avoided for best results. The CODC system consist of :

• Density monitor ( Vibrating reed devise) • Convertor • Pneumatic control proportional valve • Mounting steel frame • Control panel with PLC card. The Crude Oil Dilution Control system shall be linked to Central Control Station via the PLC and network computer.

6


0.3 DEPERICARPER CONTROL SYSTEM. The Depericarper control system shall be designed to achieve an efficient separation of nuts, kernel and fibre in the depericarper winnowing column and further to optimised the recovery of nuts and kernels. The control system is to monitor and maintain a consistent air flow velocity in the separating column irrespective of the volume of the material in the column.

The system will incorporate variable features of :

• Predetermined air velocity required for efficient separation. • The change of volume of material in the column • The number of screw presses in operation The system shall consist of : 01. Programmable Logic Controller (PLC). 02. Pneumatic control actuators and dampers. 03. Sensors for level switches, air flow and recorders. The sensor will measure the air flow and compare it with the set value which will automatically adjust the damper to the operating requirement. The Depericarper Control system shall be linked to Central Control Station via the PLC and network computer.

7


0.4 CRACKED MIXTURE WINNOWING COLUMN CONTROL SYSTEM. The CMWCC system shall be design to effectively monitor, separate and recover the kernel for the mixture. The control system is to monitor and maintain a consistent air flow velocity in the separating column irrespective of the volume of the material in the column.

The system will incorporate variable features of :

• Predetermined air velocity required for efficient separation. • The change of volume of material in the column • The number of screw presses in operation The system shall consist of : A. Programmable Logic Controller (PLC). B. Pneumatic control actuators and dampers. C. Sensors for level switches, air flow and recorders. The sensor will measure the air flow and compare it with the set value which will automatically adjust the damper to the operating requirement. The Cracked mixture winnowing control system shall be linked to Central Control Station via the PLC and network computer.

8


0.5 BACK PRESSURE RECEIVER (BPR) CONTROL SYSTEM. The system shall be designed to achieve the optimum balance of steam from the Boiler, during the sterilisation process and turbine operation in a continuous and balance manner. The system is designed to operate in the following modes :

• Automated operation controlled by PLC • Semi automatic operation by manual activation of pushbuttons. • Manual operation. The features of the system are that when the steam pressure at the back pressure receiver falls below a set point, the makeup valve will open via the reducing valve and regulate the high pressure steam from the boiler and into the back-pressure receiver. The makeup valve will close when the steam pressure at the back-pressure receiver exceeds the set point amount. In the event that the boiler pressure drops below the allowable limit the pressure switch at the upstream will override the makeup valve that will permit the turbine to operate at the cycle of frequency. The Back Pressure Receiver (BPR) control system consist of : I.

Programmable Logic Controller (PLC).

II.

Pneumatic control Valves with turn wheel for manual operation of the valves

III.

Sensors for pressure, temperature and recorders.

The BPR control system shall be linked to Central Control Station via the PLC and network computer.

9


0.6 BOILER COMBUSTION CONTROL ( with the 3 element control ) AND SCRUBBER SYSTEM. The system shall be designed to achieve the optimum utilization of waste solid fuel and the correct amount of air for effective boilers combustion, the generation of steam for the turbine operation, the sterilization operation and processing steam in a continuous and balance co-ordination. The system is designed to operate in the following modes :

• Automated operation controlled by PLC • Semi automatic operation by manual activation of pushbuttons. • Manual operation. The system shall consist of : A. Programmable Logic Controller (PLC). B. Pneumatic control actuators and dampers. C. Sensors for pressure and temperature D. 3 element boiler drum level switches. E. Air flow meter and recorders. F. Control valves. G. Fuel feeder and spreader complete with Variable speed drives. H. Boiler scrubber unit complete with water spraying equipment. The BCCASS control system shall be linked to Central Control Station via the PLC and network computer.

10


11

0.7 SPECIFICATION OF HARDWARE AND SOFTWARE.

The Process Monitoring and Control (PMC) System shall be supplied of proven in operation, rigid components designed specifically for an oil palm mill environment and consist of one or more racks containing modules, interconnecting power and data cables. The Oil Palm Mill environment conditions are : Temperature

27° - 40°C

Humidity

99%

Power

230 / 415 volts 50 Hz

Power Interruption

Operate through a total loss of power for 17.6 msec.

ITEM

DESCRIPTION

TYPE

1

Central Processing Unit (CPU) Server type

Intel PIII

1 unit

2 3

Programmable Logic Controller (PLC) Personal Computer (PC) complete keyboard, 21 monitor and mouse

Intel PIII

5 units 2 units

4

Printer - Colour graphic type

600x1200 pdi

1 unit

5

Modem ( Data / Fax/ Voice )

56 K bps

1 unit

6

Uninterrupted Power Supply (UPS)

2000 VA

1 unit

7

Custom built PMC system software

8

Microsoft Windows

NT Pro

1 lot

9

Microsoft Office

2000 Pro.

1 lot

10

AutoCAD

Ver. 14

1 lot

11

Acrobat Suite

12

Cables to field instruments

Perunding AME / March 1999 Noel Wambeck.

QUANTITY

1 lot

1 lot Bradon

1 lot

THE DEVELOPM ENT OF OIL PALM IN MALAYSIA.

1

THE DEVELOPMENT OF OIL PALM IN MALAYSIA. ACTIVIT IES FOR PALM OIL AND FRACT IONS By Noel Wambeck 2nd September 1997.

General Overview. The Malaysian oil palm based industry has grown to become the second largest foreign exchange earner in the country, next to petroleum and gas. Malaysia today exports about 95 percent of its total production of 9 million mt palm oil in the form of refined and fractionated products whereas the bulk of its palm kernel oil is still being exported in the crude form. Manufacture of higher value added products such as oleochemical and fat products based on palm oil and palm kernel oil is still limited and besides being the largest producer of oil palm, Malaysia is already the largest single exported of total oils & fats, ahead of the United States of America which had been the leader up till now.

Competitive edible oil. The existing high prices of all edible oils indicate the general trend in demand. The Tenera material makes possible in Malaysia yields up to 6 tons of oil per hectare ( 2.5 tons of oil per acre ) on alluvial clay soil and indications are that higher yields may be possible on rich volcanic soils such as those of Papua New Guinea, East Malaysia and Indonesia. The oil palm is by far the highest producer of oil per hectare of any commercial planting or crop.

VEGETABLE OIL YIELD PER HECTARE PER YEAR

Kg.

5000

Kernel

4500

1000

4000 3500 3000 2500 2000

4000

1500 1000 500 0

220

330

Cotton Seeds

Soybean

500

620

Rape Seed Sunflower

740

940

Coconut

Peanut

Kernel / Palm oil

Commodity

In this respect oil palm has an advantage over such competitive annual oil crops as soyabean, rape seed, sunflower, cotton seed, coconut and groundnut.


2

To extend the advantage every measure should be taken to ensure technical development for the production of high quality palm oil. The Malaysian palm oil industry has undergone three distinct phases of growth, each reflecting a progress towards the overall establishment of the palm oil industry. During the first phase there was massive planting of oil palm and construction of Oil Palm & Palm Kernel Mills. This was in response to the encouragement given by the Government in the 1970’s to diversify Malaysia’s agricultural sector. The second phase of growth was in the rapid establishment of a palm oil downstream fractions processing and the establishment of the Oleochemical sector in the 1980’s. In the third phase of development was the joint venture projects undertaken by both, the Government and private sector in palm oil marketing and investment in palm oil refinery processing activities in foreign countries such as China, Vietnam, Egypt, Indonesia, England, etc. Malaysia is in position today to expend its planting activities and have embark on the forth phase of its plan which was launched in the early 1990’s by the establishment of joint venture plantation companies in counties where oil palm can be seen to have been planted, ie. Indonesia, Philippine, South America …. In business and government circles, there is a sense of exhilaration about what has being achieved but the process of de-regulation which started in the early 1990’s has brought about a virtual re-birth of the New Order in the industry and the Government has realized that the private sector is truly the engine of growth in the economy. There is an in-debt desire by the Government and business circles to achieve the aims of the new order but whereas the Government's inclination is for creating a macro economic balance and on the other hand agree to the continued expansion of the private sector's preference to profit in development.

Demand for Palm Oil. As the world population increases the demand and consumption of Edible oil’s will increase and in particular palm oil products to a level above 15.5 kg per capita consumption by the year 2000. The table below shows the actual and projected consumption of oils and fats up to the year 2000. 100 Million 96.0

* 85.5 79.0 67.6 Million MT

*

*

* 50 Million

YEAR POPULATION CONSUMPTION

1985 4.83 ( Billion ) 14.0 kg per capita

1990 5.45 14.5

1995 5.70 15.0

BASED ON UNITED NATIONS ESTIMATED POPULATION GROWTH.

2000 6.20 15.5


3

Review of the marketing palm oil and fractions. The countries with the most need for edible oil, are usually those which are the least able to afford large scale imports. They are also likely to be the same countries least likely to have adequate processing facilities for crude palm oil. In the context of Malaysia's future activities for palm oil and fractions, the marketing of palm stearin represents a special case, as Malaysia increases the amount of Palm Olein placed on the world and its domestic cooking oil market, an inevitable consequence will be the co-production of increasing amounts of palm stearin. Not all of this additional production will be absorbed locally; discovering or creating new overseas markets for the balance, is a priority for the Malaysian marketing organization. Palm Stearin, although ideally food grate material has been placed with some success in those markets, usually serviced by beef and / or mutton tallow. Palm Stearin is a useful source of a completely natural, hard fat component, for such products as compound shortenings, pastry margarine and other products which capitalize on the specific crystallization attributes of palmitic acid. Commercial fatty acids are derived almost entirely from natural fats. The fatty acids are an abundant raw material, produced from a renewable resource, and serve as building blocks for the entire Oleochemical Industry. Historically, the main fats used for the manufacture of fatty acids have been beef tallow, as the source of Palmitic C16 acids and Stearic / Oleic C18 acids, together with coconut oil, the only significant source of lauric C12 acids. Tallow production is a function of red meat consumption and is estimated to be growing at a rate of only 1.5% per year. World population is projected to grow at a rate of 1.6% per year while world palm oil production is expected to grow at a rate of 7.3 % per year. (Oil World.) Palm Stearin and Palm Kernel oil, whose production growths have been out-stripping those of tallow and coconut oil by a wide margin, are equally rich source of these acids. It is to be expected that Palm oil derived inputs will continue to be available at prices attractive relative to those of tallow and coconut oil, and that their use in oleochemical manufacture will also grow. With recent developments in Eastern Europe an expanded market for Palm Oil based material, both for food and technical uses will emerge. Coupled with these regional changes, developments in the oleochemical field, driven by demands for even increasing utilization of renewable resources, mean that fats, oils and their fatty derivatives will be subject to increasing demands in the future; in other words the raw material supply will be available on long term with no effect on the year to year basis.


4

Research & Development. It is evident that a lot has been achieved in the last century for the development and technology in the oil palm industry. Advances in R & D undertaken by the industry in brief, are: < Pioneer strategic marketing technique. < Development of palm oil e-business and e-commerce. < Advanced training programs for managers, planters, technical and process engineers. < Mechanisation in planting, maintenance and harvesting in the plantations. < Higher density planting of palm trees and the cloning of high yield oil palm research. < Biological pest control. ( Owls and Bats ) < New potential use of palm oil in food products and nutrition. E.g. Vitamin research < Use of palm oil for body care products, Biodegradable detergents, engine oil, inks, molecular electronics etc….. < Technical use of oil palm waste in the automobile, plastic & composite material. E.g. Fibre in car sits and mattress, trunk in fibre board, glassy carbon. etc. < New processing equipment and systems including Larger capacity oil palm mills, refineries and processing plants. < Quality product handling, packing and transportation ( ie. Containerization) of palm oil produces. < Better oil palm processing techniques and the use of IT systems, computerization, robotic, automation etc… < The incorporation of operating procedures, equipment, plant and process systems to meet the ecological, hygienic and cleanliness of the plant on par with good food manufacturing industrial plants standards. Palm oil production will be a major factor in 5 years time, but it is today, secondary to the increased production of seed crop oils. The superior quality of CPO and its derivatives are the marketing organisation’s assurance for the future of its product. Cultural and religious practices tend to favour Palm Oil derivatives. complete acceptance for both food and cosmetic applications.

In the Islamic world, it has

The favour which palm oil attracts is likely to grow and every marketing organisation using edible oils and fats will wish to have palm oil and its derivatives available for its products.

The development of Oil Palm continues ……………….. By Noel Wambeck 2nd September 1997.

THE OIL PALM EXTRACTION PROCESS MATCHING WITH TYPE OF FFB. By Noel Wambeck - 25th September 1974.

The oil extraction of palm fruit can be carried out by 3 different methods : a. b. c.

Centrifuge equipment by Leaching or wet process ( water washing ) Piston or discontinuous pressing ( Automatic hydraulic press. ) Continuous pressing ( by single or twin screw press.)

Other methods have been considered and experimented, such as solvent extraction, extraction by saturated steam, by pressing of fruit pulp only, simultaneous extraction of palm and palm kernel oil after crushing the whole fruit and high-pressure critical extraction.

The chart above shows the different methods that have to be applied for the selected fruit with different pulp contents.

THE PROCESS MATCHING WITH TYPE OF FFB.

Page 2.

A DURA cake is for instance, an agglomeration of nuts with fibres in between, whereas a TENERA cake is a fibre mattress with dispersed nuts. The ratio of nuts to fibre or nuts to pulp decides the type of equipment to be used for oil palm milling or extraction process. However, there are not only these ratios which will affect the choice of equipment, process systems and the design of the oil palm mill, but also the fact that pulp and fibre show characteristics that do not appear as long as they mixed with nuts, but become apparent when the continuous phase is made up with fibre and cellular debris. This important feature is the imperviousness of pulp and cake. This phenomenon is generally known as ‘’ OIL WALL “. Cake imperviousness is explained by the clogging up of fibrous mesh by cellular debris and cell clusters.

The introduction of TENERA material, came one of the most important process phases in modern oil palm milling, the extraction of oil from pre-treated digested fruit, the continuous twin screw press.

 25th Sept.1998 Noel Wambeck.

THE PROCESS MATCHING WITH TYPE OF FFB.

Fig.1 Centrifugal type extractor.

Fig.3 UDW - P15 type Twin Screw Press.

Page 3.

Fig.2 The Automatic Hydraulic Type press

OIL PALM EMPTY BUNCH DISPOSAL BY THE INTEGRATED INCINERATION. By Noel Wambeck  22 nd April 1999.

The processing oil palm is one of the most unique self-sufficient processes in Agro-based manufacturing industry, yet the most pollution contributor to the environment. In 1998 about 400 oil palm mills were known to be in operation producing approximately 9.3 million tons of crude palm oil, 15 million tons Empty bunches of unused solid waste and 300 thousand tons of revenue yielding Potash per year in Malaysia.

The salient air pollutants from the oil palm mill process, are :

• •

Smoke and dust from the boiler. Smoke and dust from the incinerator.

The Smoke and dust from the boiler is a subject of another paper. This brief paper will deal with the disposal of empty bunches a solid waste from the process of an oil palm mill. Empty bunch a solid waste product of the Oil Palm Milling process has a high moisture content of approximately 55 – 65% and high in silica content , form 25% of the total weight of Palm Fruit Bunch. The treated Empty bunch are mechanically crushed ( de-watered and de-oiled ) in the process but are rich in major nutrients and contain reasonable amounts of trace elements. When properly incinerated they yield 0.3 to 0.5 % of ash and such ash contents the following average contitutients : • • • •

Potassium 28% Phosphorous 1.2% Calcium 2.3% Magnesium 4%

They have a value when returned to the field after incineration as POTASH for the enrichment of soil. Many new systems for empty bunch disposal other than the incineration process and

EMPTY BUNCH INCINERATION

2

disposal for land application are being tried but no generally accepted system by the industry has yet emerged.

The existing simple design of the incinerator to burn empty bunch is to be phased out and disapproved for use in new mills by DOE due to high air pollution and discomfort to the local Authority, who have to attend to complains of smoke and haze made by inhabitants of the area. The Incinerator which are subjected to shock loads and unstable combustion resulting in high amounts of dust particles in the flue gas emitted to the atmosphere. All efforts to find a solution are being encouraged by DOE, PORIM and the Industry and to some extend, partial results have taken placed in the development of ne w technology in the treatment of effluent and air pollution control. We envisage that the thermal oxidation system, being the direct approach to the problem may be able to solve the hazards and control of the environment in providing a means to reduction of the flue gas discharge of the incinerator. The integrated system proposed is for the empty bunches to be de-watered and where the oil is recovered in the crushing process and than finally the solid waste residue disposed off by thermal oxidation in the incineration process has economical merit when considering the alternative cost for the mulching system.


3

OIL PALM MILL EMPTY BUNCH INCINERATOR WITH DUST COLLECTOR AND ASH REMOVAL SYSTEM.

The Environmental quality ( clean air ) regulation 1978 stipulate the permitted level of solids concentration in gases emitted from solid waste thermal plants to be not more than 0.4 g per cubit meter. Air emissions from oil palm mill incinerators, being mainly gases with particulates such as tar and soot droplets of 20 – 100 microns and a dust load of about 3000 to 4000 mg. / NM3. Incomplete combustion of the incinerator produces dark smoke resulting from burning of empty bunches. The introduction of the proposed system will alter the situation whereby the incinerator shall emit clean smoke in accordance to the DOE standard requirements. Dewater / de-oiled empty bunches are fed into the incinerator chute fitted with smoke trap door. Flue gas from the incinerator furnace with a temperature of approximately 600 deg. C flow through the axial flow votex tube type dust collector that is mounted in line of the flue gas ducting system. The Dust collector is an axial flow centrifugal separation devise used to separate particulate matter from gas streams by centrifugal action. The cooled clean gas is conveyed by the ID fan that blows the exhausted gas to the chimney The system consist of : • Inlet chute


4

• Incinerator furnace complete with steel structure, fire bricks and insulation. • Shaking grate & pneumatic assembly.

• Ash removal conveyor • Dust collecting unit. • Induce draught Fan. ( 30 kw 20,000 m3 / hr 100 mm wg ) • Chimney with ladder and platform ( 22 m ) • Inter-connecting fittings and duct works. • Control , Instrumentation & wiring.

1. Capacity ( dewatered / deoiled )

: 9000 kg Empty bunch per hour

2. Persons to operate

: Two ( 2) for bagging of Potash

3. Power requirement

: 30 kW

4. Estimated cost of system

: RM 900 thousand.

5. Delivery schedule

: 9 months

The above system vendor guarantee an emission at the chimney outlet of less than 400 mg./ NM3 and in accordance to the DOE allowed standard.

FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics

1

FAO / Chapter 4: African oil palm. Feeding Pigs in the tropics –

1998 ORLAC / FAO p 255 - 267

The African oil palm, Elaeis guineensis (Jacq.), is characterized by its vertical trunk and the feathery nature of its leaves. Every year, 20 to 25 new leaves, called "fronds", develop in continuous whorls at the apex of the trunk. The fruit bunches develop between the trunk and the base of the new fronds. Although new plantations start to bear at three years, generally the first commercial crop requires between five and six years and continues to produce for 25-30 years, or until the palms grow too high to be harvested. Once a plantation reaches full production, a new inflorescence is produced every 15 days. It weighs between 15 and 20 kg and can contain up to 1500 individual palm fruits of between 8 to 10 grammes each. The individual fruits consist of the following four parts: a pericarp, a thin outer skin, which upon ripening changes from brown to orange; a mesocarp, a layer of fibrous material, which surrounds the nut; an endocarp or hard inner shell (nut) to protect the seed or kernel, and the seed (kernel).

PRODUCTION AND TECHNOLOGICAL PROCESS Production The African oil palm, which yields about 20t/ha/yr of fresh fruit bunches (Bolaños, 1986; Espinal, 1986: Garza, 1986), is capable of producing between three to five t/ha of crude oil from the fruit (mesocarp) and an additional 0.6 to 1.0 t/ha from the palm kernels (Ocampo et al., 1990a). Its productivity is influenced by climate, soil type, genetic factors, maturity, rainfall, fertilization and the harvest period. Mijares (1985) has stated that for optimum annual production the African oil palm requires a minimum of 1600 mm of well distributed precipitation, a relative humidity no less than 75%, a minimum and maximum temperature of between 17 and 28 C., a total of 2000 hours of light and a soil depth of 100 centimetres. There are two distinct types of oil palm: the "dura" and the "pisifera". The basic difference has to do with the inner nut. The nut of the dura type of oil palm has a thick and hard shell while the pisifera type has a small kernel, with no shell, but rather surrounded by a matrix of fibre. When a pisifera male is crossed with a dura female, a "tenera" type of fruit is produced; its shell is of intermediate thickness. Currently, it is this type of oil palm that is most widely grown in plantations. The African oil palm produces two main commercial products: raw or crude oil, approximately 22% of the weight of the fresh fruit bunch, and the palm nuts which represent 4-6%. When the nut is processed, it yields palm kernel oil and palm kernel meal. The two main industrial residues, the oil-rich fibrous residue and the palm nut shells, are used as sources of energy to run the factory. The empty fruit bunch is normally incinerated and the ash is returned to the plantation as fertilizer.


2

The initial interest in the African oil palm as a feed resource for pigs was in the extracted and nonextracted palm kernel meal. This was because when nuts of the oil palm were first brought to Europe from Africa as ship's ballast, they were jettisoned into the sea before the ships were reloaded. However, soon the oil millers recognized their value and began processing them for oil in order to supplement copra oil in the manufacture of soap, paints and for other industrial applications (Collingwood, 1958). The meal was used as a major protein supplement for pigs and cattle until soya bean meal became commercially available. Oil palm cultivation started at the beginning of this century (Devendra, 1977). By 1980, production of oil had risen to slightly more than five million tons and, by 1992, annual world production reached thirteen million tons. As seen in Table 4.1, the primary areas of production are Southeast Asia, followed by the west coast of Africa and Latin America. Currently, Malaysia produces half the world's production of palm oil, followed by Indonesia and Nigeria. Presently, the fourth and fastest growing producer of palm oil is Colombia, where production has more than quadrupled in 12 years. In that country, (Ocampo et al., 1990b) has reported that the average annual production of fruit is 15 t/ha of which raw oil represents slightly more than three tons.

Table 4.1. Production of African palm oil: world, regional and top four countries, tonnes (FAO, 1992). Geographical area

1979-81

1992

World

5 046 308

12 725 346

Africa

1 337 913

1 835 888

Nigeria

666 667

900 000

Latin America

190 780

753 251

Colombia

70 500

304 496

Asia + Oceania

3 502 851

10 136 207

Indonesia

720 826

3 162 228

Malaysia

2 528 947

6 373 461


3

TECHNOLOGICAL PROCESS The technological process by which the oil is extracted from the palm fruit consists of the following steps; note that the fresh fruit bunch includes the stem and the adhering individual palm fruits. Reception: where sand, dirt and gravel are separated from the fresh fruit bunch. Sterilization: necessary to rapidly inactivate certain enzymes which tend to reduce the quality of the oil by increasing the amount of free fatty acids. In addition, this process contributes to the mechanical separation of the fruit from the stem and to the rupture of the oil cells within the mesocarp. Oil extraction: An oil press, into which hot water is injected, is used to separate the crude oil from the solid or fibrous-like material containing the nuts. The crude oil is then pumped to the purification section. Figure 4.1 shows the quantities of the principal components of the oil palm based on 100 tons of the fresh fruit bunch. The nuts are treated and cracked to extract the kernel which contains approximately 50% oil. The oil-rich fibrous residue, traditionally used as a source of energy to run the plant, has a caloric value superior to 18.8 MJ/kg. This is largely due to the residual oil, calculated as between 8 and 18 percent (Brezing, 1986; Solano, 1986; Wambeck, 1990). Similar to the proposal for livestock diversification within the sugar industry (FAO, 1988), the integration of pig production within the oil palm industry might introduce a certain degree of flexibility in the entire enterprise, resulting in: an increase in the productive capacity of the plant, particularly during the period of maximum industrial yield; a significant reduction in plant maintenance; increased employment opportunities related to the utilization of the different byproducts for livestock feeding; the production of animal wastes and thereby organic fertilizer for the plantations and, perhaps most importantly, an overall reduction in the amount and/or concentration of the industrial effluents which threaten the contamination of the surrounding ecosystem (Ocampo, personal communication). As a follow-up to these observations, the following information summarizes the average daily amount of products and sub-products produced in a oil palm processing plant of 125 t/day and 10t/hour (Table 4.2). One factor that might require attention if derivatives from the African oil palm present new opportunities to be used as energy feed resources for pigs is the cyclic nature of its production. Bolaños (1986) has reported that in Costa Rica the average monthly yield of fresh fruit bunch can vary from 6% during the dry winter months to 10 or 12% during the rainy, summer season. In that country, the annual yield of the fresh fruit bunch is 20 t/ha and with the oil-rich fibrous residue representing 12% of this amount, this could mean the production of 0.3 t/ha of oil-rich fibrous residue during the wet season as opposed to only 0.15 t/ha during the dry or winter season.


4

Table 4.2. Potential feed resources in an African oil palm processing plant, air-dry basis. mt / day

mt / year

mt / ha /yr

Fresh Fruit Bunch

125

25000

20

Palm oil

25

5000

4

Palm kernel meal

2.5

1000

0.8

Empty Fruit Stem

40

8000

6.4

Ash (from stem)

0.6

125

0.1

Effluent

80

16000

13

Oil-rich fibrous residue

13.7

2750

2.2

Shell (from kernel)

12

2500

2

Ash (from shell)

0.6

16000

13

Source: Brezing (1986) However, if sugar cane, generally harvested only in the dry season, was integrated into this feeding system, the two energy feed resources might complement each other. The data in Tables 4.6 and 4.7 tend to support this interesting concept.

USE FOR PIGS As earlier mentioned, one of the first references to the use of derivatives of the oil palm for pigs referred to the use of the extracted and non-extracted palm kernel meal in complete, dry rations for growing/finishing pigs. Most pig farmers contended that the gritty texture of the meal affected consumption, and therefore performance. However, palm kernel meal continued to be used for many years as a replacement for scarce cereals, mainly because it was available, relatively inexpensive and highly nutritious (Crowther, 1916, cited by Collingwood, 1958). In the 1930s, when a commercial process for extracting oil from the soya bean was perfected and it was seen that a higher quality animal protein supplement (soya bean meal), would be commercially available, the byproduct from the extraction of the oil from the kernel, palm kernel meal, was destined for ruminants (PNI, 1990). Currently, palm kernel meal represents about one per cent of world trade in oil seed meals. Table 4.3 gives the chemical composition of several oil palm byproducts.


5

Table 4.3. Chemical composition of African oil palm byproducts. Component

Oil-rich fibrous residue a (% DM)

Dry sludge a (% DM)

Fresh centrifuged sludge solids b (% AD)

Dry matter

86.2

90.3d

15.0-20.8

Crude protein

4.0

9.6

3.1-3.4

Crude fibre

36.4

11.5

3.0-5.2

Ether extract

21.0

21.3

2.4-3.5

Ash

9.0

11.1

2.8-3.4

Nitrogen free extract

29.6

46.5

-

Calcium

0.31

0.28

-

Phosphorous

0.13

0.26

-

Gross energy (MJ/kg)

18.1

18.7

-

Sources: a Devendra (1977); b Ong (1982) To date, derivatives of the African oil palm have shown potential feeding value for pigs in conventional, cereal-based rations: the de-hydrated palm oil mill effluent and the fresh centrifuged sludge solids have been studied both by Devendra et al. (1981) and by Ong (1982), and the whole palm nut by Flores (1989) and Chavez (1990). However, recent interest has focused on the use of primary products and by-products of the African oil palm as a partial or complete energy source replacement in swine rations, particularly where the protein is offered separately, in the form of a restricted amount of a high-quality supplement. It has been shown that the oil-rich fibrous residue (ORFR), normally used as a source of energy to run the factory, can also furnish the necessary energy for the pig (Ocampo et al., 1990a, 1990b). As exemplified in following sections, the successful experimental use of the crude oil (Ocampo, 1994b), combinations of the crude oil and sugar cane juice (Ngoan and Sarría, 1994) and even the whole fresh palm fruit (Ocampo, 1994a, b) further emphasize the fact that other oil palm byproducts can serve to completely replace cereals in rations for swine.

Crude (raw) palm oil Crude palm oil has traditionally been used up to about 5% in dry diets for pigs in a manner similar to molasses: to improve palatability, to reduce dustiness, to supply vitamins and to improve the texture of rations prior to pelleting (Devendra, 1977; Hutagalung and Mahyudin, 1981). The oil contains approximately 80% of unsaturated fatty acids (Table 4.4) and 10% of linoleic acid, an essential fatty acid required at a dietary level of 0.1% for pigs (NRC, 1988).


6

Table 4.4. Composition of the fatty acids in the oil from fruit and kernel of the African oil palm (% AD). Fatty acids

Palm oil

Palm kernel oil

Myristic

1.6

-

Palmitic

45.3

7.8

Stearic

5.1

2.5

Oleic

38.7

12.6

Linoleic

9.2

1.7

Lauric

-

15.7

Capric

-

47.3

Caprilic

-

4.1

Caprolic

-

4.3

Source:Pardo and Moreno (1971), cited by Ocampo et al. (1990b) The addition of from 2 to 10% of crude palm oil in the diets of growing pigs was studied by Fetuga et al. (1975) who found no significant effect on performance. When palm oil was compared to groundnut oil, lard or beef tallow, there were no significant growth differences, however, increasing the level of palm oil in the diet slightly increased the percentage of lean cuts (Babatunde et al., 1971, 1974, cited by Devendra, 1977). This same observation was reported by Balogun et al. (1983) cited by Ngoan and Sarría (1994) who noted that the addition of 30, 64 or 97 g/kg of palm oil to the ration increasingly improved muscle development. In Malaysia, it was reported that six groups of pigs from 16 to 81 kg were fed iso-nitrogenous diets containing different levels of palm oil, from 5 to 30 percent. Although the results were reported as not significant, the average daily gains obtained on the experimental diets were 10% superior compared to that of the cereal control; in addition, where palm oil was included, the conversions were improved by an average of 17 percent (Devendra and Hew, cited by Devendra, 1977). Recently, Ocampo (1994b) showed that palm oil and a source of protein, either fortified soya bean meal and rice polishings, or combinations of fortified soya bean meal/fresh Azolla and rice polishings, might provide an interesting feeding system for the production of pigs in the tropics, particularly if the pigs were integrated with the palm plantations. Pigs of an initial average liveweight of 30 kg were fed diets in which 10, 20 and 30% of the protein from fortified soya meal was replaced by fresh Azolla filiculoides, a water fern (Table 4.5).


7

Table 4.5. Composition of diets using crude palm oil, rice polishings and fresh Azolla filiculoides as a replacement for the protein in soya bean meal (kg AD/day). % replacement of protein in soya bean meal by Azolla growing phase: 30-60 kg

finishing phase: 60-90 kg

0

10

20

30

0

10

20

30

Protein supplement

0.50

0.45

0.40

0.35

0.50

0.45

0.40

0.35

Rice polishings

0.10

0.10

0.10

0.10

0.15

0.15

0.15

0.15

Crude palm oil

0.50

0.50

0.50

0.50

0.80

0.80

0.80

0.80

Fresh Azolla

0.0

1.74

3.48

5.21

0.0

1.74

3.48

5.21

Source: Ocampo (1994b); * contains: soya bean meal, 86%; dicalcium phosphate, 10%; salt, 2% and a vitamin/mineral premix, 2% In the morning, the pigs were fed the daily ration of protein supplement and rice polishings, and half the daily allowance of oil and Azolla. In the afternoon, they received the remaining portion of Azolla and oil. The average daily gain (g) and dry matter feed conversion for the control treatment, without Azolla, and the groups where 10, 20 and 30% of the protein in soya bean meal was replaced by that of Azolla were: 526, 2.10; 561, 1.98; 535, 2.00 and 452, 2.20, respectively. In the same publication reference was made to a commercial piggery that used the following "palm oil feeding system". For that, a total of 170 growing/finishing pigs, in 4 groups, were fed daily one kilogramme of protein supplement and 0.5 kg of crude palm oil. The protein supplement contained: 450 g soya bean meal, 374 g palm kernel meal, 150 g rice polishings, 20 g dicalcium phosphate and 3 g each of salt and a vitamin/mineral premix. The initial average liveweight (kg), average daily gain (g) and dry matter feed conversion for each of the 4 groups were 32.0, 722, 1.80; 24.2, 628, 2.00; 25.8, 524, 2.40 and 26.0, 464, 2.80, respectively. In spite of the fact that the diet was the same for all groups, no explanation was offered for the observed variation in performance, inferring, perhaps, that the "palm oil feeding system" requires further refinement. Palm oil has also been studied as either a partial or complete energy source replacement for pigs, also fed fresh sugar cane juice and a restricted protein supplement. The oil replaced 25, 50, 75 and 100% of the energy in cane juice in both the growing and finishing phases of this most interesting and unique feeding system to study the potential integration of sugar cane and the African oil palm as dry/wetseason energy feed resource alternatives for pig production in the tropics (Table 4.6). The average daily gain was not significantly affected by treatment in the growing phase, however, during the finishing phase, gains were significantly lowered when palm oil replaced 75 and 100% of the juice (Table 4.7). In both phases, the average daily feed intake was lower for those pigs fed palm oil which according to the authors, might have been related to its low palatability or high energy content. They reported a digestible energy value for palm oil and sugar cane juice in pigs as 37.5 and 14.5 MJ/kg of DM, respectively. Feed conversions were significantly improved by the addition of palm oil. Carcass measurements were not affected.


8

Table 4.6. Replacement of the energy in sugar cane juice (SCJ) by that in palm oil (PO) for growing/finishing pigs (kg AD/day). * Liveweight, kg

<30

40

50

60

70

80

90

>90

100 SCJ

6.0

7.5

8.5

9.5

10.5

11.5

13.0

>14

75 PO/25 SCJ

4.5/.1

6.0/.15

7.0/.2

8.0/.2

9.0/.25

10/.25

11.0/.3

12.0/.3

50 PO/50 SCJ

3.0/.2

4.0/.3

4.5/.35

5.0/.4

5.5/.45

6.0/.5

6.5/.55

7.0/.6

25 PO/75 SCJ

1.5/.3

2.0/.45

2.5/.5

2.5/.6

3.0/.65

3.0/.75

3.5/.8

3.5/.9

100 PO

0.4

0.6

0.7

0.8

0.9

1.0

1.1

1.2

Source: Ngoan and Sarría (1994); * plus 500 g/d of a 40% crude protein supplement Table 4.7. Performance of finishing pigs (50-90 kg) fed a restricted protein supplement (RPS)* with energy from sugar cane juice (SCJ) increasingly replaced by palm oil (PO). 100 SCJ

75 SCJ 25 PO

50 SCJ 50 PO

25 SCJ 75 PO

100 PO

Initial liveweight, kg

51.1

50.1

48.9

50.2

45.2

Final liveweight, kg

99.5

93.7

91.2

89.8

84.2

ADG, g

768

693

672

628

615

DM feed intake, kg/d

3.05

2.32

2.14

1.77

0.92

DM feed conversion

3.97

3.35

3.18

2.82

1.47

Source: Ngoan and Sarría (1994); Ngoan (1994); *The RPS was 500g/day of 91% soya bean meal, 6% minerals, 1% salt and 2% of a vitamin premix Oil-rich fibrous residue (ORFR) The residue which remains after the crude oil is separated from the sterilized fruit by means of a screwpress, represents approximately 12 to 15% of the fresh fruit bunch. The chemical composition of this residue is presented in Table 4.3. This material, reported to contain from 63% (Wambeck, 1990) to 70 or 85% dry matter (Solano, 1986) still contains from 6 to 8% of residual oil. It is of a deep yellowtangerine color, with a fibrous consistency, sweetish smell and greasy-like texture (Ocampo et al., 1990a). It is used as the main source of energy to run the plant. ORFR has been studied as a complete replacement for the energy derived from cereals. Diets in which sorghum was the sole energy source, or where 25, 50, 75 or 100% of the energy from sorghum was replaced by this residue, were offered ad libitum to pigs from 20 to 90 kg, also fed a restricted amount of fortified soya bean meal to meet the current, daily, NRC (1988) requirement for crude protein (Ocampo et al., 1990a).


9

Preliminary results showed that pigs can grow extremely well on this type of feeding system. Where ORFR replaced 100% of the energy supplied by sorghum, the average liveweight growth was 639 g/day. The pigs consumed a daily average of 0.75 kg of protein supplement together with 2.32 kg of oilrich fibrous residue (Table 4.8). Table 4.8. Oil-rich fibrous residue as a partial or complete replacement for the energy in sorghum for pigs (20-90 kg). 0% ORFR

25% ORFR

50% ORFR

75% ORFR

100%ORFR *


19.8

20.6

21.7

22.2

22.6


89.7

91.1

92.5

92.6

94.2

Days to finish

133

119

112

112

112

ADG, g

525

592

632

629

639


2.1

2.1

2.2

2.3

2.8

DM feed conversion

4.00

3.59

3.49

3.75

4.47

Source:Ocampo et al. (1990a); * fed 0.55, 0.64 and 0.9 kg/day of fortified soya bean meal (see Table 4.5) during the 3 phases of: weaners, growers and finishers, respectively Following this initial trial, Ocampo et al. (1990b), attempted to prove an observation of Sarría et al. (1990), that when pigs are fed a restricted amount of a high quality protein supplement, particularly when the required levels of essential amino acids are supplied by soya bean meal, lower amounts of total crude protein are feasible. This amounts to approximately 200 g/day and can be provided in 500 g/day of a 40% protein, soya bean meal-based supplement. The concept had been first developed through feeding systems based on sugar cane juice (see Chapter 3). For this study, the basic diet was ORFR, fed ad libitum. Three groups of growing/finishing pigs were fed constant amounts (high, medium or low) of fortified soya bean meal throughout the entire experimental period. A fourth group, the control, received different amounts of fortified soya bean meal (high, medium and low) to correspond with the needs of each of the three developmental phases: weaners, growers and finishers (Table 4.9). The authors concluded that the two groups that received the least amount of protein exhibited an inferior performance but gave the highest economic returns. A more recent trial studied the effect of supplementing this unusual feeding system (ad libitum ORFR and a restricted amount of protein supplement) with methionine and/or B-complex vitamins (Ocampo, 1992). None of the experimental treatments produced significant results.


10

Table 4.9. Different amounts of restricted protein supplement (RPS) * and free-choice oil-rich fibrous residue for pigs from 22 to 90 kg. Control **

High kg/d)


22.7

22.8

22.8

22.1


90.2

90.0

90.4

90.3

Days to finish

121

126

124

135

ADG, g

558

532

545

505

AD feed intake, kg/d: RPS

0.70

0.64

0.57

0.50

ORFR 2.33

2.44

2.22

2.56

4.80

5.20

4.60

5.40

DM feed conversion

(0.64 Medium (0.57 kg/d Low ) kg/d)

(0.50

Source: Ocampo et al. (1990b); * see Table 4.5; ** 0.50, 0.64 and 0.90 kg/day of RPS fed during three consecutive 40-day periods: weaners, growers and finishers.

Palm oil mill effluent and palm oil sludge The palm oil mill effluent, the final liquid discharge after extracting the oil from the fresh fruit bunch, contains soil particles, residual oils and suspended solids but only 5% of dry matter. While Wambeck (1990) stated that it represents 0.5 t/t of fresh fruit and can cause serious problems to the entire surrounding ecosystem, Brezing (1986) went one step further and estimated that a processing plant with a capacity of 10 tons fresh fruit per hour would require a water treatment plant comparable to that required by a population of half a million inhabitants! Palm oil sludge is the material that remains after decanting the palm oil mill effluent (Devendra et al., 1981). It can be either filter-pressed, before dried and ground to produce dehydrated palm oil mill effluent, or centrifuged in the wet state, after having undergone anaerobic, thermophilic and acidophilic fermentation. In the latter case, the product is known as fresh centrifuged sludge solids of 15 to 20% dry matter and may be dehydrated to form dry centrifuged sludge solids of between 94 and 97% dry matter (Table 4.3). The composition of the essential amino acids in palm oil sludge and palm kernel meal is given in Table 4.10. Although, there is insufficient information concerning the amino acid composition of different African oil palm products, data from Table 4.10 suggest that lysine is not present in an appropriate proportion in the protein.


11

Table 4.10. Composition of essential amino acids in palm oil sludge and palm kernel meal (% CP). Amino acid

Palm sludge

Arginine

0.19

Histidine

oil Palm meal

kernel

Amino acid

Palm sludge

oil Palm meal

2.20

Methionine+cystine

0.28

1.98

0.14

0.27

Phenylalanine+ tyrosine

0.77

1.28

Isoleucine

0.35

0.63

Threonine

0.34

0.54

Leucine

0.60

1.05

Tryptophan

0.12

0.17

Lysine

0.21

0.56

Valine

0.36

0.9

kernel

Source: Devendra (1977) Fresh centrifuged sludge solids have been incorporated in a concentrate ration daily at a level of 14% total dry matter for pigs from 30 to 90 kilogrammes. The average daily gain and dry matter feed conversion for the maize control group and one of the experimental treatments containing fresh centrifuged sludge solids was: 700g, 3.36 and 650g and 3.83, respectively (Ong, 1982). Dehydrated palm oil mill effluent has been incorporated up to 20% in dry rations for growing/finishing pigs; however, with increasing inclusion of dehydrated palm oil mill effluent, performance was poorer and carcass fat deposition increased (Table 4.11). Table 4.11. The use of dehydrated palm oil mill effluent for growing/finishing pigs (19-92 kg). 0%

5%

10%

15%

20%

Maize, ground

78.9

74.9

70.4

65.9

61.4

Soya bean meal

13.5

12.5

12.0

11.5

11.0

Dehydrated palm oil mill effluent

-

5.0

10.0

15.0

20.0

ADG, g

730

700

690

720

650

AD feed intake, kg/d

2.24

2.30

2.34

2.38

2.34

AD feed conversion

3.04

3.31

3.38

3.34

3.60

Fat, % of carcass

16.7

17.9

20.4

19.9

19.5

Source:Ong (1982); all diets contained. 5.5% fishmeal, 1.95% minerals and vitamins and 0.15% methionine


12

There have been numerous attempts to convert palm oil mill effluent into a viable animal feed resource; however, most methods have been discontinued due to the large initial capital investment required, and particularly to the cost of fuel for dehydration. In Malaysia, one method used to convert fresh palm oil mill effluent into a potential feedstuff involved concentration by centrifugation or decantation, followed by absorption on other dry feeds like tapioca chips, grass meal or palm kernel meal. The absorption process can be repeated several times before final dehydration (Webb, Hutagalung and Cheam, 1976, cited by Devendra et al., 1981). Perhaps, one idea would be to promote the use of the fresh centrifuged sludge solids (15-20% dry matter) for finishing pigs which, compared to younger animals, have a greater capacity to effectively use larger amounts of more liquid feeds. To date, apparently, this material has only been used in dry, concentrate rations (Ong, 1982). This approach might require supplementation to increase the crude protein content to that of a cereal, as well as some molasses to improve palatability. It would have to be fed immediately, preferably near the factory in order to avoid transportation of a product that contains 80% of water. Interestingly, this approach was indicated by Devendra et al. (1981) for feeding sheep and cattle (Devendra, 1992); he referred to the use of this residual product alone, or combined with oil-rich fibrous residue. Perhaps, this same recommendation might be applied to feeding pigs. In Ghana, oil palm slurry (sludge) has been used to replace 15, 20, 25 and 30% of maize in ad libitum diets for growing pigs to 70 kg. The control group was fed a maize-based diet; performance was not affected by the use of sludge. It was emphasized that with the exception of the loin-eye area, carcass measurements were improved when pigs were offered the slurry-containing feed (Abu et al., 1984). The use of unconventional feeds for pigs in Ghana was also studied by Hertrampf (1988), who reported using oil palm sludge in place of maize at a level of from 15 to 30 percent. An increase in the daily feed intake and the average daily gain, in addition to a significant reduction in feed costs, was reported.

Palm kernel meal The palm kernel represents 5% of the weight of the fresh fruit bunch; it contains approximately 50% oil (Beltrán, 1986). The meal is produced by extracting the oil from the kernel within the palm nut. The resultant meal, sometimes also referred to as "palm kernel cake", can contain from 12 to 23% of crude protein depending upon the efficiency of the process used to extract the oil (Table 4.12) . As expressed earlier, the first oil palm by-product reportedly used for feeding pigs was the extracted and non-extracted palm kernel meal. It was first used in Europe as a substitute for wheat bran in rations for growing/finishing pigs. Currently, because of its poor palatability and high fibre content, it is more commonly fed to ruminants where it produces a hard, white carcass fat in meat animals and a saturated fatty acid profile in the milk of lactating animals (PNI, 1990). In Nigeria, palm kernel meal was used for pigs but it ranked lowest in protein quality compared to other local protein sources and produced a loss in weight (Fetuga et al., 1974, cited by Devendra, 1977).


13

However, in Colombia, good results have been reported (Ocampo, 1994b) when almost 40% of palm kernel meal was used in the form of a restricted protein supplement that also contained soya bean meal. Correct storage, to reduce the risk of mould and the production of alfa-toxins, was emphasized. The chemical composition and digestibility of palm kernel meal is shown in Table 4.12. Table 4.12. Chemical composition/digestibility of palm kernel meal for pigs (%). average composition

digestibility

Dry matter

90

-

Crude protein

16

60

Crude fibre

16

36


48

77

Ether extract

10

25

Source: PNI (1990)

Whole fresh palm fruit The chemical composition of the flesh (mesocarp) which surrounds the palm nut, and interior kernel, is presented in Table 4.13. The whole fresh palm fruit constitutes a potential energy feed resource for the small-scale pig producer without access to factory produced palm oil derivatives, such as, crude oil or oil-rich fibrous residue. In an experiment to determine the performance of pigs from 27 to 90 kg, fed twice daily with a restricted amount of protein, and whole fresh palm fruit as a partial or complete replacement for sorghum, Ocampo (1994a) surprisingly found that, apart from consuming easily the fibrous material adjuring to the nut, the pigs often ate the entire fruit including the palm nut and the interior kernel. It was observed that first they ate the fibrous material surrounding various nuts, accumulated the nuts, then proceeded to crack and extract the kernel within the nuts. One interesting observation was that when the fresh fruit was stored for more than seven days, palatability, and therefore voluntary consumption, was noticeably affected.


14

Table 4.13. The chemical composition of the pulp (mesocarp) and kernel of the fruit of the African oil palm (% DM). pulp

kernel

Crude protein

9.26

11.9

Crude fibre

25.5

31.6


31.3

25.9

Ether extract

28.6

26.9

Ash

5.4

2.5

Source: Ocampo (1994b) Although the data in Table 4.14 show that best growth was obtained when only 25% of the fresh fruit was used in place of sorghum, it was emphasized that best economic gains were when 75 or 100% of the fruit was used. In a second trial, Ocampo (1994c) used 4 groups to study the optimum amount of rice polishings as a source of carbohydrate for growing/finishing pigs, also fed a restricted protein supplement (500 g/day) and whole, unprocessed African oil palm fruit, fed ad libitum. The amount of rice polishings offered during the growing phase (20-60 kg) was 100, 200, 300 and 400 g/day, and during the finishing phase (60-90 kg), 150, 250, 350 and 450 g/day. During the entire experimental period, the average consumption of the fresh fruit was 1.1, 1.1, 1.0 and 0.9 kg AD/day; the average liveweights were: 485, 515, 492 and 497 g/day and dry matter conversions were: 3.20, 3.20, 3.30 and 3.30, respectively. Reportedly, the most economic levels of rice polishings were 200 g/day during the growing phase and 250 g/day during the finishing phase. Table 4.14. Whole fresh palm fruit (WFPF) as a partial or complete replacement for sorghum in diets for pigs from 27-90 kg. % WFPF

25%

50%

75%

100%


28.1

27.0

26.7

27.0


89.3

85.7

90.2

85.7

Days to finish

98

98

126

126

1.30

0.86

0.20

0.00

0.54

0.97

1.43

1.53

ADG, g

625

598

503

466


2.02

1.94

1.68

1.59

DM feed conversion

3.20

3.20

3.30

3.40

AD feed * intake, kg/d: sorghum oil palm fruit

Source: Ocampo (1994a); *also fed 500 g/d of protein supplement : soya bean meal, 97.6%; dicalcium phosphate, 2%; salt, 0.3% and vitamin/mineral premix, 0.3 percent


15

For the low income farmer in the tropics, the possibility to fatten a pig with one's own fresh palm fruit, and perhaps purchase only 60 kg of a high-quality protein supplement, or even use some rice polishings, is definitely an example of an alternative feeding system for pigs. This same author also emphasized that if a feeding system based on the whole fruit was used, there would be approximately 100 g/day of protein availabe to the pig via the kernel, and that this fact merited even further study. Obviously, the African oil palm has definite potential as a feed resource for pigs in the tropics. Perhaps, its utilization might be improved if more basic information related to its nutritional value was available.

References Abu, A.A., Okai, D.B. and Tuah, A.K. 1984. Oil palm slurry (OPS) as a partial replacement for maize in the diets of growing-finishing pigs. Nutrition Reports International 30 (1): 121-127. Bolaños, M.A. 1986. La palma aceitera en Costa Rica. En: IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 23-25. Beltrán, C. 1986. Requisitos, Calidades y Usos del Palmiste. En: IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 145-146. Brezing, D. 1986. Subproductos de la Palma Africana en Plantas de Beneficio Primario: El Tratamiento de Efluentes. En: IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC FAO p 151-160. Chavez, J.M. 1990. Full fat african palm kernel nuts as energy source for weaned pigs from 5 to 10 weeks of age. Ing. Agr. Thesis, Panamerican School of Agriculture, Honduras pp 68. Collingwood, J.G. 1958. Palm kernel meal. In: Processed Plant Protein Foodstuffs Ed: A. M. Altschul, Academic Press, New York pp 995. Devendra, C. 1977. Utilization of Feedingstffs from the Oil Palm. In: Proc. Symp. Feedingstuffs for Livestock in South East Asia p 116-131. Devendra, C. 1992. Non-conventional Feed Resources in Asia and the Pacific: Strategies for Expanding Utilisation at the Small Farm Level. 4th edition International Development Research Centre, Sinapore, FAO Regional Animal Production and Health Commission for Asia and the Pacific, Bangkok.


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Devendra, C., Yeong, S.W. and Ong, H.K. 1981. The Potential Value of Palm Oil Mill Effluent (POME) as a Feed Resource for Farm Animals in Malaysia. Proc. of National Workshop on Oil Palm By-Product Utilization December 14-15 Kuala Lumpur. Espinal, M. 1986. Informe de la Coordinación Nacional Técnica en Palma Africana. En: IV Mesa Redonda Latinoameric ana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 31-34. FAO 1988. Sugarcane as Feed. FAO Animal Production and Health Paper No. 72 FAO Rome pp 319. FAO 1992. Production Yearbook. FAO, Roma . Fetuga, B.L., Babatunde, G.M. and Oyenuga, U.L. 1975. The effect of varying the level of palm oil in a constant high protein diet on performance and carcass characteristics of the growing pig. Ef. Afr. Agric. Ror. J. 40: 264-270. Flores, R. 1989. Full fat african palm kernel nuts as energy source for growing pigs. Ing. Agr. Thesis, Panamerican School of Agriculture, Honduras, pp 60. Garza, E.F. 1986. Situación actual de la palma aceitera en México. En: IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 35-36. Hutagalung, R.I. and Mahyudin, M. 1981. Feeds for animals from the oil palm. Proc. Inter. Conf. on Oil Palm in Agriculture in the Eighties. p 609-622. Hertrampf, J. 1988. Unconventional feedstuffs for livestock. Muhle + Mischfuttertechnik 125(9):108109. Mijares, N.R. 1985. Aspectos ecológicos de la palma africana de aceite. En:Potential Productivo de la Palma Africana en Venezuela, Facultad Agropecuaria, Maracay, Venezuela p 17-40. Ngoan, L.D. 1994. The use of African palm (Elaeis guineensis) oil as energy source for pigs. Swedish University of Agricultural Sciences. M. Sc. Thesis. Uppsala. Ngoan, L. D. and Sarria, P. 1994. Effect on growth performance of replacing sugar cane juice energy with African palm oil in diets for growing and finishing pigs. Conferencia presentada en el II Seminario Internacional "Sistemas Agrarios Sostenibles para el Desarrollo Rural en el Tr¾pico" y IV Seminario Nacional "Alternativas de Producci¾n Animal con Recursos Tropicales" Univ. Tecnologica de los Llanos Orientales, Villavecencio, Colombia. NRC 1988. Nutrient Requirement of Domestic Animals. Nutrient Requirement of Swine. 8th ed. National Academy Press, Washington, D.C.. Ocampo, A., Lozano, E. and Reyes, E. 1990a. Utilización de la cachaza de palma africana como fuente de energía en el levante, desarrollo y ceba de cerdos. Livest. Res. Rur. Dev. 2(1): 43-50.


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Ocampo, A., Castro, C. and Alfonso, L. 1990b Determination del nivel óptimo de proteína al utilizar cachaza de palma africana como fuente de energía en raciones para cerdos de engorde. Livest. Res. Rur. Dev. 2(2):67-76. Ocampo, A. 1992. Oil-rich Fibrous Residue from African Oil Palm as Basal Diet of Pigs; Effects of Supplementation with Methionine. Livest. Res. Rur. Dev. 4(2):55-59. Ocampo, A. 1994a Utilizacion del fruto de palma Africana como fuente de energia con niveles restringidos de proteina en la alimentacion de cerdos de engorde. Livest. Res. Rur. Dev. 6(1):1-7. Ocampo, A. 1994b. Raw palm oil as the energy source in pig fattening die ts and Azolla filiculoides as a substitute for soya bean meal. Livest. Res. Rur. Dev. 6 (1): 8-17. Ocampo, A. 1994c. Efecto del nivel de pulidura de arroz en una dieta basada en el fruto entero de palma africana para el engorde de cerdos. Livest. Res. Rur. Dev. 6(2): (18Kb). Ong, H.K. 1982. The Use of Palm Oil Sludge Solids in Pig Feeding. (Paper presented at First Asian Australasian Animal Science Congress, Sept. 2-5th, 1980) Animal Production and Health in the Tropics pp307-311. PNI (Pig News and Information) 1990. Palm Kernel Meal. 11(4) pp 11. Sarría, P., Solano, A. and Preston, T.R. 1990. Utilización de jugo de caña y cachaza panelera en la alimentación de cerdos. Livest. Res. Rur. Dev. 2(2): 92-99. Solano, R. 1986. Principales subproductos de las plantas extractoras de aceite. En IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 161-167 . Wambeck, N. 1990. La experiencia Malasiana en el desarrollo de la industria de la palma aceitera con la tecnologia avanzada de Estechnik. In: VI Mesa Redonda Latinoamerica sobre Palma Aceitera San José, Costa Rica 12-16 marzo 1990 ORLAC/FAO p 255-267

File:// 1990 ORLAC/FAO p 255 – 267 : 11. FAO Feeding pigs.doc Sep.1999/ NW.

PREPARATION OF AN OIL PALM MILL PROJECT. By Noel Wambeck ( Revised 30th October 1997 )

INTRODUCTION. Once a project have been initiated, and the decision has been taken to go ahead with a project, the management team will need the totally committed backing of the investors and that the degree of confidence and faith in the project can only come from a thoroughly prepared project study and appraisal. To the investor, it is important that they should generate a good cash flow as early as possible through well planned but speedy development, income arising from early plantings or from revenues, exploitation of natural resources, eg. Sales of timber from land preparation or from tree crops during replanting cycles. Timely provision of infrastructure including roads of access for development inputs and for produce evacuation, water supply, housing and offices, power, communications with adequate processing facilities and logistics for points of export, shall all be part of the preparation of project. Although a lot have been said and written on the subject of “ PROJECT STUDY “ the basic phases involved from project inception to project implementation are as follows: OVERALL APPROACH The project work will be divided into 4 main stages and later, further sub-divided in accordance with the yet-to-be-determined Phases of development. Stage 1 is described in detail and the subsequent stages are described in general since these stages depend on the Stage 1 findings.

We recommend that these work stages be as follows:-

Stage 1

:

Initial assessment of the proposed project site and preparation of a Feasibility Study Report.

Stage 2

:

Compilation of additional information and basic design for submission to Local Authority and approvals.

Stage 3

:

Detailed Project Design and Drawings, Tender Documents to Tender Evaluation and Contract Document.

Stage 4

:

Implementation and Supervision of the project.

PREPARATION OF AN OIL PALM MILL PROJECT.

2

STAGE 1. PROPOSED SITE SELECTION AND FEASIBILITY STUDY REPORT

The essential elements in Stage 1 are as follows :1.1

Discussions with the Client’s project members regarding their objectives for the proposed oil palm plantation project in the short, medium and long-term requirements. The discussions would include marketing strategy and determine whether Market Research or an Economic Study would be required at Stage 2.

1.2

The project team to inspect the proposed project site identified by the client. The site visit will include locating possible sites for the operation command base, plantation, nursery area, processing facilities and infrastructure such as, roads water source, waste water effluent discharge point, housing area, utility requirements for estate, such as treated water and electrical power etc…..

1.3.1

Liaise with local Authority in order to take into account any restrictions the Authority may have on the establishment and operation of the proposed project.

1.4

Assess location of plantation site with regards to the communication and transportation logistics.

1.5

Consider the following items to determine the advantages and disadvantages of each site.

1.6

Access to site during land preparation, construction of infrastructure, planting and during operation.

1.7

Location of each site relative to the shoreline and access roads.

1.8

Assess the size of each site for the proposed project.

1.9

Determine the capacity and zoning for expansion at each site.

1.10

Estimate the ground level at each site relative to the tide levels and assess the need for flood prevention including reclamation and shoreline protection.

1.11

Investigate the Environmental effects, including effluent disposal. Determine the requirements for the Environmental Impact Assessment which will be carried out at Stage 2.

1.12

Assess location of sites with regards to source for construction materials.

1.13

Investigate the requirements of Local Government and of other Approval Authorities for the construction of a project

1.14

Preliminary investigation into source of processing equipment and in particular, we would explore the possibility of using locally manufactured equipment.

1.15

Study the existing site investigation details. Determine the extent of further investigation and topographic and surveys required at each site. The Investigation and Surveys would be carried out at Stage 2.


3

1.16

Determine in principle the foundations required for the buildings and structures based on Existing soil information.

1.17

Identify whether Market Research and Economic Studies are required.

1.18

Prepare order-of-cost budget estimates for the preferred site, including approximate comparisons with the other site if appropriate. The budget estimate would include the cost of soil investigation, Earthworks, Reclamation, Infrastructure, Services, and the Processing Plant. In addition the estimate shall nclude i the approximate costs for upgrading existing roads if required.

1.19

The results of the study will be presented in a report highlighting the advantages and disadvantages of each site recommending which site should be selected for Stage 2 investigations.

This stage is intended to provide an overview of the main issues, and does not become involved in detail. The project site selection, assessment and feasibility study will make use of as much data that is available at the time, including charts or surveys indicating general topography and preliminary knowledge of soil conditions from the existing site investigation.

This data will be augmented by data obtained in the field during the site visit. The study will take into account the Client’s requirements in preliminary terms and will aim to confirm that the desired facilities within the development plan can be efficiently located on the proposed site. During Stage 1 it is expected that several discussions will take place in order to establish the medium and long-term requirements of the project. It will be identified whether there is a clash between the short-term needs of the Client and their long-term objectives. This will be assessed in Stage 2. The deliverables in Stage 1 would be presented as a document recording the data used and the risks involved pending later detailed surveys and soils investigations. It will include layouts at small scale with descriptive text and preliminary order-of-cost budget estimates. The cost estimates for the site will be based on the existing soil investigation at the site.


4

STAGE 2. COMPILATION OF ADDITIONAL INFORMATION AND BASIC PROJECT DESIGNS FOR SUBMISSION TO LOCAL AUTHORITIES AND APPROVALS.

The commencement of Stage 2 services would be dependent on written instructions from the Client to proceed. The activity and work components of Stage 2 would generally be as follows :-

2.1

Establish Short, Medium and Long-Term Requirements of the Plant

Based on the outline concept layout selected from the Stage 1 work, establish in precise terms by discussion, the detailed objectives and strategies required to achieve the Client’s business plan for the short, medium and long-term.

2.2

Review and Acquisition of Project Design Data.

At a detailed level, and in close cooperation with Operational Staff, considerable amounts of data will need to be reviewed, or if not available, acquired. Such data would include size of the proposed oil palm plantation, utility requirements including capacities and distribution round the processing plants. In addition, if it is found during Stage 1 that further studies such as Market Research and Economic Studies, these studies would also be carried out, during Stage 2. On completion of the required on-site surveys, investigations and the desktop studies, all such data would be entered into a Project Design Specification Document, which is updated and reissued to the Client as and when required. This document forms the basis for the recording of agreed data, and provides the Client with a permanent means of easy reference in the future. Stage 2 would also include an Environmental Assessment Report. The assessment would include a study into the present and future needs of the project against the present and expected future legislation. Included in the study will be required data and forms for the applications and approvals by Local Authorities.

2.3

Definition of the Agreed Project Scheme.

Based on the reviews of data, the acquisition of essential new data, and detailed discussions on proposed project scheme to meet business plan objectives. These Study report taken together with the Basic Design Specification document define the Agreed Scheme, from which on the instructions of the Client, detailed engineering would commence.


STAGE 3.

5

DETAILED DESIGN, TENDERS AND CONTRACT DOCUMENT.

The activity and work components of Stage 3 would generally be as follows: -

3.1

Detailed Engineering Design

Based on the Agreed Scheme layouts and associated drawings and on the contents of the Design Specification, taken in conjunction with the results of surveys and any necessary studies, detailed engineering calculations would be prepared together with sufficient general arrangement and detail drawings required to allow selected Contractors to submit concise tenders for each package of work. The project team would make use of our comprehensive in-house computer facilities for specialist design tasks and by means of our AutoCAD system for the production of almost all of the drawings. In addition to their own broad experience, the members of our Project Team would be able to call upon the specialized knowledge of experts within industry whenever required. The Consultant would also provide the Quality Management function ensuring both that the correct management and control functions are in place, and carry out key design checking procedures, which include the all important design reviews.

3.2

Technical Specifications

In conjunction with the preparation of detailed engineering design, full specification for materials and construction of the works and procurement of the plant will be provided, taking into account the latest thinking for the most efficient operation of a processing plant and for low maintenance. Emphasis will be placed on the use of practical materials and construction requirements including where possible the elimination of overly complex details to ensure easy maintenance and satisfactory durable structures suitable for the harsh environment.

3.3

Contract Documents for Tender Issue

On a contract by contract basis, these documents would generally comprise: • • • • • •

Tender Notice Instructions to tenderers Form or Forms of Contract, to be discussed and agreed with the Client taking into account Client specific requirements, project constraints, and international practice to include a reasonable allocation of responsibility between the contracting parties. Technical specifications, discussed above Any necessary schedules (e.g. of suppliers) Bills of Quantities

Client and site specific conditions would generally be dealt with under Part 2 of the General Conditions of Contract.


3.4

6

Tender Evaluation

The tender period would vary depending on the scale and complexity of the work. While there is always a desire to shorten tender periods in order to expedite the project, we would recommend the allowance of an adequate time to ensure that tenderer’s preparations are not rushed so that sufficient attention can be paid by them to the details of the work and the competitiveness of their bids. During the tender period members of our team would be available to answer tenderers queries and where appropriate, would undertake the issue of clarification notices to all tenderers. Upon receipt of tenders we would carry out a full evaluation and prepare a report for review by the Client. It is likely that this would take the form of a preliminary report on the tender submissions to be followed by meetings with those submitting preferred bids. The report would then be updated and include recommendations for the award of contract. In its final form the report would include: • • • •

A tender summary and breakdown of principal items for all tenderers More detailed price breakdown for the leading tender Notes of Meetings and Negotiations Comments on tenderers’ submissions and approach to the project

If alternative designs are submitted by tenderers these would be examined and assessed and, if necessary, discussed with the tenderer concerned. The final report would contain an assessment of such alternatives and recommendations as to whether or not this would be acceptable. The deliverables for Stage 3 would comprise initially a full set of tender documents for Client confirmation and, after receipt of final approval, a master set of tender documents for issue to all selected tenderers by the Client. The Consultant will provide assistance with the pre-selection of tenderers early on in Stage 3. In addition, the Client would receive detailed reports on the assessment of each of the tenders.


STAGE 4.

7

CONSTRUCTION STAGE, SITE SUPERVISION

The commencement of Stage 4 services would be dependant on written instructions form the Client to proceed. The activity and work components of the Stage 4 services would generally be as follows:-

4.1

Preparation of Contract Documents etc.

Upon confirmation of selection of Contractor by the Client we will prepare two sets of original contract documents including: • • • • • • • • • •

Form of tender Form of Contract Form of Bond Conditions of Contract Specifications Bills of Quantities/Summary of Prices as priced by the successful tenderer Schedule of Drawings Contract Drawings Technical Schedules Agreed notes of meetings, relevant correspondence and notices of clarification pertaining to the acceptance of the tender

These will be issued to the selected Contractor and then to the representative of the Client for signature and following this 3 certified copies would be prepared. The two originals will then be returned to the contract parties for retention. At the same time as the original contract documents are being prepared and processed, full sets of construction drawings, specifications and other documents will be prepared and issued to the Contractor.

4.2

Project Management Services

We would confirm that the nominated Project Manager, or equivalent alternative, is fully used to managing multi-disciplinary projects.

4.3

Pre-construction Meeting

We would hold a pre-construction meeting prior to the commencement of all the contracts. The purpose of this meeting would be to review with the successful Contractor the requirements of the Tender Documents to develop a list of information that he is required to provide as stipulated in the Tender Documents and to solicit from him, his programme of activities as required by the Tender Documents.


4.4

8

Review and Approve Contractor’s Programme

For each separate contract, the control programme submitted by the Contractor indicating his proposed timing and phasing of various operations will be reviewed. Following that review, advice will be given on any changes deemed necessary in the programme proposed by the Contractor. It is also necessary to monitor carefully the Contractor’s control programme to check his progress and compare actual progress with the programmed progress. From time to time as required by circumstances, the Contractor will be required to update his programme. The Client will be advised of any developments threatening the delay of completion and recommendations will be made on any actions necessary to facilitate timely completion. The construction programme must be prepared by the Contractors using CPM techniques and contain the key elements and timetables for the completion of his work. We will review the programmes and any subsequent changes deemed appropriate.

4.5

Establish Project Files, Prepare Monthly Reports and Attend Job Meetings.

Essential to any project is the establishment of a project filing system such that shop drawings, contract correspondence, daily reports, monthly reports, time schedules, etc., can be readily retrieved from files and utilized for the purpose of administering the Project. A computerised record file consistent with our needs as the Consultants and the Client is established. Monthly progress reports will be prepared for submission to the Client. These monthly progress reports will report on all phases of the work in all disciplines, on delivery schedules, on the development of programme updates, identify particular construction problems or quality control problems during the course of the month and will further include the degree of physical completion and expenditures under each contract. As the project construction proceeds actual costs may vary from the previously estimated costs due to changes in quantities of work and materials, or due to unforeseen circumstances. A close control over these costs and their affects on the overall project costs will be undertaken so that strict budgetary control is exercised. On a regular basis, formal progress meetings will be held with the Contractor. An agenda will be prepared with input from the Contractor and the Client.

We will prepare the final minutes of the meeting. It is important to the orderly progress of the job that progress-meeting minutes are maintained accurately.


4.6

9

Recommend Tests on Materials and Equipment

We propose that laboratory, shop, and mill tests on materials and equipment are incorporated in the Project. As appropriate, our sit e staff or representatives will observe the actual performance of such tests.

4.7

Review Test Reports and Witness Tests

At various points in the progress of the project it will be required by the Contract Documents that specific materials or equipment be tested and certificates be issued for their performance. The objective of such tests is to ensure that the Contractor complies with the requirements of the Contract Documents and that the materials and equipment meet the appropriate contract specifications. Where witness tests are required for specific pieces of equipment, we would be able to provide the necessary manpower to witness the tests as required by the Contract Documents. Under the provision of the Contract Documents, the Contractor will also be required to submit certification of materials testing and certified test results ensuing from such tests. This system will be monitored and such certificates and tests reports reviewed and approved and provided as historical records.

4.8

Review and Approval of Fabrication Drawings

The Contractor will be required to submit fabrication drawings for approval prior to construction and installation of specific materials and equipment items. These fabrication drawings will be reviewed in accordance with the procedures laid down in the Quantity Plan. It is also critical to the conduct of the Project that fabrication drawing review be expedited and that the Contractors’ submittals are as accurate as possible. Poor quality fabrication drawings frequently result in increases in engineering costs as well as frustrations to the Client. Detailed construction drawings, fabrication and erection drawings, charts, and any other related proposals required to be submitted by the Contractor, will also be checked for adequacy and compliance with the terms and conditions of the Contract Documents. Comments concerning required revision of the Contractor’s submittals will be prepared in writing for approval of the Client prior to presentation to the Contractor. Copies of Contractor’s submittals, comments and the finally accepted documents will be maintained in permanent files until completion and final acceptance of all construction undertaken by each Contractor.


10

Archiving will then be carried out in accordance with the Quality Plan with the transfer of appropriate document records to the Client as agreed.

4.9

Prepare Diaries and Records

During the execution of the work, we will prepare detailed daily diaries and records concerning the work, site, ground and weather conditions, material quantities delivered to the job sites, and related information. Copies of such records will be provided to the client upon request. These diaries and records are invaluable in cases of later disputes with Contractors and possible arbitration or legal action.

4.10

Evaluation of Extra Payment Claims

Contractors or suppliers may make claims from time to time for extra payment. Any such simple claims will be reviewed and evaluated impartially and professionally by the site staff and recommendations made to the client with respect to the admissibility of a claim. Where a claim is considered allowable and approved by the client, a variation order will be initiated for the client approval.

4.11

Variation Orde rs

Throughout the progress of the Project, certain changes by virtue of site conditions may be required. Changes may be required to plans and / or specifications due to site conditions being at variance with those assumed during design. We are obliged to advise the Client of any such changes and variation orders deemed necessary. When such conditions arise we will prepare the appropriate variation orders with the backup information and explanation as to the need and reason and submit it to the client for approval. Each variation order will accompanied by an analysis concerning the appropriate amount by which payments to the Contractor are to be increased or decreased as a result of the changes to the work included in the variation order.

4.12

Contractor’s Progress Payment

Progress payments by the Client will be made to the Contractor on a schedule basis throughout the job, based on payment certificates, which we will issue as Engineer. We will maintain records sufficient to review and check the progress payment request in detail. Monthly project photographic records will also be required, as these are often a substantial aid in identifying project conditions and degree of project completion.


4.13

11

Final Inspection

After the contracts are virtually completed, we will undertake final inspection during the period of each contract and advise the Contractor of any additional work required. On completion of the remedial work, we will issue a final certificate for each contract.

4.14

Supervise Commissioning and Handing Over

We will provide qualified personnel to supervise and monitor all required final tests and commissioning to be performed by the Contractor and to make appropriate recommendations. The relevant Government agencies and Authorities shall be notified in advance by the Contractor for final inspection and approval by such authorities. Supervision of the no load trial run of the plant and ancillary shall be carried out by the Consultant after which the Client will be notified to arrange for raw material for process to be delivered to the plant. A pre-commissioning meeting shall be conducted between the Contractor, Plant Manager, Supervisors, key personnel and Consultant on the procedure, safety requirements and expectations. It is suggested that the operators and / or other selected personnel of the Client, who will later be responsible for the operations of the new plant, should be in attendance during the final acceptance testing. This approach will familiarize those operators with the new systems. Following completion of the final tests and commissioning, a final report will be submitted to the Client.

4.15

As-Built Drawings and Documents

During the course of construction a record set of the contract drawings for each contract will be maintained and marked up by the Contractor and agreed by the Resident Engineer to show ‘as built’ work. This is particularly important where approved changes may have been made to the contract drawings so that their true location in the field is properly recorded. On completion of the construction contracts, the ‘as-built’ modifications will be recorded on a master set of reproducible AutoCAD drawings (reduced and full size) and 3 ½ inch diskettes which will be supplied by the Contrac tor and submitted to the Client as a permanent record of the asconstructed works. The appropriate specification, vendor’s data, spare parts lists and similar aspects will accompany the ‘as built’ drawings.


4.16

12

Operation and Maintenance Manuals and Training

All suppliers of machinery and equipment will be contractually bound to provide Manuals of Instructions to facilitate satisfactory operation and maintenance of mechanical and electrical and other equipment. The manuals will be compiled by the Contractor into bound documents, each of which explains the operational and maintenance programmes for each piece of equipment installed. The Client will then have easy reference to the methodology and requirements for operating and maintaining the equipment under their supervision. The Consultant shall advise and assist the Client in the recruitment of personnel. The on-site commissioning engineer will provide operation of machinery and plant, quality control and maintenance schedules, and prior and during the commissioning period short courses and training of personnel on the process systems.

4.17

End of Maintenance Period

A final inspection of the works will be carried out at the end of the maintenance period; corrective action list(s) will be prepared and submitted to the Contractor. The final completion certificate will be issued a completion of defect rectification.

4.18

WORK PROGRAMME

Stage 1 : Site Selection and Feasibility Study work is the starting point from which clear project definition emerges, it is appropriate at this very early stage of the Project to concentrate only on the work required to achieve completion of Stage 1. The Site Selection and Feasibility Study should be completed in final draft form within 6 weeks from the commencement of the initial site selection visit.

Salient notes of the size of plantation with the corresponding basic data and project cost of Oil Palm Mills are enclosed.

 Noel Wambeck / Reprint June1999.

MATRIX FOR OIL PALM MILL PROJECT - DESIGN CAPACITY, COST ESTIMATES, BASIC DATA AND OPERATING REQUIREMENTS. APPLICABLE TO COUNTIES WITH AMOUNTS SHOWN IN ITS CURRENCY BELOW :

ITEM

Details

Design Capacity MT Fruit Bunches / HOUR

Basic Data for Project Planning

DATE :

5

10

20

30

20/40

45

30/60

45/90

60 / 120

BASED ON MALAYSIAN TENERA MATERIAL WITH 25 MT FFB / HA. 25% OIL CONTENT & OER AT 22% CPO 5% PK.

1 1.1

PLANTATION FRESH FRUIT BUNCH ( 25 mt / Ha )

ha mt / year

2 2.1 2.2 2.3

MILL CAPACITY Operating on 24 hours per day Operating on 20 hours per day Operating on 16 hours per day

mt / hr mt / hr mt / hr

3 3.1 3.2

PRODUCTION Production of CPO per Year Production of PK per Year

mt / 22% mt / 5%

4 4.1 4.2 4.3

HUMAN RESOURCES Management & Staff Manpower requirements Total manpower

persons persons / per shift persons / 3 shifts

5 5.1 5.2 5.3 5.4 5.5 5.6

OTHER REQUIREMENTS Water requirements Electrical power requirements Land required Mill & Appurtenance Effluent Ponds Project time schedule

m3 / hour KW hectares ha ha months

6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11

CAPITAL COST Land Preliminary/ Soil Invest./ Survey/ Prof. Fee Infrastructure / Earth Works & Piling Civil & Structure with Buildings Proprietary Equipment Mechanical & PI Electrical works Effluent treatment system Lab & Workshop equipment Vehicles Staff Quarters TOTAL for Malaysia

RM RM RM RM RM RM RM RM RM RM RM RM

7 7.1 7.2 7.3 7.4

COUNTRIES West Africa / South America India / Sri Lanka Indonesia Papau New Guinea

USD 3.8 India Rs.11.5 Indonesian Rp.2300 PNG Kina 2.8

Capacity mt/hr

1,000 25,000

2,000 50,000

4,000 100,000

5,000 125,000

7,000 175,000

8,000 200,000

10,000 250,000

15,000 375,000

20,000 500,000

3.99 4.79 5.99

7.99 9.58 11.98

15.97 19.17 23.96

19.97 23.96 29.95

27.95 33.54 41.93

31.94 38.33 47.92

39.93 47.92 59.90

59.90 71.88 89.84

79.86 95.83 119.79

5,500 1,250

11,000 2,500

22,000 5,000

27,500 6,250

38,500 8,750

44,000 10,000

55,000 12,500

82,500 18,750

110,000 25,000

3 12 39

3 24 75

3 28 87

6 30 96

9 34 111

9 36 117

9 42 135

9 50 159

9 56 177

10 150

20 300

40 600

60 900

80 1000

90 1125

120 1500

180 2,250

240 3,000

2 2 16

2 2 18

6 6 20

6 6 20

8 8 22

8 8 22

8 8 24

Client

Client

300,000 450,000 1,000,000 2,200,000 1,000,000 500,000 200,000 200,000 150,000 Not required 6,000,000

Client

550,000 900,000 2,000,000 3,150,000 2,500,000 900,000 500,000 300,000 200,000 Not required 11,000,000

Client

650,000 1,600,000 3,000,000 6,000,000 5,000,000 1,200,000 900,000 300,000 350,000 2,000,000 21,000,000

Client

800,000 1,800,000 3,600,000 7,200,000 6,900,000 1,400,000 1,200,000 300,000 400,000 2,400,000 26,000,000

5

10

20

30

2,052,632 69,000,000 15,870,000,000 2,785,714.29

3,763,158 126,500,000 29,095,000,000 5,107,142.86

7,184,211 241,500,000 55,545,000,000 9,750,000.00

8,894,737 299,000,000 68,770,000,000 12,071,428.57

Client 900,000 2,000,000 4,400,000 7,900,000 7,200,000 1,500,000 1,600,000 300,000 400,000 2,800,000 29,000,000

20/40 9,921,053 333,500,000 76,705,000,000 13,464,285.71

Client

1,100,000 2,250,000 4,950,000 8,600,000 7,700,000 1,800,000 1,800,000 400,000 400,000 3,000,000 32,000,000

45 10,947,368 368,000,000 84,640,000,000 14,857,142.86

1,300,000 2,400,000 6,600,000 9,500,000 8,800,000 2,100,000 2,000,000 400,000 500,000 3,400,000 37,000,000

30/60 12,657,895 425,500,000 97,865,000,000 17,178,571.43

10 10 24

Client

12 10 24

Client 1,600,000 2,700,000 7,700,000 11,100,000 9,300,000 2,900,000 2,400,000 400,000 500,000 3,900,000 42,500,000

45/90 14,539,474 488,750,000 112,412,500,000 19,732,142.86

1,800,000 3,600,000 8,800,000 12,900,000 10,800,000 3,300,000 3,400,000 400,000 500,000 4,500,000 50,000,000

60/120 17,105,263 575,000,000 132,250,000,000 23,214,285.71

Noel Wambeck 26th March 1999 revised.

5/13/00

Perunding AME / MaY 99 / NW.

PROJECT MANAGER'S CHECK LIST

DATE ; PROJECT NO.

PROJECT :

PROJECT MANAGER:

Project Deivery : ……………………………………………. Months Completion Date : ………………………………………………. 199……. ITEM

TASK IN BRIEF

A

Design stage - Preliminaries

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Master list of Machinery & Appurtenance Preliminary layout Engineer's Cost Estimates Project Report Drawing List Layout review & approval by client Proposal for Effluent control & system DOE site approval State Authority approval MIDA application ( Industrial manufacturing Licence ) PORLA application ( for Palm Oil projects ) DOE writen approval Fire Department Chieft Electrical Inspector Indah water approval Local town board approval for buildings Other

B

Preparation of Drawings & Documents

18 19 20 21 22 23 24 25 26

Clearance of all applications Pre-qualification of Contractors Soil investigation tender Proprietary equipment tender Earth works tender Civil & Structural works tender Mechanical & PI works tender Electrical works tender Other

C

Tender & Award Stage

27 28 29 30 31 32 33 34 35 36

Tender notice ads in local news / by invitation Tender acknowledgement Evaluation report Letter of acceptance Preparation of Contract Proformance bonds / guarantees Insurance certificate Prepare monthy reports to client / PORLA OR MIDA Certify claims by Contractors Other

STATUS

ACTION BY

TARGET

COMPLETION

DATE

DATE

COMMENTS

D

Construction Stage

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Confirm taking over of site by contractor Check Contractors quarters and facilities at site Check bench marks and setting out of project sites Check all safety requirements & sign display at site Inspection of fabrication works at contractor's site Conduct pre-delivery meeting with proprietary supplies Check delivery schedules JKJ approval to commence installation of machinery & Plant Inspection of site works Conduct site meetings Certify works at site Issue variation instruction Prepare monthy reports to client / PORLA OR MIDA Certify claims by Contractors Other

E

Commissioning Stage

52 53 54 55 56 57 58

64 65 66 67 68

Check all machinery, equipment and plant installation, fittings etc. Call for CEI inspection & JKJ hydrostatic test of pressure vessels Conduct hydrostatic test & setting of safety valves Check drying out of Boilers & start up proceedures Loading of tanks with water to check for leakage & stabilisation Setting of switch gear, earthfault etc. & test power supply Check all piping & valves position, connections, supports & blowing out of steam pipes Check all lubrication requirements Fire & safety requirements & sign board displays Conduct pre-commissioning meeting with client, supplies & contractors Check all raw material, manpower and utility requirements Notice by letter to client, contractors, insurance company and authorities for confimation of commissioning date Conduct & supervice commissioning Chech and adjust speeds of machinery, fans & conveyors Conduct capacity test with control of performance Conduct training of machinery operators Follow up defective works by contractor

F

Closing of Project

69 70 71 72 73

Submit commissioning report & certify hand over cetificate Submit machinery parts & service manuals Collect & submit "as built" drawings Wind up all contracts Release all retention funds

59 60 61 62 63

STATUS

ACTION BY

TARGET

COMPLETION

DATE

DATE

COMMENTS

PROJECT MONTHLY REPORT

1

PROJECT MONTHLY REPORT PROPOSED CONSTRUCTION OF ………………………….

FOR ( Client ) ………………………………………………………………………………………………… …………………………………………………………………………………………………

(For the month of November 1998)

Prepared by :


2

The Contract

The Employer:

The Employer’s Representative:

The Contractor:

Essential Terms Agreed: 1. Contract Sum :

RM Malaysian Ringgit :

2. Contract Sum Analysis :

To be provided by the contractor

3. Revised Contract Period :

4. Liquidated and Ascertained Damages :

RM ………… per calendar day.


3

INDEX

1.0

General

2.0

Progress against Schedule - Site progress - Manpower - Imported items - Submission - Next month schedule

3.0

Monetary report - Progress payment - Variation orders - Day works - Others

4.0

Information Requested - from authorities - from the employer - from the contractor

5.0

Important issues that might give rise to Contractual dispute in due course.

6.0

Progress photographs

7.0

Project Manager’s recommendations

8.0

Monthly Report submitted by Contractor 8.1 Contract Agreement : 8.2 Meetings & Site visit : 8.3 Works Completed : 8.4 Works Outstanding : 8.5 Pending Information :

OIL PALM MILL DESIGN BASIS F OR A 45 – 90 MT F F B P ER HOUR

The information herein contains strategies, trade secrets, intellectual properties and other confidential information and the protection of its secrecy is critical to the future financial well-being of Perunding AME. Accordingly, this document is provided on the conditions of confidentiality and non-disclosure and parties to whom this document is supplied by the document, acknowledge and agree to respect the sensitivity and exclusivity of the information, affirm that the document and its contents are confidential; and further, agree to hold and treat it in strictest confidence, not permit, directly or indirectly, the disclosure of the information contained herein to third parties, and if so required by Perunding AME to return the document without any photocopies or other duplications being made.

SPECIFIC GRAVITY

SPECIFIC GRAVITIES AND DENSITIES OF OIL PALM COMPONENTS & SUBSTANCE USED IN THE CALCULATION IN THE DESIGN BASIS SHEETS. ITEM / COMPONENTS / MATERIAL OR SUBSTANCE

Ash Bunch Cracked mixture Crude Palm Oil Diluted crude oil Fibre Fresh Fruit Bunch Fruitlets Palm Kernel Oil Palm Nuts Palm Olein Palm Stearin Press expelled cake Pure water without air at 30degC Shell Sludge Sterilized Fruit Vegetable oils Water at 4 deg.C max

Specific Gravity

Bulk Density Average weight

SG

mt / m3

0.550 0.628 0.535 0.8927 0.890 0.257 0.580 0.640 0.892 0.653 0.9015 0.8865 0.550 0.994 0.650 0.899 0.640 0.945 1

0.437 0.550 0.653 0.893 0.900 0.350 0.480 0.680 0.892 0.653 0.902 0.880 0.650 0.994 0.750 0.900 0.660 0.950 1

DESIGN OF LOADING RAMP ITEM : PROJECT:

OIL PALM MILL

CLIENT: POWER

230/415V 50Hz

CODE :

DATE:

Steel

Input data by:

Pressure

Nil

1st Ph

Mill Capacity Minimum Storage Period Capacity of each cage

90

mt FFB/hr hr Tonnes FFB

12 7

Bulk Density Of FFB Capacity Per Door Of Loading Ramp Number of loading ramps / hoppers Loading Ramp Slab: Assume Average storage Operating period Choose number of loading doors Number of doors required

2nd Ph

45

kg/m3 Tonnes 24 Nr. m m m hr/day doors per bay 48 Nr.

480 15 12 n/a n/a 0.45 24 2 24

Length Width depth

CALCULATE Total storage required Storage in the ramp / hopper Storage on slab Storage in cages Nr.of cages required

540

(Minimum)

Number of Loading Ramps with Hoppers

180 0 360 51

1,080 360 0 720 103

tonnes tonnes tonnes tonnes Nos

12

24

Nr.

Page 1 of 1

16-Jun-99 NW

Perunding AME Consulting Engineers

GIVEN DATA LOADING RAMP & HOPPERS

DESIGN BASIS 1.02

DESIGN OF CAGE TRANSFER CARRIAGE PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

DESIGN BASIS

ITEM :

1.4 16-Jun-99

CODE:

BS2654

DATE:

Steel

ST 37

Input data by:

Pressure

Nil


GIVEN DATA

CAGE TRANSFER CARRIAGE Mill Capacity Tranfer cycle time Capacity of each cage CONSIDERATION Design for final phase

1st Ph

2nd Ph

45

90

mt FFB/hr min tonnes FFB

90

mt / FFB per hour

9 7

90

CALCULATE Transfer capacity required Nr.of cages required per transfer Number of transfer capacity

6.43 0.96

12.86 1.93

2

2

Page 1 of 1

cages/hr

cages per transfer

NW

DESIGN OF FFB STERILIZER PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

DESIGN BASIS

ITEM :

2.2 16-Jun-99

CODE:

BS2654

DATE:

Steel

ST 37

Input data by:

Pressure

3.16 Bar.g


GIVEN DATA FFB STERILIZER Mill Capacity Capacity of each cage Nr.of cages per steriliser Cycle time

2nd Ph

1st Ph 45

90 7

7

7 120

mt FFB/hr tonnes FFB cages minutes

CALCULATE Nr.of steriliser required Nr.of units to be provided

1.84 2

Page 1 of 1

4

3.67 Nos units

NW

DESIGN OF FFB CAGE TIPPLER

DESIGN BASIS

ITEM :

3.1 16-Jun-99

PROJECT: OIL PALM MILL

CODE:

BS2654

DATE:

CLIENT:

Steel

ST 37

Input data by:

Pressure

Nil


Power

230/415 V 50 Hz

GIVEN DATA CAGE TIPPLER Mill Capacity Capacity of each cage Nr.of Tippler

1st Ph

2nd Ph

45

90 7

1

mt FFB/hr tonnes FFB

2

CALCULATE Nr.of cages required to be tippled Time taken per tippling cage ACCEPTABLE

6

13 9.33

YES

Page 1 of 1

per hour minutes

NW

PERUNDING AME - Consulting Engineers

DESIGN OF FRUIT ELEVATOR (45MT /HR ) PROJECT:

OIL PALM MILL

CODE:

CLIENT: PowerPower

DESIGN BASIS

Steel 230/415 V 50 Hz

ITEM :

4.1

DATE:

16-Jun-99

Input data by:

Pressure

Nil

NW


GIVEN DATA Mill Capacity MATERIAL BULK DENSITY CAPACITY, TF/ Material Ratio VERTICAL HEIGHT INCLINATION SPROCKET C/C SPROCKET TEETH SPROCKET PCD SPROCKET REV SPEED BUCKET SPACING CHAIN PITCH BUCKET THICKNESS

FRUIT ELEVATOR mt 45 mt/HR Sterilized Fruit 3 pf 640 kg/m M r H α t c

30 100% 14 60 15 12 0.2964 33.12 30.84 0.75 150 3

m C m T mm rpm m/min m mm mm 3 7200 kg/m

S z l t ps

STEEL DENSITY

mt/HR

o

CALCULATE MASS FLOW NO.OF BUCKETS WEIGHT OF material per bucket

Mf=rxMx1000

NET VOLUME OF BUCKET CHOOSE BUCKET SIZE:

Vb=Qf/pf

29,700 kg/hr 41 bucket/min 12 kg/bucket 3 0.0188 m /bucket

n=S/z Qf=Mf/(60*n)

width depth length

a d b

0.25 m 0.25 m 0.70 m 3

Vb=1/2xaxdxb

VOLUME OF BUCKET

0.021875 m 2

2 0.5

-3

WEIGHT OF BUCKET

wb=[ad+2b({a/2} +d ) ]tpsx1.1x10

10.78 kg

WEIGHT OF MATERIAL

Wm=Mfxc/(60xS)

240.8 kg

NO.OF BUCKET ON LOADED STRAND

Nb=c/z

WEIGHT OF MATERIAL PER BUCKET

wm=Wm/Nb

12.0 kg

DREDGING PULL

F1=20.12 x wm/z

323 kg

ESTIMATED WEIGHT OF BUCKET+CHAIN

Wb=wbx4xNb

863 kg

PRELIM CHAIN PULL

F2=(Wm+F1)f1+Wbxf1/2

995 kg

MIN.BREAKING STRENGTH

f1=

1.0

fs=

10

20

F3=F2xfs

Page 1 of 2

9,950 kg

86%


FINAL CHAIN PULL

( Renold conveyor chain booklet )

Choose: Chain: Pitch Strength: Weight:

150 mm 13,636 kg 11.68 kg/m

Total weight of chain, Total weight of bucket

Wc=wb x Nb

350 kg 431 kg

Total weight of chain + bucket,

Wt=Wc+Wb

782 kg

Final chain pull,

(Wm+F1)f2+Wt/2(f2+f3)

955 kg

f2=

1.0

f3=

0 fsa

Actual safety factor,

14

Power

5.32 KW f4=

1.2

f5=

0.03 1.5

S.F=

Installed motor

7.5 KW

Page 2 of 2

DESIGN OF DIGESTER PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :

DESIGN BASIS 4.5 16-Jun-99

CODE:

BS2654

DATE:

Steel

ST 37

Input data by:

Pressure

Nil


GIVEN DATA DIGESTER Mill Capacity Ratio of fruitlet / FFB Digestion time Bulk density

1st Ph

2nd Ph

45

90 66% 12 640

mt FFB/hr min kg/m3

CALCULATE Amount of fruitlets Volume of fruitlets Total volume of digester Nr of digester chosen to operate Nr. of stand-by digester Capacity per digester Choose digester capacity Number of units to be provided

30 46.41 9.28 3 1 3,094

59 92.81 18.56 6 2 3,094 3500

4

Page 1 of 1

8

mt/hr m3/hr m3

m3 litres

NW

DESIGN OF TWIN SCREW PRESS PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :

DESIGN BASIS 4.6

CODE:

DATE:

16-Jun-99

Steel

Input data by:

Pressure

Nil


GIVEN DATA

TWIN SCREW PRESS

1st Ph

2nd Ph

Mill Capacity Capacity of each press

45

90 15

mt FFB/hr mt FFB/hr

CALCULATE Nr.of presses required Nr.of presses as spare Number of units to be provided

3 1 4

Page 1 of 1

NW

6 2 8

Units

DESIGN OF SAND TRAP TANK PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :


CODE:

BS2654

DATE:

Steel

ST 37

Input data by:

Pressure

Nil


GIVEN DATA SAND TRAP TANK Mill Capacity Ratio of diluted oil/FFB Tank retention time

1st Ph

2nd Ph

45

90 60% 15

Density of diluted crude oil

mt FFB/hr min kg/m3

890 CALCULATE

Amount of diluted crude oil produced Volume of diluted crude oil produced Volume of sand trap required Use tank capacity Nr.of tank required Nr of sand trap tank to be provided

27 30.34 7.58

54 60.67 15.17 8

0.948 1

Page 1 of 1

1.896 2

mt/hr m3/hr m3/hr m3

NW

DESIGN OF OIL CLARIFIER PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :


CODE:

BS2654

DATE:

Steel

ST 37

Input data by:

Pressure

Nil


GIVEN DATA OIL CLARIFIER Mill Capacity Crued oil to FFB Density of crude oil Retention time

1st Ph

2nd Ph

45

90 60% 890 4

mt FFB/hr kg/m3 hr

CALCULATE Amount of diluted crrude oil produced Volume of Clarifer required Capacity per clarifier Nr.of clarifiers to be provided

27.00 121.3

54.00 mt/hr 242.7 m3 120

1

2

Page 1 of 1

m3 m3

NW

DESIGN OF OIL PURIFIER PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :


CODE:

BS2654

DATE:

Steel

ST 37

Input data by:

Pressure

Nil


GIVEN DATA OIL PURIFIER Mill Capacity Oil to FFB Density

1st Ph

2nd Ph

45

90 22% 890

mt FFB/hr kg/m3

CALCULATE Amount of oil produced equivalent to Choose purifier capacity Nr.of purifier required Nr.of purifiers to be provided

9.90 11,124

19.80 22,247 4,500 2.47 4.94 3 5

Page 1 of 1

mt/hr litres/hr litres/hr Nos Nos

NW

DESIGN OF VACUUM DRYER

DESIGN BASIS ITEM :

PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

CODE:

BS2654

DATE:

Steel

ST 37

Input data by:

Pressure

Nil


GIVEN DATA VACUUM DRYER Mill Capacity Oil to FFB Density of oil

1st Ph

2nd Ph

45

90 22% 890

mt FFB/hr kg/m3

CALCULATE Amount of oil produced Use capacity per purifier Nr.of dryer required Nr.of dryer to be provided

9.90 19.80 12 0.83 1.65 1 2

Page 1 of 1

mt/hr mt/hr Nos Nos

16-Jun-99 NW

DESIGN OF PURE OIL TANK PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :


CODE:

BS2654

DATE:

Steel

ST 37

Input data by:

Pressure

Nil


GIVEN DATA PURE OIL TANK Mill Capacity Pure oil to FFB Density of oil Retention time

1st Ph

2nd Ph

45

90 22% 890 1

mt FFB/hr kg/m3 hr

CALCULATE Amount of oil produced Volume of pure oil tank required Use capacity per pure oil tank Nr.of tank required Nr.of tank to be provided

9.90 11.1

19.80 mt/hr 22.2 m3 15 m3 0.742 1.483 1 2

Page 1 of 1

NW

DESIGN OF SLUDGE TANK PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :


CODE:

BS2654

DATE:

Steel

ST 37

Input data by:

Pressure

Nil


GIVEN DATA SLUDGE TANK Mill Capacity Crued oil to FFB Density of crude oil Retention time

1st Ph

2nd Ph

45

90 35% 890 1

mt FFB/hr kg/m3 hr

CALCULATE Amount of sludge oil produced Volume of sludge tank required Use sludge tank capacity Nr.of sludge tank required Nr.of sludge tank to be provided

15.75 17.7 0.88 1

31.50 mt/hr 35.4 m3 m3 20 1.77 2

Page 1 of 1

NW

DESIGN OF CRUDE OIL TANK ITEM :



CODE:

BS2654

DATE:

CLIENT:

Steel

ST 37

Input data by:

Pressure

Nil


Power

230/415 V 50 Hz

GIVEN DATA CRUDE OIL TANK Mill Capacity Ratio of diluted oil/FFB Tank retention time Density of diluted crude oil

1st Ph

2nd Ph

45

90 60% 15 890

mt FFB/hr min kg/m3

CALCULATE Amount of diluted crude oil produced Volume of diluted crude oil produced Volume of crude oil tank required Use tank capacity Nr.of tank required Nr of tank to be provided

27 30.34 7.58

54 60.67 15.17 8

0.948 1

1.896 2

Page 1 of 1

mt/hr m3/hr m3/hr m3

NW

DESIGN OF DECANTER PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

DESIGN BASIS

ITEM :

5.9

CODE:

DATE:

16-Jun-99

Steel

Input data by:

Pressure

Nil


GIVEN DATA DECANTER Mill Capacity Sludge to FFB Density of sludge

1st Ph

2nd Ph

45

90 35% 890

mt FFB/hr kg/m3

CALCULATE Amount of sludge produced Volume of sludge produced Use capacity per decanter

15.75 31.50 mt/hr 17,697 35,393 18,000 liters/hr

Nr.of Decanter required Use Nr.of decanter

0.98 1

Page 1 of 1

NW

1.97 2

m3 Nos

DESIGN OF DEPARICARPER ITEM :



CODE:

DATE:

CLIENT:

Steel

Input data by:

Power

230/415 V 50 Hz

Pressure

Nil


GIVEN DATA DEPARICARPER Mill Capacity Fibre to FFB Bulk density Air to fibre ratio Air density

1st Ph

2nd Ph

45

90 18.5% 257 6 1.177

mt FFB/hr kg/m3 kg/m3

CALCULATE Amount fo fibre produced Amount of air required Airflow rate required Use fan Nr.of fan required Nr.of units to be provided

NW

8.33 16.65 49,950 99,900 42,438 84,877 24,959 49,918 25,000 0.998 1.997 1 2

Page 1 of 1

mt/hr kg/hr m3/hr cfm cfm Units Units

DESIGN OF DESTONER PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :

DESIGN BASIS 6.7

CODE:

DATE:

16-Jun-99

Steel

Input data by:

Pressure

Nil


GIVEN DATA DESTONER

1st Ph

Mill Capacity Nut to FFB

45

Bulk density Air to nut ratio Air density

2nd Ph 90

mt FFB/hr

15.0% 535 2.75 1.177

kg/m3 kg/m3

CALCULATE Amount of nut produced Amount of air required Airflow rate required Select fan cfm Nr.of fan required Nr. Of units to be provided

6.75 13.50 18,563 37,125 15,771 31,542 9,275 18,551 11,000 0.84 1.69 1 2

Page 1 of 1

NW

mt/hr kg/hr m3/hr cfm cfm

DESIGN OF NUT HOPPER PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :

DESIGN BASIS 7.2

CODE:

DATE:

16-Jun-99

Steel

Input data by:

Pressure

Nil


GIVEN DATA NUT HOPPER Mill Capacity Nuts to FFB

1st Ph

2nd Ph

45

90

mt FFB/hr

15%

Bulk density Buffer time

653 1

kg/m3 hr

CALCULATE Amount of nuts produced Volume of Silo required Use hopper capacity per line Number of hopper required Number of hopper to be provided

6.75 10.3 1.03 1

NW

13.50 mt/hr 3 20.7 m 3 m 10 2.07 2

Page 1 of 1


DESIGN OF NUT ELEVATOR PROJECT:

DESIGN BASIS

OIL PALM MILL

CODE:

CLIENT: PowerPower

Steel 230/415 V 50 Hz

ITEM :

7.4

DATE:

16-Jun-99

Input data by:

Pressure

Nil

NW


GIVEN DATA Mill Capacity MATERIAL BULK DENSITY CAPACITY, TF/ Material Ratio VERTICAL HEIGHT INCLINATION SPROCKET C/C SPROCKET TEETH SPROCKET PCD SPROCKET REV SPEED BUCKET SPACING CHAIN PITCH BUCKET THICKNESS

NUR ELEVATOR mt 45 PALM NUTS pf 653 M 11 r 100% H 11 α t 60 c 15 12 0.2964 33.12 S 30.84 z 0.75 l 100 t 3 ps 7200

STEEL DENSITY

mt/HR 3

kg/m

mt/HR m C m T mm rpm m/min m mm mm 3 kg/m

o

CALCULATE MASS FLOW NO.OF BUCKETS WEIGHT OF material per bucket

Mf=rxMx1000

NET VOLUME OF BUCKET CHOOSE BUCKET SIZE:

Vb=Qf/pf

11,250 kg/hr 41 bucket/min 5 kg/bucket 3 0.0070 m /bucket

n=S/z Qf=Mf/(60*n)

width depth length

a d b

0.22 m 0.23 m 0.30 m 3

Vb=1/2xaxdxb

VOLUME OF BUCKET

0.00759 m 2

2 0.5

-3

WEIGHT OF BUCKET

wb=[ad+2b({a/2} +d ) ]tpsx1.1x10

4.84 kg

WEIGHT OF MATERIAL

Wm=Mfxc/(60xS)

91.2 kg

NO.OF BUCKET ON LOADED STRAND

Nb=c/z

20

WEIGHT OF MATERIAL PER BUCKET

wm=Wm/Nb

4.6 kg

DREDGING PULL

F1=20.12 x wm/z

122 kg

ESTIMATED WEIGHT OF BUCKET+CHAIN

Wb=wbx4xNb

387 kg

PRELIM CHAIN PULL

F2=(Wm+F1)f1+Wbxf1/2

407 kg

MIN.BREAKING STRENGTH

f1=

1.0

fs=

10 F3=F2xfs

Page 1 of 2

4,070 kg

92%


FINAL CHAIN PULL

( Renold conveyor chain booklet )

Choose: Chain: Pitch Strength: Weight:

150 mm 13,636 kg 11.68 kg/m

Total weight of chain, Total weight of bucket

Wc=wb x Nb

350 kg 193 kg

Total weight of chain + bucket,

Wt=Wc+Wb

544 kg

Final chain pull,

(Wm+F1)f2+Wt/2(f2+f3)

485 kg

f2=

1.0

f3=

0 fsa

Actual safety factor,

28

Power

2.04 KW f4=

1.2

f5=

0.03 1.5

S.F=

Installed motor

3.3 KW

Page 2 of 2

DESIGN OF CM WINNOWING PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :

DESIGN BASIS 7.10

CODE:

DATE:

16-Jun-99

Steel

Input data by:

Pressure

Nil


GIVEN DATA CM WINNOWING Mill Capacity Cracked Mixture to FFB Bulk density Air to Cracked mixture ratio Air density

1st Ph

2nd Ph

45

90 11.0% 535 4 1.177

mt FFB/hr kg/m3 kg/m3

CALCULATE Amount fo cracked mixture produced Amount of air required Airflow rate required Use fan for each line Nr of fan required Nr. Of units to be provided

NW

4.95 9.90 19,800 39,600 16,822 33,645 9,894 19,787 10,000 0.99 1.98 1 2

Page 1 of 1

mt/hr kg/hr m3/hr cfm cfm units units

DESIGN OF KERNEL DRYER SILO PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :

DESIGN BASIS 7.17

CODE:

DATE:

16-Jun-99

Steel

Input data by:

Pressure

Nil


GIVEN DATA KERNEL DRYER SILO Mill Capacity Kernel to FFB Bulk density Drying time

1st Ph

2nd Ph

45

90 8% 653 30 1.3

mt FFB/hr kg/m3 hr days

CALCULATE Amount of kernel produced Volume of Silo required Capacity per silo Storage required

NW

3.60 165.4 83 2

Page 1 of 1

7.20 330.8 83 4

mt/hr m3 mt Nos

per hr

DESIGN OF PK STORAGE SILO ITEM :



CODE:

DATE:

CLIENT:

Steel

Input data by:

Power

230/415 V 50 Hz

Pressure

Nil


GIVEN DATA PK STORAGE SILO Mill Capacity Kernel to FFB Bulk density Storage capacity required

1st Ph

2nd Ph

45

90 8% 653 5

mt FFB/hr kg/m3 days

CALCULATE Amount of kernel produced Capacity per silo Nr. Of storage silos required Nr. Of storage silos to be provided

3.60 432 83 5.20 6

NW

7.20 864 83 10.41 12

Page 1 of 1

mt/hr mt mt Nos Nos

DESIGN OF WATER TUBE BOILER PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :

DESIGN BASIS 8.5

CODE:

DATE:

16-Jun-99

Steel

Input data by:

Pressure

Nil

NW


GIVEN DATA WATER TUBE BOILER Mill Capacity Power requirement HP steam required for power @ 21 barg LP steam req'd for process @ 3 barg Total power required

1st Ph

2nd Ph

45

90 18 24 660

810

1620

mt FFB/hr kW/mt FFB kg/kWH kg/mt FFB KW

CALCULATE Total HP steam req'd for power Total LP steam req'd for processing Maximum steam required Choose operating capacity of boiler Boiler capacity required Choose boiler capacity Nr. Of boilers required Nr. Of boilers for spare Nr.of boiler to be provided

19,440 29,700 29,700

38,880 59,400 59,400

85% 34,941 69,882 35,000 0.998 1.997 0 0 1 2

Page 1 of 1

kg/hr kg/hr LP is higher than HP kg/hr of rated kg/hr kg/hr units units units

DESIGN OF STEAM TURBINE PROJECT:

OIL PALM MILL

CLIENT: Power

230/415 V 50 Hz

ITEM :

DESIGN BASIS 9.1

CODE:

DATE:

16-Jun-99

Steel

Input data by:

Pressure

18 / 3.16 Bar.g


GIVEN DATA STEAM TURBINE Mill Capacity Power required for machinery Power required for housing ( Domestic ) Power required per house

1st Ph

2nd Ph

45

90 18

46 4

152 4

mt FFB/hr KW/mt FFB KW

CALCULATE Total power required for mill Total power required for housing Total power required Choose capacity of turbine Nr.of turbine required

810 184 994

1620 608 2,228 1,200 0.83 1.86

Turbine running at No. of units to be provided

83% 1

Page 1 of 1

93% 2

NW

KW KW KW KW Nos

units

CPO Storage Tank

DESIGN OF CRUDE PALM OIL STORAGE TANK PROJECT:

OIL PALM MILL

CODE:

CLIENT:

Steel

CAPACITY

Pressure

DESIGN BASIS

BS2652

ITEM :

10.1

ST 35

DATE:

16-Jun-99

Input data by:

GIVEN DATA CRUDE PALM OIL STORAGE TANK Mill Capacity Oil extraction rate Maximum storage period Maximum operating hour per day

1st Ph

2nd Ph

45

90 22% 15 24

mt FFB/hr days hrs

CALCULATE CPO produced CPO produced for 20 days Use tank capacity Nr.of tank required Choose Nr.of tank

238 3,564

475 7,128 2,000

1.78 2

Page 1 of 1

3.56 4

mt /day mt mt Nr Nr

NW

DESIGN CALCULATION FOR WATER SUPPLY DESIGN BASIS PROJECT:

OIL PALM MILL

CODE:

CLIENT:

Capacity

Pressure 3 Bar.g

ITEM

11.0

DATE

04-Mar-01

Input data by

GIVEN DATA

Mill Capacity Processing period Processing time Water consumption include quarters Clarifier retention time Reservoir retention time

10 25 24 2 2 3

mt FFB/hr days/month hr/day m3/mt FFB hr months

CALCULATE Total consumption Clarifier capacity Monthly capacity Reservoir volume

20 23 6,000 18,000

Page 1 of 1

m3/hr m3 mt FFB m3

NW

Energy Balance

DESIGN CALCULATION FOR ENERGY BALANCE ( Fuel / Steam / Power ) PROJECT

OIL PALM MILL

CLIENT CAPACITY

45-90 mt FFB per hour

CODE

ITEM

Steel

DATE

Pressure

DESIGN BASIS 13 a. 4-Mar-01

Input data by

NW

INPUT DATA Mill Capacity Specific power requirement for POM Specific steam requirement for POM Specific steam requirement for back pressure turbine Turbine load factor Boiler load factor Fibre Content Shell Content Empty Bunch Content Net Calorific Value Of Fibre Net Calorific Value Of Shell Net Calorific Value Of Empty Bunch

16.5% 7.7% 22%

45 17.5 550 25 80% 80% 7.44 3.48 9.90 10,000 15,900 6,000

90 17.5 550 25 80% 80% 14.89 6.96 19.80 10,000 15,900 6,000

mt FFB/hr KWh/mt FFB kg/mt FFB kg/KWh

mt/hr mt/hr mt/hr KJ/Kg KJ/Kg KJ/Kg

Steam Generation Energy required to raise 1 kg of water @ 60C, atm to @ 21 barg 35C superheat

2382

2382 KJ

Assume boiler thermal efficiency Actual energy required Steam can be produced by 1 kg of fibre Steam can be produced by 1 kg of shell Steam can be produced by 1 kg of EB Total steam can be produced by fibre Total steam can be produced by shell Total steam can be produced by fibre+shell Total steam can be produced by bunch

70% 3,403 2.94 4.67 1.76 21,877 16,253 38,131 17,456

70% 3,403 2.94 4.67 1.76 43,754 32,507 76,261 34,912

Total therotical steam can be generated

55,587

111,173 Kg/hr

Total steam can be generated by burning Fibre, Shell & Bunch

55,587

111,173 Kg/hr

Steam required for specified Boiler capacity Excess Total available steam Percentage of excess energy

35,000 20,587 59%

70,000 kg/h 41,173 kg/h 59% %

Total steam can be generated by burning Fibre & Shell only Steam required for specified Boiler capacity Excess Total available steam Percentage of excess energy

38,131 35,000 3,131 9%

76,261 70,000 6,261 9%

kg/h kg/h kg/h %

1,575 49,500 39,375 1,969

KW kg/h kg/h KW

KJ/Kg of water kg kg kg Kg/hr Kg/hr Kg/hr Kg/hr

Excess available Energy a

b

Energy Generation & Requirement Turbine capacity Total power required LP steam required for processing HP steam required for power generation Minimum turbine capacity

788 24,750 19,688 984

Specify Turbine Capacity

1,200

2 x 1,200 KW

Boiler capacity Total HP steam requirement Minimum boiler capacity

24,750 30,938

Specify Boiler Capacity

35,000

[Page] of 1

49,500 kg/h 61,875 kg/h 2 x 35,000 kg/h

PERUNDING AME

DESIGN CALCULATION FOR EMPTY BUNCH MULCHING AREA DESIGN BASIS

PROJECT

OIL PALM MILL

CLIENT CAPACITY

45 - 90 mt FFB per hour

CODE

ITEM

14

STEEL

DATE

04-Mar-01

Pressure

INPUT DATA

Symbol

Mill capacity

C

Ratio of empty bunch/FFB

r

Bulk density of crushed empty bunches

d

INPUT DATA BY

Formula

Value

45 25% 0.27

NW

Value

90 ton/hr 25% 0.27 ton/m3

Empty bunches decomposing period

T

90

90 days

Maximum operating period

t

24

24 hr

Width of mulching area

f

3

3m

Height of staking

h

1

1m

Distant between rows of palm trees

s

9

9m

CALCULATION Weight of empty bunches produced

w

Cxr

11.25

W

wxt

Volume of empty bunches produced

V

W/d

Nr. Of rows of mulching area for a 100m wide

n

100/s

11

A

n x 100 x f

3333

3333 m2/ha

L

A x 70%

2333

2333 m2/ha

Q

Lxh

2333

2333 m3/ha

Mulching capacity of empty bunch in 1 ha

K

Q/V

2.33

Total area required for 90 days cycle

H

T/K

38.57

270 1,000

22.5 ton/hr 540 ton/day 2,000 m3/day 11 rows

plantation Area available for mulching in 1 ha (100m W x 100m L) Assume only 70% can be used, net area available for mulching Net volume available for mulching based on 1m stack 1.17 days/ha 77.14 ha

Conclusion The total area required for mulching based on 90 days cycle time is:

40

80

HECTARES

A PALM KERNEL OIL MILL PROJECT  Noel Wambeck / May 1999

PALM 1 .

KERNEL

OIL

MILL________

A PALM KERNEL OIL MILL PROJECT By N oe l Wa mbe ck / M a y 19 99 .

01. OUR UNDERSTANDING OF THE PROJECT Our understanding is that the client wishes to establish a Processing complex for the production of Palm kernel oil and PK meal. The client has acquired a suitable site for the project. The proposed Palm Kernel Oil Expeller Mill shall have capacity of 10 mt Palm Kernel per hour or approx. an average of 240 mt Palm Kernel per day. The proposed project processing plant will include facilities for: a.

Infrastructure & Buildings in the processing complex.

b.

The Storage of raw material for process and finished produce.

c.

Main process line machinery, equipment and plant will include the raw material reception and storage, oil extraction by expeller presses, oil filter station, bins, silos, conveyor elements, piping, pumps and storage of produce.

d.

Utilities such as electrical power, water supply and fire protection systems.

e.

Consideration for Environment Impact and treatment.

f.

Design considerations for future expansions.

This proposal is based on our engineering know-how and project management in accordance to the Turnkey Contract conditions for the proposed processing plant including the design, fabrication, the supply C & F port of entry into Indonesia, supervision of erection, commissioning and guarantee for 12 months after handing over of equipment, machinery and plant, manufactured in Malaysia and third country by experienced and proven good sub-suppliers with part supply of manufactured items or construction in buyer’s country under good supervision with drawings applied for erection at site.

PALM 2 .

KERNEL

OIL

MILL________

The equipment, machinery, plant and systems offered are essential and regarded as operation requirement process sections of a modern plant and recommend that the buyer gives serious consideration to the advantages the systems we have to offer.

PALM 2 .

KERNEL

OIL

MILL________

02. METHODOLOGY.

OVERALL APPROACH, based on our experience, we anticipate that the turnkey project work will be divided into 3 main stages and later, further sub-divided in accordance with the yet-to-bedetermined Phases of development.

We recommend that these work stages be as follows:Stage 1

:

Initial assessment of the proposed sites and preparation of a project site report that will include the compilation of additional information regarding soil conditions, survey and logistics data, earth works, local material and cost estimates, required for the preparation of the basic design by the turnkey contractor for submission by the client to and approval of the Authorities.

Stage 2

:

Detailed Engineering Design, Specifications and Drawings for client’s consideration and approval, the submission of the final turnkey contract price, the purchase of proprietary equipment, the manufacture and fabrication works and delivery to site.

Stage 3

:

Supervision at Site for construction, erection, commissioning, training of process operators and handing over project for commercial production.

The basic design, project requirements and schedule will be established with the Client in the very early stages of the project. We have always considered several factors as being extremely important in our design concept.

•

Maintenance and Operation.

This is a very important point to consider in the design concept. It depends very much on the level of the operation and maintenance staff that can be expected to operate and maintain the plant and availability of spare parts.

PALM 3 .

•

KERNEL

OIL

MILL________

Extraction Efficiency and Performance.

The extraction efficiency is a factor, which must be taken into consideration at all times during the design stage that will take into account an efficient plant in terms of extraction rate, throughput and operation cost.

•

Flexibility of Design.

Flexibility of the design is equally important factor to be considered although sometimes it means additional cost. In some cases, it may be necessary so that the plant can be operated even under adverse conditions. However in this respect, we would consult the Client to seek agreement.

PALM KERNEL OIL MILL

03.

4

PALM KERNEL OIL EXTRACTION PROCESS.

The Oil Palm Industry offers advantage of its resource base and to optimize its profit centres. One such profit centre is the Palm Kernel Oil extraction milling process.

Extraction of oil from palm kernel can be processed in three basic processes. 1. Mechanical pressing of palm kernel in high-pressure expeller screw presses are common for capacities between 10 mt PK to 300 mt per day. 2. Direct extraction after suitable preparation of the palm kernel in a solvent extraction plant should be considered for capacities above 300 Mt PK per day. 3. A combination of the above two basic systems whereby the palm kernel after suitable preparation is processed in a pre-pressed to extract 75% of the oil at a comparatively low barrel pressure in the press. The pre-press meal is treated in a solvent extraction plant to remove 23% of the oil with a high total yield of 98% of the total oil input raw material. The direct solvent extraction system is more efficient in terms of extraction yields and operating cost per ton process material, among the three systems for palm kernel oil extraction. Mechanical pressing can be carried out in single or double pressing system. Single pressing has certain drawbacks as to double pressing, as enumerated below : (a) The major portion of the oil ( 80%) will be extracted at the pre-pressing and as the cone pressures are kept low, the oil temperature will not exceed above 80 deg. C resulting in a better grade of oil in terms of FFA and PV increase during the extraction process.. (b) Extraction at lower temperature will reduce the electrical load, the amount of solid matter ( call foots ) discharged with oil that would result in better utilisation and life of the vibrating screen, oil pumps and filter press. (c) Thus, the system selected would intrinsically prolong and life of wear parts that would reduce the operating cost of the complete plant. (d) The 2nd pressing or finish press and associated conveying elements is better utilised because less fines ( foots ) are being recycled with possible excess than rated capacity of machinery and plant.


5

(e) The finish press will extract the balance of the extractable oil ( say 20% ) from the prepress meal at a cone pressure as high as for a single pressing system but as the quantity is only 60% of the input raw material, therefore the cooling of the press shaft and barrel with water or oil is not required in turn would eliminate the use of heat exchangers and cooling equipment. (f) Deterioration in oil quality is eliminated by not using the extracted oil which is cooled and sprayed on the barrel to lower the temperature of the fresh extracted oil. Design features of double pressing system, which is common in Palm Kernel Mills in Malaysia, take into consideration the following :

•

Easy and lower maintenance.

•

Longer life of wear parts.

•

Higher yield of palm kernel oil and cake.

•

Eliminate or reduce the cost of utilities, such as steam and cooling water.

•

Lower investment cost.

The “double pressing system “ eliminates expensive preparation equipment such as roller mills, flakers and cookers. Take one more variable that if inadvertently the mill is not kept at peak efficiency would ruin the quality of the final products and loss of process capacity that could cause considerable embarrassment if not also monetary loss to the company.


THE PROCESS DESCRIPTION. The general arrangement of the Palm Kernel Oil expeller extraction mill is relatively simple and can be followed by process flow schematic enclosed. Process lines are made up of a raw material reception area, two rows of expeller presses, each Press with a capacity of 10 mt palm kernel per day ( 24 hours ) and an oil clarification station, housed in a steel structure main process building. The appurtenance consists of the raw material and finished produces storage facilities.

Reception. Palm Kernel with 7% moisture and 5% dirt content are conveyed directly from the kernel silos of the palm oil mill or delivered in bulk or bags from outside source and unloaded in the reception area after being weight and stored in PK storage hoppers by conveyors. Each hopper can hold approximately 100mt palm kernel or provided with larger size silos in accordance to the design capacity of the plant. The raw material of palm kernel are evacuated by screw conveyors at the bottom of the loading storage hopper and thereafter the material is transferred to the milling section of the process. The receiving conveyor is fitted with permanent magnet for the removal of tramp iron, transports the PK into the pre-press buffer bins mounted on a steel structure of the main process building.

Pre-Pressing section. Palm Kernel or PK for short is fed into the pre-press, each with capacity of 10 mt PK per day (24 hours ) via a chute fitted with slide valve or feed screw provided for presses with such an arrangement. The pre-press cake or meal discharged is conveyed and fed into the silos of final press line, whilst the crude oil extracted ( approx. 80% of total oil ) flows into the screw conveying gutter and to the oil clarification section for further process.

Finish Press section. The pre-press material with an oil content of less than 20% is fed into the finish presses extruding two products, oil and meal. The meal as “finished product” is corrected with a moisture content of 10% and conveyed to the PK meal bulk storage silos or bagging area.

6


Crude Oil section. The crude oil from the oil gutter flows onto the vibrating screen for removal of foots and stored in the head tank which feeds the filter press. Foots collected from the circular vibrating screen an filter press are recycled back to the finished press for the removal of residual oil in solid matter. The filtered oil is fed into the Vacuum dryer for the removal of moisture content and discharge into the security filter, filled with citric acid where by dosing of the finish oil to minimised the chance of oxidation and to enhance the stability of the PALM KERNEL PRODUCT.

Storage of Products. The clean and dry kernel oil with a moisture content of 0.09% is conveyed by stainless steel canpumps to the oil storage tank or filled into steel drums for delivery to BUYER.

PALM KERNEL OIL EXTRACTION PROCESS SCHEMATIC FLOW.

Perunding AME / May 1999 / NW.

7

PALM KERNEL OIL MILL ________

8 .

04. THE PROJECT BRIEF 4.1

SCOPE OF WORKS.

The contract will include the design, manufacture, fabricate, supply of proprietary equipment, delivery to site, unloading, safe keeping, construction , erection, installation, Authority inspection and approval, testing, commissioning, training of operators, handing over for commercial production and guarantee for 12 months after handing over of plant with the limits of the plant complex, Manufactured in Malaysia and third country by experienced and proven good sub-suppliers with part supply and manufactured items in buyer’s country under good supervision with drawings applied for erection at site.

4.2

PROPOSED PROJECT.

A 10 mt Palm Kernel Oil expeller extraction per hour mill complex including the following: ITEM. 1

2

3

DETAILS

QUANTITY

Civil & Structure Internal Roads & drains Guard & weighbridge house Office & Lab. Canteen Palm Kernel Mill Building Store & workshop Warehouse for Meal Storage and packing

20 m2 120 m2 72 m2 600 m2 200 m2 600 m2

Reception station Weighbridge Receiving Hopper & Feed conveyor Palm kernel silo or Bin ( 250 mt ) Pneumatic conveyor Crusher / Breaker Mill Screw Conveyor Bucket Elevator Horizontal Screw Conveyor & Feed chutes

1 1 1 1 2 1 1 1

Pre - Pressing station Kernel Hopper & Steel structure Vibro Feeder & Metal trap Pre - Press Expeller Scraper conveyor Breaker mill Cross Bucket conveyor Screw Conveyor

8 8 8 1 1 1 1


ITEM. 4

5

6

7

8

9 .

DETAILS

QUANTITY

Finish - Pressing station Hopper & Steel structure No.2 Vibro Feeder & Metal trap No.2 Final Press Expeller Scrapper conveyor No.2 Breaker mill No.2

6 6 6 1 1

PK Meal Bulk Storage Bucket Elevator Screw Conveyor Meal Bulk Silo

1 1 1

PK Oil Clarification Oil Gutter Oil Transfer Tank & Pumps Filter Pressure Press Solids discharge tray and chute Circular Vibrating screen Oil Purifier Vacuum Dryer & pumps Piping, Valves, Fittings & insulation

1 2 2 2 2 1 1 Lot

Electrical works Main switch gear and MCC Cable & wiring to motors Lighting & power points Stand by Diesel generating set - 300 kw

Lot Lot Lot 1

Fire Protection System Alarm system Fire hose reel system Fire Hydrants Fire fighting equipment

Lot 4 4 Lot

9

Shipping & Insurance

600 mt

10

Commissioning & Training of operators

10 days

11

Operation & Maintenance Manuals

3 sets

12

As built Drawings

3 sets


4.3

10 .

SPECIFIED OFFER.

The offer is based on the buyer’s invitation to bid for the specified requirement and does not include the following :

• • • • • • • • • • •

4.4

Application and approval for Authority Licenses. Land for the project site. Site soil investigation and surveys. Application and supply for site facilities such as Electrical power and water supply. Site preparation and earthworks. Port clearance, customs, SGS inspection. All insurance requirements in buyer’s country. All duties and taxes from or in buyer’s country. Inbound transport, haulage and forwarding charges and unloading at site. All raw material, lub-oils, fuel, management, staff and labour for commissioning & hand over of plant for commercial operation. All other supply and works outside the limits of the plant complex.

TIME OF DELIVERY.

We confirm a delivery time from the date of the contract award provide that all technical and financial obligations are finalized as follow: Eighteen months from the date of award of contract and provided we receive the proposed site three ( 3 ) months from the date of award of contract.

4.5

VALITY OF OFFER.

The price offered in this bid shall be valid for 60 days.


4.6

11 .

PERFORMANCE AND GUARANTEE.

We guarantee that the complete equipment, machinery and plant supplied by us for the proposed project are brand new and of first class quality and workmanship that is proven in operation shall be supplied in the contract. We guarantee that the complete equipment, machinery and plant supplied by us in the proposed project will be able to process good quality Palm kernel in accordance to the accepted standards after an appropriate start up time in regular uninterrupted operation of the plant. Quality of raw material for process. Tenera type Palm kernel of normal standard will consist and based on 1,000 kg input material are as follows:

• • • •

Oil ( including FFA ) contents

43.15%

Dry substance

43.85%

Moisture

8%

Dirt ( impurities ) at Max.

5%

Quality & Quantity of Products.

• • • • • 4.7

FFA increase in process

0.25%

Moisture

0.09%

Dirt

0.10%

Filtered Kernel oil

42%

PK Meal ( Moist.9% Oil 7% )

58%

LIABILITY LIMITS.

We are not liable for personal injury and damage to property, equipment, machinery and plant or third party claims during the execution of the contract and outside the battery limits of our scope of supply and works and in particular will not pay for any loss of profit, compensation and production.

4.8

CONDITION OF SUPPLY.


12 .

Conditions of supply shall be in accordance to the IEM conditions of turnkey contract for design, build and hand over of project.

MATRIX FOR PALM KERNEL OIL ( Expeller Press ) EXTRACTION.

04-Mar-01

x

1

2

3

4

5

6

7

PALM KERNEL PROCESSED mt Per hour mt / hr Per Day mt / day

Design Capacity

9

mt per 24 hr / day

1

2

4

10

12

16

20

24

48

96

240

288

384

480

25

50

100

250

300

400

500

100 50 60

200 100 120

400 200 250

1,000 500 600

1,200 600 700

1,600 800 1,000

2,000 1,000 1,100

42% 58% 42% 58%

0.42 0.58 10.08 13.92

0.84 1.16 20.16 27.84

1.68 2.32 40.32 55.68

4.20 5.80 100.80 139.20

5.04 6.96 120.96 167.04

6.72 9.28 161.28 222.72

8.40 11.60 201.60 278.40

mt

2%

0.48

0.96

1.92

4.80

5.76

7.68

9.60

UTILITIES Power Water

kwh m3

55 0.02

55 0.50

110 1

220 2

550 5

660 6

880 8

1,100 10

LAND AREA Diamensions Square area Hectares

m m2 ha

40 x 80 3,200 0.32

40 x 100 4,000 0.40

40 x 120 4,800 0.48

60 x 120 7,200 0.72

60 x 120 7,200 0.72

100 x 200 20,000 2

100 x 200 20,000 2

1 1 1 6 3 3 6 6 1 9 9

1 1 1 6 3 3 6 6 1 9 9

1 1 1 6 3 3 6 6 1 9 9

1 1 1 6 3 3 6 9 2 9 9

1 1 1 6 3 3 6 9 2 12 12

1 1 1 6 3 3 6 9 2 12 12

1 1 1 6 3 3 6 9 2 12 12

46

46

46

50

56

56

56

Raw material storage capacity PK Oil storage capcity PK Meal storage capacity

mt mt mt

4 days 4 days 4 days

PRODUCTION PKO per hour MEAL per hour PKO per Day MEAL per Day

mt mt mt mt

LOSSES Oil in Meal

MANPOWER Manager Admin. Accounts Assistant General clark Weighbridge clark Mill Supervisor Wireman Forklift Driver Fitter Welder Machine operator General worker TOTAL

8

24 hrs

PRODUCTION COST General charges Direct manufacturing charges Sales & Distribution cost total

INVESTMENT Infrastructure Civil & Structure Mechanical & PI Electrical Works Fire Protection system Lab. & Workshop equipment Shipping & Insurance Commissioning & Training Professional Fees Mobilisation & Contingency TOTAL IN RM

Persons 1 1 1 2 1 1 2 2 1 3 3

Shifts 1 1 1 3 3 3 3 3 1 3 3

18

RM / mt RM / mt RM / mt

4 29 3 36

Mill Capacity mt per day

5.5% 22.0% 51.0% 6.0% 2.0% 1.5% 3.0% 0.5% 3.5% 5.0%

96 696 72 864

192 1,392 144 1728

384 2,784 288 3456

960 6,960 720 8640

1,152 8,352 864 10368

1,536 11,136 1,152 13824

1,920 13,920 1,440 17280

25 82,500 330,000 765,000 90,000 30,000 22,500 45,000 7,500 52,500 75,000

50 137,500 550,000 1,275,000 150,000 50,000 37,500 75,000 12,500 87,500 125,000

100 220,000 880,000 2,040,000 240,000 80,000 60,000 120,000 20,000 140,000 200,000

250 412,500 1,650,000 3,825,000 450,000 150,000 112,500 225,000 37,500 262,500 375,000

300 544,500 2,178,000 5,049,000 594,000 198,000 148,500 297,000 49,500 346,500 495,000

400 792,000 3,168,000 7,344,000 864,000 288,000 216,000 432,000 72,000 504,000 720,000

500 1,072,500 4,290,000 9,945,000 1,170,000 390,000 292,500 585,000 97,500 682,500 975,000

2,500,000

4,000,000

7,500,000

9,900,000

100.0% 1,500,000 1500000

Perunding AME

2500000

3/4/01

4000000

7500000

9900000

14,400,000 14400000

19,500,000 19500000

220 M

WORKSHOP & STORE

60 M

SURAU

WATER TOWER CANTEEN & REST ROOMS

PARKING AREA PALM KERNEL SILOS

42 M CAR SHED

MAIN PROCESS BUILDING

MEAL STORAGE BUILDING

100 M OIL STORAGE TANKS

OFFICE & LAB.

GUARD HOUSE

OIL LOADING SHED WEIGHBRIDGE

TNB sub-station

P PR RO OP PO OSSE ED DP PA ALLM M KE ER RN NE ELL O OIILL M MIILLL –– TTYYP PIIC CA AL G GE EN NER RA ALL LLA AYYO OU UTT

VIEW OF A PALM KERNEL OIL MILL COMPLEX INCLUDING THE RAILWAY SYSTEM.

VIEW OF THE EXPELLER PRESSING STATION IN OPERATION.

PERUNDING AME / 24TH MAY 1999 / NW.

REFINING PROCESS

1

AN INTRODUCTION TO REFINING PROCESS FOR PALM OIL AND OTHER DOWNSTREAM PROCESSES. By Noel Wambeck 20th September 1997.

Introduction. Edible oils and fats have traditionally been refined by the process of neutralising the fatty acid with a base such as caustic soda or alkali refining plant. The disadvantages of such a process are the high cost of chemicals and the problem of soapstock, which requires expensive effluent treatment. Further, the percentage of oil loss and operational cost of production are advantages in favour of Physical refining process. Palm oil can be subjected advantageously to physical refining and dry fractionation processes to produce more diversified products at competitive prices.

REFINING PROCESS

2

Our view on the general approach to a Palm Oil refining project for palm oil and other downstream process whiles taking into consideration that the finished products will be bottled, packed and marketed to consumers in a competitive market will require careful planning and selection of the right process design and component equipment to process various qualities palm oil to produce the highest quality finish products to sustain a long self life. The process systems discussed in this paper, are as follows :

§ § § §

Pre- treatment and wet de-gumming process. Continuous Bleaching plant. Steam Refining cum Deodorization system. Dry Fractionation system.

The aim is to produce refined produces of high quality in terms of oil colour, odorless, blend taste, stability for long shelf life at a reasonable cost of production. Basic features required producing high quality products from crude palm oil and palm kernel oil. Basic features required to produce high quality products are as follows : It is well accepted that impurities and phospholipids that are present in the crude palm oil plays a great part in the stability of the refined product. Therefore it is impertinent that this impurity be removed to an absolute minimum in the pretreatment stage or de-gumming process. Although the dry pretreatment can handle the de-gumming process but the wet de -gumming offer a more reliable pretreatment process of lesser quality feed crude palm oil. To do this the crude oil needs to undergo treatment with the resultant gums washed out with diluted phosphoric acid in hot water and than separated through centrifuge. The pretreated oil is to be dried before the bleaching process under suitable temperature, retention period and vacuum conditions. A feature at the bleaching stage is to allow quick changeover of feed stock and complete drainage and having minimum chance of contamination. It is an established fact that steam refiner cum deodorizer process or “ Physical refining process combined with the wet de-gumming and continuous bleaching process“ will produce a better quality product where the feed material is heated and cooled down in the same column under similar vacuum condition and proper retention time in the refining process will produce a refined product of a reasonable high quality and stability. Dry fractionation process also known, as “winterisation process” has become a common feature in modern refineries with the introduction of the membrane filter press resulting in yields and quality better than the detergent process. Manufactured fat products are generally foreseen as a requirement to ensure that freshly refined oils are available as feed stock, which is also economical for such integration. Ideally, the plant is to be equipped with a suitable control system to reduce the use of manpower on its operation. Among the control systems, the distributed and monitoring computerized control system seems appropriate for such a plant.

REFINING PROCESS

3

A CONCEPTIONAL PROPOSAL FOR A PALM OIL REFINERY PROJECT This proposal in brief, aims to provide guidance to those who may be involved in or a new comer to the identification and preparation of a palm oil refinery complex project. Our understanding is that the management have made the decision to invest in the expansion of their manufacturing activities after having prepared a thorough project study or business plan for a target market but require clarification on the advantages of the Palm Oil Refinery complex. Our view on the general technical approach to the project, will require careful planning and selection of project site, the right process design, equipment component and system to process various quantities, added values palm oil products to sustain a long self life, that is in demand by the buyer. Arguments for its economic viability, marketing requirements and corporate strategy are not address in this paper. The proposed project for the time being is restricted to the integration of : A 500 mt per day (24 hours) physical refinery and 400 mt per day (24 hours) Fractionation Plant to process crude palm oil (CPO) with the option of Palm Kernel oil as raw material for process. The matching of the oil palm mill capacity with the refinery is of equal importance to the availability of the raw material for process when considering the integration. The project business plan should have scope and potential to diversify and expand in the area of production of various down stream palm oil based products.

1. The Products. The proposed physical refinery and fractionation complex shall produce basic product mix, as follows: Palm Oil based : Refined, Bleached and deodorized Palm Oil. Crude Palm Olien Crude Palm Stearin RBD Olien RBD Stearin High purity FAD Palm Kernel Based : Refined, Bleached and deodorized Palm Kernel Oil. Crude Palm Kernel Olien Crude Palm Kernel Stearin RBD PK Olien RBD PK Stearin High purity FAD

REFINING PROCESS

4

2. The Advantages for Project Integration. An integrated processing complex offers several advantages including the following : & Reduce cost in Management, administration, communication, maintenance and labour & Reduce capital cost with common buildings to house the above. & Reduce capital cost of plant and equipment, such as effluent treatment system, cooling

system and steam generators. & No cost of transportation and insurance premium between processes. & Security monitoring requirements.

The selection of a suitable processing complex site is an important exercise as it has direct effects on the capital cost and long-term operation requirements.

3. Factors to consider for Integration. The refinery complex should have incorporated in the initial design of the plant adequate facilities for:

• Suitable space to house the refinery, fractionation plant, infrastructure, tank farm and appurtenances.

• The proposed plant shall be designed with consideration for and incorporation of the latest technology available in the industry.

• The equipment, plant and process systems will be design for high efficiency, quality and yields.

• Consideration and the incorporation of safety aspects that comply with Occupational Safety and health act, such as to provide for good ventilation, working space, dust free and noise levels within permissible limits.

• Consideration and the incorporation operating procedures, equipment, plant and process systems to meet the ecological, hygienic and cleanliness of the plant on par with good food manufacturing industrial plants standards.

• The plant and process shall be environmentally friendly and that the environment Control act requirements will be addressed in accordance to the standards prescribed.

• The plant will be designed for cost effectiveness for operation and maintenance.

REFINING PROCESS

5

4. Estimated Cost of a Refinery. The estimated cost of a Refinery complex with optimum capacities, based on the project matrix and current ( Exchange rate at USD 1 : RM 3.80 November 1998 ) cost of material, equipment and plant in the year 1998, are as follows:

1.

PROCESS PLANT

NOTES:

Preliminaries. Soil Investigation, earth works, Piling works etc. Temporary site facilities

Input : 150,000 mt CPO per year. Exclude cost of land (6 Ha)

2.

Infrastructure, Civil & Struct. Works and Buildings

3.

Equipment, systems & plant Road weighbridge Physical refinery Dry Fractionation Mech. & PI Fire fighting Electrical works Tanks – Infeed / chemicals / buffer etc. Utilities & Auxiliaries – Boiler / Diesel gen-sets / cooling system Support services i.e. Lab equip & sundries SBR effluent treatment plant

4.

Bulking farm

5.

Professional fees

TOTAL

COST IN RM.

2,700,000 2,600,000

( 500mt CPO per day ) ( 400mt Oil per day )

200,000 7,400,000 6,600,000 4,500,000 600,000 1,500,000 100,000 1,800,000 900,000 600,000

( 6,000mt produce mix )

5,000,000 1,500,000

RM 36,000,000

Take note that estimates can vary extensively, depending on the location of the site, terrain, type of soil, accessibility, selection of quality of equipment and design factors applied. The proposed design of the complex will give a reliable, easy to operate with the best up-todate performances for maximum efficiency with minimum product losses and quality products. However, we must understand that each project, operation and commercial consideration will defer in the actual implementation of the design for processing needs to meet the changing requirements and conditions of management priority.

REFINING PROCESS

6

5. Selection of Process System. Edible oils and fats have traditionally been refined by the process of neutralising the fatty acid with a base such as caustic soda or alkali refining plant. The disadvantages of such a process are the high cost of chemicals, the percentage of oil loss and the problem of soap stock, which requires expensive treatment are advantages in favor of Physical refining process. It was in the early eighties that palm oil could be subjected advantageously to physical refining and dry fractionation processes to produce more diversified products at competitive prices. The search for new markets for its products and the rapid development in the industry, found demand of other down stream production of palm oil mid fractions, cocoa butter equivalent, hydrogenated oils, etc. The most complimentary extension can be in the area of valuable Red Palm Oil containing Tocopherols (VitaminE) and derivatives with high yielding carotenoids and tocopherols. It fulfills a vital role as a means of control on product cost without any loss of properties and loss of performance in the product. However, the refinery plant with the molecular distillation process required to produce such value added products is deferred from the conventional physical refinery process and should not be compared in terms of process utilization to produce a range of marketable products, operation requirements and cost of investment. Therefore the rational and final selection of process system will depend on the result of the project study or business plan target market which dictate the products to be produced for marketing economics and should not be based on the products that can be produced by the process system. The manufacturer is usually also the marketing organizer. Marketing is the first consideration; to manufacture is a tool of the marketing organization. The superior quality of Crude Palm Oil and its derivatives produced in the integrated process are the marketing organization assurance for the future of its products.

REFINING PROCESS

7

6. BRIEF PROCESS DESCRIPTION. Fig. 1 CONTINUOUS PRE-TREATMENT & BLEACHING SCHEMATIC FLOW.

1. 1A. 2. 3. 4. 5.

BLEACHING CLAY DOSING STATION ADDITIONAL ACTIVE CARBON DOSING VACUUM OIL DRIER RECUPERATIVE HEAT EXCHANGER FINAL HEATER RETENTION LINE.

6. 7. 8. 9.

COOLER FILTER STATION SAFETY FILTER STATION VACUUM EQUIPMENT

Fig. 2 CONTINUOUS PHYSICAL REFINING SCHEMATIC FLOW.

1. 2. 3. 4. 5. 6.

Recuperative heat exchanger Deareator Final heater Physical refiner / deodorizer Oil cooler Polishing filter

7. 8. 9. 10. 11.

Vacuum equipment High temperature generator Start heater / stop cooler Vapour scrubber Anti oxidant equipment

REFINING PROCESS

8

Crude oil is preheated and acid treated, allowing for sufficient holding time and washed with hot water. The gummy matter precipitates and preheated oil is separated through a self-flushing centrifuge. The pretreated oil is to be dried before undergoing the bleaching process under regulated temperature and vacuum conditions. Bleaching clay is dosed and mixed with pretreated oil in the reaction vessel. Sufficient retention period is to be allowed for maximum and stabilizing effects. The slurry is than filtered through one of the two alternative working Pressure leaf filters. The partly bleached oil is than filled into intermediate holding tank before being processed further at the Steam refiner. The bleached oil is dried before being fed into the refining column. In the column the oil is heated up to a low distillation temperature with the distillation and deodorization effects being enhanced by injecting stripping steam. Some heat economizing is carried out within the steam refiner. The distillation and deodorization of the oil is to be well defined in terms of homogeneous retention time while retaining the endogenous carotene and vitamin E in the Red Palm Oil being process. The refined product is cooled to storage temperature using heat exchangers internally after which ant-oxidants treatment of the product is an essential part of the process to prevent oxidation and to enhance its stability. Free fatty acid vapours omitted during the distillation and deodorization stage in the steam refiner is condensed and scrubbed through a highly efficient vapour scrubber,resulting in clean steam vapour being removed through the ejector vacuum system. The cooled refined oil is stored in the storage tank or transferred to the Fractionation process or to the bottling and packing before the delivery to buyer.

REFINING PROCESS

9

FEED STOCK INLET TO PROCESS

1. CRYSTALLIZERS

2. REFRIGERATION UNIT

4. COMPRESSED AIR GENERATOR

3. MEMBRANE FILTER PRESS

5. LIQUID OLEIN OUTLET

6. MELTED STEARIN OUTLET

Generally, RBD palm oil is seeded, ( crude palm oil can also be used ) preheated before being filled into one of several units of the crystallization tanks. On reaching the required volume, the filling is cut off automatically and the crysatallization process is activated with the programme required. Upon completion of the crystallization cycle with well defined and uniformed crystal formation, the slurry is filtered through the Florentine belt filter press and or membrane filter press. Crystallization slurry is filtered through each filtration cycle after which the press will be inflated with air automatically to squeeze and to released any remaining liquid oil from the solid stearine cake. The hydraulic system of the press will operate automatically upon reaching the required preset pressure the filter elements will open to discharge the solid stearine cake. the cake would drop into the stearine melting tank directly below the filter press and after which the melting stearine will be transferred to the cooler for storage in the air-conditioning storage area or the stearine could be used as a building block for other downstream processes. The liquid fraction of Olein is transferred to the storage tank pending delivery to customer.  Sept 1999 Noel Wambeck.

APPENDIX

PORLA GUIDELINES.

PALM OIL REGISTRATION & LICENSING AUTHORITY CONTENTS • • • • • • • •

Introduction. PORLA's Role in Quality Assurance. Responsibilities of the Various Parties in the Export Chain. Responsibilities of the Producer/Supplier. Responsibilities of the Traders / Exporters. Responsibilities of the Bulking Installation Operators. Responsibilities of the Independent Chemist. Responsibilities of PORLA Port Stations

Enforcement of Quality Control Practices. • • • •

Regulation and Monitoring Monitoring of the Professional Services. Inspection of Bulking Installations at the ports. Inspection of Laboratories.

Implementation of Quality Control Programme • • • • •

Palm Oil Surveying Course Malaysian Palm Oil Surveyors Examination. Recommended Practices for Surveying Palm Oil Products Palm Oil Laboratory Accreditation. Malaysian Laboratory Accreditation Scheme (SAMM)

1

PORLA GUIDELINES.

2

GUIDELINES AND CHECKLIST ON QUALITY FOR THE EXPORT OF MALAYSIAN PALM OIL.

INTRODUCTION. The objective of this document is to provide the guidelines and checklist for promoting quality awareness among the exporters or suppliers of Malaysian palm oil. It will outline all the necessary actions and precautions to be taken in assuring that the quality of palm oil products meets the quality specifications specified in their contract of sales at the point of export. Quality assurance can be defined as `controlling the process to produce a product free of defects'. Instead of relying entirely on inspection to assure product quality by rejecting defects, inspection is focused on the process itself that can provide feedback so that the process can be improved and perfected, thereby ensuring quality product. The role of Palm Oil Registration and Licensing Authority (PORLA) is to conduct inspection programmes on the quality of oil palm products at their strategic points of processing and of the trade including at ports of export to ensure the users that only oil palm products with the appropriate quality delivered. PORLA undertakes quality control activities starting from the stage of planting materials right to the final point of export of palm oil products. The quality of palm oil products may suffer most damage at certain stages of processing, handling and transportation, the inspection programmes are designed in such a way that PORLA's Inspectors are present to conduct quality inspections at the critical point of processing, handling and transportation. PORLA'S ROLE IN QUALITY ASSURANCE PORLA's function in promoting and regulating quality practices in the palm oil industry is stipulated in its Act :-• • • •

to regulate and improve the manner of storing and shipping of oil palm products; to promote efficient handling of oil palm products; to promote measures toward attaining a high quality for oil palm products including the laying down of standards and the establishment of an efficient grading system; and generally to do everything for the betterment and proper conduct of the palm oil industry.

This Act also empowers PORLA to discharge the above function through the following means:-• • •

registration and licensing of persons in respect of all activities within the scope of functions of the Authority; provide standard practices to be observed or avoided in the palm oil industry; and specify and define the standards and grades of oil palm product and make provisions for giving effect to such standards and grades, including provisions for or relating to labelling; and prescribe records to be kept and returns to be submitted by licensees.

The Palm Oil Industry (Licensing) Regulations (Amendments) 1984 provides that any persons who move, sell, purchase, broker, export, import, store, survey or test any oil palm product must be licensed. . In issuing the license, PORLA imposes conditions and restrictions to regulate the trade and to promote quality practices to ensure the products or services rendered is of the highest quality.

RESPONSIBILITIES OF THE PARTIES IN THE EXPORT CHAIN. Palm oil proceeds through a series of parties namely producers or suppliers, traders and exporters before reaching the point of export. These parties may either be separate individuals or one individual who perform all the roles or part of it. Supplementing the export chain is the service sector namely bulk installation operators, independent surveyors and independent chemist. While installations provide bulking, handling and storage facilities at the export point; independent surveyor and chemist provide independent inspection and certification of product to determine the quantity, quality, loading superintendent and confirmation required in a commercial transaction.

PORLA GUIDELINES.

3

The parties in the chain of export are legally bound to perform their contractual commitment to one another unequivocally and efficiently. It is PORLA's policy to ensure that the palm oil products for export meet the buyer's requirements and reasonable expectations. If the chain of obligations and responsibilities are broken or abused by the parties concerned, it will lead to losses, disputes, arbitration or litigation and ultimately causes damage to the smooth trading of oil palm products. RESPONSIBILITY OF THE PRODUCER/ SUPPLIER Producers adopt proper harvesting practices so that only ripe palm fruits are harvested and delivered to the palm oil mills. The mills will inspect the quality of the raw materials (Fresh Fruit Bunch) using the " PORLA's Fresh Fruit Bunch Grading Manual" The fruits are processed with good care and efficienly so as not to damage the quality of oil during the process of extraction. It is the responsibility of the producer/supplier to ensure :-• • • • •

that the buyers' quality specifications are determined and confirmed before production begins. that the refining process employed will achieve the desired contracted specifications of the buyer. that the product has been laboratory tested and confirmed to conform to the contractual specifications for which it was intended. that the product is properly stored in such a manner that the product quality is maintained before being transferred or transported to the bulking installations at the port for export. that the movement, transport and handling of the product to the bulking installation at the port for export are carried out in a manner that will ensure that the product quality is maintained.

RESPONSIBILITY OF THE EXPORTER/TRADER From the mills, the palm oil products are channeled to the refiners, kernel crushers or oleochemical plants. Strict quality control programmes are implemented to ensure that the quality is maintained in their processing of the palm oil products. It is the responsibility of the Trader/Exporter to ensure :-• • • •

• • • • •

that all contracts of sales or purchases are registered with PORLA by telex or telegram not later than 4.00 p.m. a day after the date of transaction; followed by sending a copy of the contract to be received by PORLA not later than 30 days from the date of contract. that records of stock, sale and purchase of palm oil are properly maintained and kept for verification by PORLA Palm Oil Inspectors. that a monthly statement of stock, sale and purchase of palm oil is sent to PORLA not later than the seventh day of the following month. that the product supplied by the producer is delivered to the bulking installation at the port at least 24 hours before shipment takes place.

that the product has been laboratory tested and certified by the supplier to be conforming to the buyers' specifications. that the palm oil is free from any contamination and the quality conforms to the standard that is acceptable to PORLA. that the product has been laboratory tested and certified by an independent chemist to be conforming to the buyer specifications as specified in the sales contract at least 24 hours before shipment. that the exporter declares in the Customs Declaration (CD 2) prescribed by PORLA that the quality of palm oil to be exported conforms to the quality specifications specified in the contract of sale with the buyer. that a sample of the palm oil is send to PORLA when required, for quality determination and verification.

PORLA GUIDELINES.

4

RESPONSIBILITY OF THE BULKING INSTALLATIONS Bulking installation ( tank farm) operator is licensed exclusively for storing and facilitating bulk handling. It is the responsibility of the bulking installation operator to ensure :-• • • • • • • • • •

that the palm oil received at the installation by lorry tankers are securely sealed. In the case of pipeline transfer, the pipeline is clean, dry and free from any previous cargo before it was being used to transfer the oil to the installation at the port. that the tank used for the storage of palm oil is dry, clean, and free from any previous cargo before it was being used to store palm oil. that the Storage and Handling Practice as recommended by Palm Oil Research Institute of Malaysia (PORIM) are always complied with that a sample is drawn upon completion of bulking and is sent to an independent laboratory to determine its quality. that the palm oil quality conforms to the quality specifications required by the buyer before shipment. that the palm oil installation is kept clean and all its storage facilities are in good working condition at all times. that the oil palm product stored is free from contamination and its quality meets the standard acceptable to PORLA. that a sample of the oil palm products stored is send to PORLA as and when required, for quality determination and verification. that a monthly statement of stock, bulking and despatch of palm oil is send to PORLA not later than the seventh day of the following month. that the records of stock, bulking and despatch of palm oil are properly maintained and kept for verification of PORLA Palm Oil Inspectors.

Surveyor performs the final independent inspections and certifications before export. The surveyors will supervise the proper handling procedures to determine the quantity and to draw a representative sample for ascertaining the product quality. It is the responsibility of the palm oil surveyor to ensure:-• • • • • • • • • • • • • • •

that the superintendent and survey of palm oil are carried out in compliance with the practices recommended in the PORLA Standard Surveying Procedures And Practices For Palm Oil And Its Derivatives. that the survey is carried out in accordance to the standard imposed by the Malaysian Government and international bodies governing the surveying of palm oil products. that the survey must be conducted by a qualified palm oil surveyor under the Malaysian Palm Oil Surveyors Examination organized by PORLA. that all necessary precautions and actions have been taken to prevent any mishap by the parties involved in the loading of the palm oil from the bulking installation to the ship. that the equipment and instruments used in surveying and sampling of palm oil are not made from copper, brass or copper alloy that is detrimental to the quality of palm oil. that the three previous cargoes of the nominated ship's tank are acceptable to the terms of the contract with the buyer. that all allocated ship tanks are clean, dry and suitable in all respect for storage and carriage of palm oil. that the allocated ship tanks are free from any toxic or leaded material in the form of solid, liquid or gas, odor or any material that is detrimental to the quality of palm oil. that all samples drawn from the shore or ship tanks are kept in tightly sealed containers and are properly labelled before being send to the laboratory for analysis. that a sample of the palm oil is sent to PORLA when required for quality determination and verification. that any protest,rejection, objection or reservation on any consignment surveyed including the condition and suitability of ship's tank be reported to PORLA within 24 hours by telex or telephone and a copy of the letter of protest,rejection, objection or reservation is sent to PORLA not later than the seventh day from the date of survey. that the integrity and professionalism expected of a surveyor is uphold at all times. that the details of survey are recorded in a record book or documented in a manner that it can be easily verified by PORLA Inspector and are kept for two years from the date of survey. that the record of survey pertaining to quantity, product type, quality and details of shore and ship tanks' condition for each consignment is properly kept for verification by PORLA Palm Oil Inspector. that the palm oil survey report issued to the client is a true and accurate account of the survey and is substantiated by records and documents.

PORLA GUIDELINES.

• •

5

that a copy of the Palm Oil Survey Report is sent to PORLA not later than the seventh day from the date of survey. that a monthly statement of all the palm oil product surveyed is send to PORLA not later than the seventh day of the following month.

Qualified surveyors are registered with PORLA which forms another measure of control to enhance professionalism. A registered palm oil surveyor is required to comply to the following Surveyor's Professional Code of Ethics:-• • • • • • • •

• • • •

A registered surveyor shall conduct himself in such a manner to uphold the dignity, standing and reputation of the profession. A registered surveyor, in discharging his duty to his employer and to the profession shall have full regard to the public and national interest. A registered surveyor shall discharge his duty to his employer withcomplete fidelity and shall not accept any payment for services endered except from his employer or with his employer's permission A registered surveyor shall not injure or attempt to injure, whether indirectly the professional reputation, prospects or business of another registered surveyor or his company with which he is employed. A registered surveyor shall all times ensure that he is fully equipped with the necessary recommended tools (equipment) when conducting his work and shall always maintain a high level of technical competency, and a high degree of professional integrity. A registered surveyor shall not conduct any survey unless he is employed by a surveying company licensed by PORLA for such purpose. A registered surveyor may delegate part of his job to any person who is not a registered surveyor but under his full supervision, and shall be fully responsible for such work carried out by the non- registered surveyor. A registered surveyor, through his company shall not accept job appointment if such acceptance renders or would render it difficult for him to maintain his professional independence.

A registered surveyor shall not be influenced by the interest of his client in the conduct of the survey in so far as such interest is inconsistent with upholding the dignity, standing and reputation of the profession. A registered surveyor shall no issue any press statement in the capacity of a registered surveyor on any matters that is likely to injure the dignity and reputation of the profession. A registered surveyor shall not issue any press statement whether of facts or opinion pertaining to any dispute be tween parties in a pending arbitration action or suit of which his survey report is a relevant issue. A registered surveyor shall assist another registered surveyor in the conduct of any joint survey between them and shall not withhold any findings or information crucial to the survey.

RESPONSIBILITY OF INDEPENDENT CHEMIST The laboratory is required to conduct testing of samples of palm oil products impartially and professionally using up to date and mutually agreed methods of tests. It is the responsibly of the independent palm oil chemist to ensure :-• • • • • • •

that the sample received for analysis is contained in new container that is properly labelled and securely sealed. that the test methods applied in the analysis of palm oil samples are in accordance to the test method specified in the contract between the buyer and seller; otherwise to locally and internationally recognized test methods. that the worksheet details of analysis are recorded in a record book or documented in a manner that it can be easily retrieved and verified byPORLA Palm Oil Inspectors and are kept for 2 years from the date of analysis. that the integrity and professionalism expected of a chemist is uphold at all times. that the palm oil analysis report issued to the client is a true and accurate account of the analysis and is substantiated by records and documentary evidence. that a copy of the analysis report issued to the client is send to PORLA not later than the seventh day after the date of analysis. that a monthly statement of all the analysis carried out on palm oil product is send to PORLA not later than the seventh day of the following month.

PORLA GUIDELINES.

6

RESPONSIBILITY OF PORLA PORT STATIONS. PORLA Inspectors are based in five Regional Offices and Branch offices throughout the country to conduct periodic spot inspection on licensed premises within the respective regions. In addition, Port Stations equipped with labarotaries are set up at five major Malaysian ports to ensure that oil palm products exported stringently meet the buyers' specifications. The activities undertaken by PORLA's port stations are : • • • • • • •

to regularly conduct sampling of palm oil products at the port installations before they are exported. to take and test pre-shipment samples in PORLA laboratories located at the port stations so as to ensure that only quality palm oil products that meet contractual specifications before they are allowed to be exported. to advise exporters whose products fail to meet the contractual specifications to undertake immediate remedial actions to ensure that their products meet the contractual specifications before export to take random samples during loading (into vessels) for the purpose of enforcement of quality control declaration under Regulation 3 of PORLA Quality Control Regulations. to send samples taken to the laboratories and Chemistry Department for analysis so as to determine whether the quality conforms to the contractual specifications as declared in the Customs Declaration Form to monitor the analysis reports from the Chemistry Department in order to determine the monthly average quality and also to detect palm oil quality problems faced the industry generally to ensure that the handling, transferring, storing, transporting, surveying and shipping practices are always in accordance with the required quality practices.

ENFORCEMENT OF QUALITY CONTROL PRACTICES Regulation and Monitoring Given the legislation and the tools to implement them, it is therefore imperative for PORLA ensure that practices towards producing good quality oil palm products are promoted and good quality control activities are observed in all sectors of the industry. PORLA enforces the Palm Oil Industry Quality Control Regulations of 1983 that provide for quality control practices of oil palm products in the local trade and export: • • •

It prohibits the act of contamination of any oil palm product with any undesirable matter or any foreign matter detrimental to the quality of the oil palm product. In the case of export, the regulations provide that all exporters must declare the contractual quality specifications in the Custom Declaration Form From the monthly quality statement QC/MF/1 sent to PORLA, analysis is then made to identify mills that are producing poor quality crude palm oil.

Mills identified of this nature is given reminders to enhance their quality control process so that their products meet the stringent standards as required by the trade. •

• • •

PORLA palm oil inspectors conduct follow-up visits to the mills to check their quality records of production and take samples of the crude palm oil for quality verification as required under the Quality Control Regulation of 1983. Mills that fail to take corrective actions and instead, continue to produce crude palm oil not conforming to stringent standard trade specifications are taken stern action against . PORLA palm oil inspectors at the various regional levels also actively monitor the activity of sludge oil traders to ensure that they do not indulge in unhealthy practices of adulterating palm oil with sludge oil. Road blocks are regularly carried out by PORLA to check on palm oil tankers. During the check, the hatch covers and outlet valves and the seals are inspected. The PORLA Form PL3 as required under PORLA licensing regulations for such movements is also inspected. Regular surveillance is also conducted to identify, locate and ambush illegal storage premises used for unauthorized siphoning of palm oil from lorry tankers. Illegal storage premises were raided and disabled. Palm oil together with the equipment and facilities used in their operations were seized by PORLA.

PORLA GUIDELINES.

7

Monitoring of the Professional Services Inspection of Surveyors • • •

PORLA's inspectors regularly check on surveyors to ensure that the records and documentation of survey carried out are properly maintained and the reports issued fulfill the contractual requirements of the buyers/sellers. The monthly statement QC/SV/1 submitted to PORLA on the quality and quantity of palm oil products exported is also verified. PORLA's inspectors at the various port stations also observe / check on the surveyors at time of actual survey, so as ensure that they strictly follow the requirements stipulated by PORLA.

Inspection of Palm Oil Installations At The Ports •

•

checking the condition of facilities and the handling and storage activities. i.e. physical inspection of tanks and tank coatings The heating coils, pipelines and pumps are checked so that they are in proper working conditions and that they do not consist of any material made of copper or copper alloy which is detrimental to the quality of palm oil exported. check the records of oil temperature in the tanks so as to ensure that proper heating procedures are strictly applied during and prior to discharge of the oil from the tanks.

Inspection of Laboratories • • • •

the checking of reports of analysis issued for palm oil products. The monthly quality statement QC/CL/1 as submitted to PORLA is also verified for its accuracy. Collaborative test on methods of testing has been organized jointly with PORIM and FOSFA with the purpose of achieving consistency in the various test methods employed. licensees found not practicing quality practice in their activities or not conforming to the recommended quality practices are advised to do so. Those found to have contravened any conditions or restrictions of the licensing regulation are given reminders and warnings, compounded or prosecuted in court.

IMPLEMENTATION OF QUALITY CONTROL PROGRAMMES Ship/ Shore Surveyors Course The has been held since 1987. PORLA, in co-operation with PORIM conducts the Ship-Shore Surveyors Course annually with the objective of not only enhancing the efficiency and quality of palm oil surveying, but also promoting knowledge on the handling, transfer, storage and transportation of palm oil. Malaysian Palm Oil Surveyors Examination PORLA holds the Malaysian Palm Oil Surveyors Examination that is intended to enhance the professionalism of Malaysian palm oil surveyors. It is aimed at getting palm oil surveyors to be thoroughly knowledgeable in both palm oil survey practices as well as understanding the physical and chemical characteristics of all oil palm products. Recommended Practices For Surveying Of Oil Palm Products PORLA has established stringent surveying procedures to ensure that surveying of oil palm products, is carried out systematically and efficiently. This standard procedure covers surveying practices during loading and discharge both at the installation and ship as well as documentation of the survey. The standards provide a yardstick to measure the quality performance of the surveyors and to ensure that reports issued by them are supported by recorded facts obtained during surveying.

PORLA GUIDELINES.

8

Laboratory Accreditation PORLA in collaboration with PORIM introduced the Palm Oil Laboratory Accreditation scheme to evaluate the facilities and competency of palm oil laboratories. The evaluation is to ensure that laboratories are manned by qualified personnel, fully equipped to conduct tests under the normal parameters as specified in standard contracts, maintain proper records of analysis, conduct routine maintenance and calibration of equipment and observe strictly all safety standards and requirement during operations. Malaysian Laboratory Accreditation Scheme (SAMM) The Sectoral Committee on Oils And Fats of Malaysian Laboratory Accreditation Scheme housed in PORLA is entrusted with the objective of ensuring that local independent laboratories conduct their business according to the stipulated standards, recognized both locally and internationally.

Further Information. The legal liabilities and palm oil quality programmes are summarized in this document. For further information, please contact :

Palm Oil Registration And Licensing Authority Lot 6 SS 6 Jalan Perbandaran 47301 Kelana Jaya Tel : 03-7035544 Fax : 03-7033533

FFB GRADING MANUAL

1

PORLA FRESH FRUIT BUNCH GRADING MANUAL

INTRODUCTION This manual serves as a practical guide for the grading of fresh fruit bunch in the mills jointly prepared by a working committee which comprised of representatives from the palm oil industry and was based on a study carried out by PORLA on mills throughout Malaysia which practised fresh fruit bunch grading. OBJECTIVE The main aim of this manual is to improve the quality and quantity of crude palm oil and palm kernel productions in Malaysia. The specific objectives are as follow: • • • •

To improve the quality of fresh fruit bunch (FFB) received at the mills. To improve the quality of Malaysian crude palm oil. To improve the efficiency of oil and kernel extraction rates in the mills. To ensure that the suppliers and millers obtain a fair deal from their transactions.

IMPLEMENTATION OF THE GRADING SCHEME Site of Grading Grading can be done anywhere inside the premises of the mill or its agent. Normally, it is best done on a platform beside the loading ramp. Who Can Perform The Grading Grading can only be done by the Grading Staff of the mills or an agent appointed by the mill who has the capability and experience in the grading of fresh fruit bunch (FFB). Documents Required Documents that are required for grading are the Grading Report Form (APPENDIX Xll), weighbridge ticket and suppliers agreement documents (if any). Only fruits received from suppliers with a valid PORLA license are to be graded.

GRADING PROCEDURES Sampling Procedures Select about 50-100 bunches at random as sample from each consignment to be graded. The sample taken should represent the top, middle and bottom portion of the consignment.

The minimum sample size of each consignment to be graded should be determined based on the following criteria :

FFB GRADING MANUAL

2

• of the net weight of the consignment is less than 5 tonnes, the minimum sample size should be 50 bunches. • If the net weight of the consignment is 5 tonnes or more, the minimum sample size should be 100 bunches. The sample size should be economical, practical and able to detect any change in the bunch quality especially the degree of ripeness at 95% level of confidence. Separate the bunches that have been sampled for grading from the rest of the bunches. Grading Frequency The minimum grading frequency for each supplier of fresh fruit bunch (FFB) with long term contract should not be less than 10% of the total consignments or at a ratio of 1:10 lorries. If there is variation in the quality of fresh fruit bunches supplied or doubts regarding the bunch quality, the grading frequency should be increased to fifty percent (50%) of the total consignments or at a ratio of 1:2 lorries. For suppliers without a long term contract, grading should be done on all consignments. Bunch Classifications Fresh fruit bunch (FFB) can be classified and graded according to the following criteria: • Ripe Bunch Ripe bunch is a bunch which has reddish orange colour and the outer layer fruitlet's mesocarp is orange in colour. This bunch has at least 10 fresh sockets of detached fruitlets and more than fifty percent (50%) of the fruits still attached to the bunch at the time of inspection at the mill. The bunch and the loose fruits are to be sent to the mill within 24 hours after harvesting. • Underripe Bunch Underripe bunch is a bunch which has reddish orange or purplish red colour and the outer layer fruit's mesocarp is yellowish orange in colour. This bunch has less than 10 fresh sockets of detached fruitlets at the time of inspection at the mill. The bunch and the loose fruits are to be sent to the mill within 24 hours after harvesting.

• Unripe Bunch Unripe bunch is a bunch which has black or purplish black fruits and the outer layer fruit's mesocarp is

yellowish in colour. This bunch does not have any fresh sockets of detached fruitlets at the time of inspection at the mill. The sockets(if any) on the bunch is not due to normal ripening process. • Overripe Bunch Overripe bunch is a bunch which has darkish red colour fruits and has more than fifty percent (50%) of detached fruitlets but with at least ten percent (10%) of the fruits still attached to the bunch at the time

FFB GRADING MANUAL

3

of inspection at the mill. The bunch and the loose fruits are to be sent to the mills within 24 hours after harvesting. • Empty Bunch Empty bunch is a bunch which has more than ninety percent (90%) of detached fruitlets at the time of inspection at the mill. • Rotten Bunch Rotten bunch is a bunch partly or wholly and together with its loose fruits have turned blackish in colour, rotten and mouldy. • Long Stalk Bunch Long stalk bunch is a bunch which has a stalk of more than 5 cm in length (measured from the lowest level of the bunch stalk). • Unfresh Unfresh bunch is a bunch which has been harvested and left at the field for more than 48 hours before being sent to the mill. The whole fruit or part of it together with its stalk has dried out. Normally, this type of bunch is dry and blackish in colour. • Old Bunch Old bunch is a bunch which has been harvested and left at the field for more than 7 days before being sent to the mill. The fruitlets still remaining on the bunch are dry and brownish black in colour. The stalk is also dry, soft, fibrous and blackish in colour. • Dirty Bunch Dirty bunch is a bunch with more than half of its surface covered with mud, sand, other dirt particles and mixed with stone or other foreign matters. • Small Bunch Small bunch is a bunch which has small fruits and weight less than 2.3 kg. (5 lbs.) • Pest Damaged Bunch Pest damaged bunch is a bunch with more than thirty percent (30%) of its fruits damaged by pest attack such as rat etc.

FFB GRADING MANUAL

• Diseased Bunch Diseased bunch is a bunch which has more than fifty percent (50%) parthenocarpic fruits and is not normal in terms of its size or its density. • Dura Bunch Dura bunch has fruits with the following characteristics: • Shell thickness - 2-8 mm • Ratio of shell to fruit - 25-50% • Ratio of mesocarp to fruit - 20-60% • Ratio of kernel to fruit - 4-20% • No fibre ring around the shell • Loose Fruit Loose fruit is a fruit detached from a fresh bunch because of ripeness and is reddish orange in colour. All loose fruits have to be sent to the mill within 24 hours after harvesting. • Wet Bunch Wet bunch refers to a consignment of fresh fruit bunches (FFB) which has excessive free water.

GRADING METHODS The sample that has been selected will be graded to determine the quality of the bunches and the extraction rate that can be given to the supplier. During grading the following practices should be carried out: • • • • •

Inspection and assessment of the bunch quality. Calculation of penalty for poor quality bunch. Determination of the basic extraction rate. Calculation of the awarded extraction rate. Inspection And Assessment of the Bunch Quality

The grading of the consignment of fresh fruit bunches should be done in the presence of the supplier or his representative such as the lorry driver or his attendant. The lorry with the consignment of fresh fruit bunches (FFB) which has been selected to be graded is directed to unload on the platform near the loading ramp. Ensure that the bunches are evenly laid out and no overlapping or layering should occur. Count the number of bunches in the consignment and calculate the average bunch weight with the following formula:

4

FFB GRADING MANUAL

5

Average Bunch............Net Weight (kg) as per Weight.....................= Weighbridge .................................=================. ..................................Total Number of Bunches From these bunches, select at random 50-100 sample bunches and separate them from the rest of the bunches. Selection of the minimum sample size should be based on the net weight of the consignment. Grade, classify and count the sampled bunches into 5 groups based on the criteria of bunch classifications: • • • • •

Ripe Bunch Underripe Bunch Unripe Bunch Empty Bunch Rotten Bunch

Inspection and assessment of the bunch quality should be done quantitatively. Record the number and the percentage of each group in the Grading Report Form as shown in APPENDIX. The total percentages of the 5 groups must be hundred percent (100%).

Grade, classify anf count agein all the sampled bunches into 5 groups as follows :• • • • •

Long Stalk Bunch Dirty Bunch Dura Bunch Old Bunch Wet Bunch

The grading should be based on the criteria of bunch classifications. Record the number and percentage of each group in the Grading Report Form as shown in APPENDIX Xll. The percentages of the 3 groups of bunch quality are calculated based on the total number of sampled bunches. • Calculation of Penalty For Poor Quality Bunch A penalty based on the discount system as shown in APPENDICES III to XI, will be imposed on the poor quality bunches. The penalty imposed will depend on the results of the grading as stated in the Grading Report Form. Check these results with the Penalty Appendices (APPENDIX III - APPENDIX XI) and from there get the actual penalty value that can be imposed on each category of poor quality bunches. Book for reference :Refer to Fresh Fruit Bunch - Grading Manual. •

Consignment of fresh fruit bunches (FFB) that has poor quality bunches and exceeding:

FFB GRADING MANUAL

• •

6

the 20% of maximum allowable limit for empty bunches or; the 30% of maximum allowable limit for dirty bunches should be rejected and return back to the supplier the whole load.

In practice, it is not possible to obtain hundred percent good quality bunches and hence a reasonably good quality consignment should comprised of the following combination of bunch quality : Bunch Category

Limit

Ripe Bunch

> 90%

Underripe Bunch

< 10%

Long Stalk Bunch

< 5%

Unripe Bunch

0%

Dura Bunch

0%

Empty Bunch

0%

Rotten Bunch

0%

Dirty Bunch

0%

Old Bunch

0%

Wet Bunch

0%

• Determination of The Basic Extraction Rate The basic extraction rate is the theoretical extraction rate which is also the maximum extraction rate of the oil and kernel. This extraction rate can be determined in 2 ways that is by the age of the palm and the bunch weight. • Determination of The Basic Extraction Rate Based On The Age of The Palm The basic extraction rate can be determined by the age of the palm provided that the information regarding the year when the oil palm was planted is known (Refer to APPENDIX I). This method is suitable for mills that receive fruits from their own estates. • Determination of The Basic Extraction Rate Based On The Bunch Weight This method is suitable for mills that receive their supplies from outside estates and dealers who do not have information regarding the age of the oil palm (Refer to APPENDIX II). The average bunch weight can be calculated by dividing the net weight (as stated in the weighbridge slip) with the total number of bunches.

GRADING REPORT • Sample Grading Report All observations and calculations during grading must be recorded in the Grading Report Form as shown in APPENDIX XII. Particulars that have to be recorded are as follow:

FFB GRADING MANUAL

• • • • • • • • • • • • • •

Net weight Number of bunches Number and percentage of unripe bunch Number and percentage of underripe bunch Number and percentage of ripe bunch Number and percentage of empty bunch Number and percentage of rotten bunch Number and percentage of long stalk bunch Number and percentage of dirty bunch Number and percentage of Dura bunch Number and percentage of old bunch Number and percentage of wet bunch Observations on bunch quality Name and signature of Grading Officer

Use separate Grading Report Form (APPENDIX ) for each grading consignment. This form is to be filled in duplicates. The original copy is to be kept by the mill and the second copy to be given to the supplier or its representative.

• Monthly Grading Summary Report All observations and calculations recorded in the Grading Form have to be summarised and recorded in the Monthly Grading Summary Form The particulars that have to be recorded are as follows: • • • • •

Amount of fresh fruit bunches received Amount and percentage of fresh fruit bunches graded Crude palm oil produced Oil and kernel extraction rates achieved Average bunch weight and age of palm

• • • • • • • • • • • •

Percentage and penalty (if any) for unripe bunch Percentage and penalty (if any) for underripe bunch Percentage of ripe bunch Percentage and penalty (if any) for empty bunch Percentage and penalty (if any) for rotten bunch Percentage and penalty (if any) for long stalk bunch Percentage and penalty (if any) for dirty bunch Percentage and penalty (if any) for Dura bunch Percentage and penalty (if any) for old bunch Percentage and penalty (if any) for wet bunch Awarded extration rate for oil and kernel given to the supplier Name and signature of the mill manager

7

FFB GRADING MANUAL

Only one copy of this form is to be filled for record and retention by the mill.

8

APPENDIX I

GRADING FORM

NAME OF SUPPLIER PHASE / LOT PORLA LICENCE NO DATE VEHICLE NO

:____________________________________________________ :____________________________________________________ :____________________________________________________ :____________________ TIME :_________________________ :______________ WEIGHBRIDGE TICKET NO :___________

PARTICULARS Nett Weight

Tones

Total Bunches Average Bunche Weight FFB Grading (1) Unripe Bunches

Kilograms NUMBER

PERCENTAGE ( % )

(2) Underripe Bunches (3) Ripe Bunches (4) Rotten Bunches (5) Empty Bunches TOTAL (1) Long Stalk Bunches (2) Dirty Bunches (3) Dura Bunches (4) Old Bunches (5) Wet Bunches TOTAL

Remarks

:___________________________________________________ ____________________________________________________ ____________________________________________________

SIGNATURE :____________________ NAME :_________________________

100%

BASIC EXTRACTION RATE FOR OIL PALM MILL TABLE I

BASIC EXTRACTION RATE FOR OIL AND KERNEL BASED ON THE YEAR PLANTED (AGE OF PALM) TENERA (DXP) * PROGENY

YEAR PLANTED <3 3-<4

PENINSULA

SABAH/SARAWAK

EXTRACTION RATE OIL KERNEL (%) (%) 14-15 4.0-4.2 15-16 4.2-4.5

EXTRACTION RATE KERNEL (%) 3.5-3.9 3.9-4.2

OIL (%) 15-16 16-17

4-<5 5-<6

16-17 17-18

4.5-4.8 4.8-5.0

17-18 18-19

4.2-4.5 4.5-4.8

6-<7 7-<8 8 - < 18

18-19 19-20 20

5.0-5.5 5.0-5.5 5.0-5.5

19-20 20-21 21

4.8-5.0 4.8-5.0 4.8-5.0

18 and above

19-20

5.0-5.5.

20-21

4.8-5.0

* For good quality FFB

PERUNDING AME - Consulting Engineers.

1

TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL. By Noel Wambeck & Aziz Jidon January 25th, 1999

This manual has been developed for use by a commissioning engineer and his team assigned to test and commission an Oil Palm Mill, machinery, equipment, system and plant. It sets forth the standard operating requirement, test procedures, data, records required and reporting program to be adopted by the commissioning engineer and his team in the function of the various aspects of an oil palm mill process and systems for commercial operation including the following :

A. Design test programme, levels of throughout, scheduling -

Quality test Endurance test

-

5 hours / day for 5 days processing 16 hours / day for 2 days processing

B. Monitoring testing phase C. Monitor equipment performance D. Analyse results of all tests E. Ensure all problems identified during testing are corrected to standards and specifications F. Certify factory is operational

This manual consist of four main section and appendices as follows :

& Preparation & Test Procedures & Finalization & Taking over and certification test & Appendices.


2

1. PREPARATION. Prior to the actual testing a number of actions need to be taken. It is important that these actions are completed well before any physical testing takes place and that the members of the terms assigned to do the checking and/or testing are involved in the pre-preparations.

1.1

Documentation & Reporting.

When construction is completed, either item by item, station by station or for the factory as a whole, all machinery and equipment installed should be listed in a Master list of Machinery and given an identification letter or number ( Appendix A ) With the aid of these lists (which will form part of the basic information for the future maintenance programme) each machine and each part of the equipment should be checked with the aid of a check list. ( Appendix B ) This checklist will also be part of the basic information for the future maintenance programme. A complete electric motor list should be made, including every electric motor installed in the factory and its ancillary equipment. ( Appendix C ). The use of computer (spread sheet) programmes will make the creating and keeping of these valuable records a less onerous task. These list / records shall be prepared before any actual testing of machinery and each member of the “commissioning team” must have a full set of these lists for his use during the test period. q The identification list can at a later stage be incorporated into the spare parts administration and the maintenance programming. q The check list can be used at any time in the future when a periodic check on the condition and status of the machinery is to be made. q The list can also be used as the index for the test programme. This list should be updated to incorporate any specific information given in the instruction /maintenance manuals for the individual machines. q The electric motor list must be updated to show : a)

for each motor the running current in Amperes under the “no load” condition and under the “full load” condition and

b)

the type of starter equipment used for the motor.


3

All data gathered must be entered into a computer spread sheet programme and be kept for future reference, for updating when machinery is changed, etc. These listings will thus contain all the basic information required to set up and organize the future maintenance and repair programmes.

1.2 Personnel.

The checking / testing should be performed by two teams (team A and B ). Each team should consist of at least two or three members ( including the client’s employee) with a good knowledge of the process to be tested, at least two members with a good knowledge of the mechanical equipment used in the process and at least one person with a good knowledge and understanding of all the electrical equipment installed. Each team must be complemented with at least two samplers. Arrangements must be made for at least two experienced analysts in the Laboratory assisted by three subsamplers per day or (during the endurance test) per shift. The tests are to be arranged over five consecutive days for five hours and followed by two days of sixteen hours continuous processing.

1.3 Fruit delivery Arrangements must be made to ensure the delivery of sufficient FFB to the new mill during these periods, i.e.based on a mill with a capacity of 45mt FFB per hour the requirement of FFB are : 5 days x 5 hours (25 hours x @ 45 ton / hr.) 2 days x 16 hours ( 32 hours x @ 45 ton/hr.) total

= 1125 = 1440 -----------------------------= 2565 mt FFB

or say for in round figures, a total of ± 2600 tons FFB. For each of the test days, assign a team to a specific area or areas in the mill and change this each day to obtain every ones view on the individual and the overall mill equipment performance. An example of the team organization is shown in Appendix D.


4

2. TEST PROCEDURES. Once the physical checks have been completed, the machinery tests for the processing of FFB can commence. These tests must as a minimum include the following checks :

2.1 Weighbridge. q Test the weighbridge according to the Manufacturer’s specifications and instructions from the manual. q Check the zero adjustment and have the weighbridge certified by the appropriate Government Inspector. q Check and record several loads, note the accuracy of the weighing, the time required to complete one weighing, the operation of the recording device and the printer out put.

2.2 Loading Ramps. q Fill the range to at least three quarter full before starting to transfer FFB into the cages. This will show up any defects in the angle of the ramp surface and whether the position of the tracks and cages under the ramps is correct in relation to the ramp. Check by filling cages and note the filling and spilling of FFB. q Check the operation of the doors or slides under the load pressure of the nearly full ramp. If in doubt, take the Ampere readings of the drive motor(s), or if the hydraulic ramp type is used, check the pressures, flow, filters, etc.

2.3 Rail Tracks. q Check the alignment and the level of the tracks under full load conditions. q Note the ease of “rolling” of the cages / bogies over the track.

2.4 Cage Transfer Unit q Check the alignment and locking into the correct transfer position when unit under full load.


5

q Shift unit to the required rail track, note again the ease of “rolling”, the alignment and the correct locking position for this track. q Transfer the cages and check hydraulic system under full load and take Ampere readings of motors when under full operating load. q In the case of a “gantry transfer” system, perform similar checks under operating load conditions.

2.5 Marshalling Yard. q Check rail levels and alignment, note the alignment and the levels to the hinged rail pieces at the sterilizers.

2.6 Cages And Bogies q Observe operation and ease of movement, linking cages into a train and the shunting of these trains. q Check the bogie bearings and the wheel alignment of each full cage.

2.7 Capstans ( Winch ) And Bollards. q Load a full train (i.e. sufficient for one complete sterilizer load) of FFB cages and check the load on the capstan motor and record the Ampere reading.

2.8 Sterilizer Operation q After loading of FFB close both doors and perform the same checks that should have been performed when the sterilizer was first tested under steam pressure, i.e., door seals (for leaks), valves and fittings (for leaks) daeration and condenser fittings for operation and the functioning and operation of the instrumentation, pressure, gauges, recorders, etc. q When under full working pressure and with a full load of FFB check the alignment and the positions of the sterilizer support saddles and rollers. q Check the functioning and the performance of the automatic cycle, the times and the pressures of the various stages and the corresponding recorder readings.


6

q Once the cycle is completed note down the full cycle time, i.e. from “doors close to doors open” and check the final blow-off performance. q Check the performance of the silencer and condensate equipment and note down any irregularities. q Check that the safety locking devices setting / location to prevent the doors opening under pressure and are functioning correctly. q The locking ring contact and door shall be not less than 75% ( 100 mm ) when the locking device is in close position. q After opening the doors, check that all condensate has been evacuated from the sterilizer vessel during the blow-off. q Check the alignment with the hinged rail pieces once more and pull the load out of the sterilizer, note the ease of movement and operation and note down any irregularities.

2.9 Hoisting Crane q Check the chain alignment on the tipping rings on the fruit cage. q Time and record the operating cycle of the crane, i.e. a) b) c) d) e) f)

lifting time tipping time lowering time next cage pick up total time and calculate the maximum throughput per hour that can be handled by the hoisting crane.

q Check the load on the crane travel motor and the hoist motor when under operating load. q Alternative : Tippler machine. – Same checks as above.

2.10 Thresher machine. q Check the tipping and spilling of sterlized fruit into and onto the thresher feeding device. q Note the operating speed of the feeder conveyor / device.


7

q Check the threshing action of the machine by following (observing) one or more marked bunches throughout the threshing action from entry to exit. q Record the time it takes for one cage load to be threshed from entry to exit. q Calculate the throughput. q Check the effectiveness by examining all the bunches that exit the thresher. q Check and record the full load Amperes of the thresher feeder motor and the drive motor for the drum. q Check the operation of the variable speed control of the thresher feeder for correct performance, i.e. adjusting to slower or faster feeding rates as required.

2.11 Empty Bunch Handling q Check all bunches released from the exit of the thresher and remove any bunches that still contain fruitlets or are partially or wholly “ Unstripped bunches”. q Deposit these bunches in a separate cage for later checking (see Thresher Operations). q Check the transport of the Empty bunches on both the horizontal and the inclined conveyor note any spillage. q Check the operation and record the full load Amperes of the conveyor drive motors. q Check the conveyors and feed chutes into the hopper incinerator ( production of potash ).

( for field disposal ) or

2.12 Incinerator. q Check incinerator performance at earliest one whole working /processing day after the process has started. q Note the composition of the ashes produced and the efficiency of the incineration process. Record the results. q Whilst the incinerator is operating check the draught conditions and the even burning of the material on the furnace grates.


8

q In the event the Hopper system is in use, check operations of the top bunch conveyor and hydraulic units and doors system.

2.13 Conveyors / Elevators q Check the conveyor screw alignment under full load operating condition and the clearance between the screw and the wear plates, taking particular note of the action of the conveying material for process passing the hanger bearings. q Check and record the full operating load Amperes on all conveyor drive motors and the elevator drive motor. q Check and note the feeding to the elevator boot to ensure that material for process is not screwed past this feed chute. q Check the “pick-up” and load of each elevator bucket and note the clearance of the buckets in the elevator boot. If this clearance is excessive, measure and have a guide plate fitted to prevent large masses of material for process remaining in the elevator boot. q Check the full load of the elevator drive motor again and record the result in the check lists. q Calculate the time required to transfer the contents of one full fruit cage to the distributing conveyors above the digesters. q Perform the checks as noted under conveyors (above) for the top distributing conveyors and the return conveyors. q Note and record the full load Amperes of the drive motors on the checklists.

2.14 Digesters. q Check that the steam heating operates and the temperature gauges indicate the correct temperature. q The temperature of the digester mash should be approximately 95 degree C before the screw press. q With the full digester, check and record the full load Amperes of the digester drive motor on the check lists.


9

q Check the digesting performance by taking a number of samples from the feeder chute to the press, after 15 minutes and 30 minutes of digesting, with the press operating. q Material for process should have the appearance of a fairly homogenous mash, with virtually all fruitlets sheared and fibre and nuts clearly separate. q Very few whole, undigested, fruits should be visible in this mash. q Check the optional digester drainage valve is in closed position during extraction process to prevent excess NOS in raw crude oil before clarification. Bottom drainage of the digesters must not be allowed. q The drainage of free oil should be done only in the event of wet expeller cake appearance at the press discharge during start up and stoppage of the screw presses or as a result of over dilution. q Check the continuous filling to the full level of the digester during the operation of the pressing. q Check for leaks, etc., from the digester bottom and the feed chute to the press.

2.15 Pressing Operation. q Check that the motor rotation and speed is correct for the given capacity, pulleys and belts, gearbox is lubricated, hydraulic unit if filled and operating in the right rotation, worm screws are correct in clearance and rotation and the hot water spraying system is functioning. q Ensure that the feeding rate from the digester to the press is as even as possible. q With the press under full load, i.e. with the pressure cones in operation / closed position, record the Amperes of the press drive motor. (To do this check properly, operate the press in the Manual Control position). q Switch control to “automatic” and observe the operation and performance of the press and the automatic cone adjustment. q Take samples of the expelled press cake and analyze on site for the nut / kernel breakage and visibly “dry” fibre. q Take frequent samples and have these analyzed immediately for “oil loss on dry fibre”. Record the results together with the particular meter readings of the press at the time the sample was taken.


10

q Calculate the press through put from the receipts of the loading of FFB on the ramp and empty Sterilized FFB Cages figures against the time recorded and note any out of the ordinary conditions during that time. q If dilution of press liquid is practiced, check on the dilution rates and the method of adjustment used, record the findings.

2.16 Crude Oil Station. q Check the free flow of the extracted and the expelled liquid mixture in the crude oil gutters. q Observe the flow and note any restrictions, under full flow conditions. q If a sand trap is used, check its operation and effectiveness at least one hour after the operation of the presses has commenced. q Record the results. q Check the operation and the performance of the vibrating screens q Check that there is no carry over of liquid with these solids. q If so, adjust the screening operation and re-check. Repeat this action until optimum results of separating the solid from the liquid fraction of the crude oil is obtained. (Especially if the “vibro energy separator” type is used, such adjustments must be made). q Check and record the electric motor load of the screen drive motor and record the Amperes. q Check the action of the crude oil pumps, transferring the crude oil to the clarification. Ensure that an as much as possible “even and steady” flow to the clarification station is achieved. q Note and record the full load Amperes of the pump drive motors. q If the crude oil tank is fitted with (closed) steam coils for heating, check the performance and record the temperatures and condensate trap operation.


11

2.17 Clarification Station. Clarification system. q Observe the entry of crude oil into the clarification equipment is consistent, this is to be as smooth and as steady as possible. q If decanters are used, check out the complete operation with the aid of the manufacturer’s specific instructions contained in the operations manual. q Observe the full load Amperes and record on the check lists. q If static clarification is used, observe the performance and take samples of the clarifier under flow to determine the oil on sludge percentage. q Check all temperatures and the steam heating equipment and record the results. q Observe and measure the thickness of the oil layer to be skimmed and adjust the skimmers if necessary to obtain the optimum “clean oil” flow to the pure oil tanks. q Take samples and have these immediately analyzed for F.F.A., moisture and dirt content.

Purifier. q Operate purifiers and check their performance with the aid of the manufacturer’s instructions manual. q Check and record the full operating load Amperes of the purifier drive motors. q Take samples after the purifier and have these analyzed immediately for moisture and dirt content.

Vacuum Oil Dryer. q Operate the Vacuum oil dryer according to the manufacturers instructions and record the temperature and pressure readings, both of the dryer and of the steam ejector equipment. q Take samples and have these analyzed immediately for moisture content only. q From the results of the analyzed samples as shown above, a “picture” can be formed of the effectiveness of the various stages.


12

q Observe the flow of sludge to the sludge tanks and the sludge separator, take samples and analyze immediately for oil content, moisture content and solids content.

Sludge Separator. q Operate the sludge separators according to the manufacturer’s specific instructions and take samples of the liquid after the separator, before flowing to the effluent systems. Analyze samples immediately and record the results. q From the results of the analyses a picture can be formed of the effectiveness of the sludge separating process and the losses sustained. q Check and record the full operating load Amperes of the sludge Separators. q Where screens, pre-cleaners, rotary brushes, pumps etc., are used, check each one and record performance and electric loads on the check lists. q Observe all piping and fittings in the clarification station and note down any irregularities. q Calculate for each machine the throughput after the tests or production run has been stopped and record findings on the checklists.

2.18 Depericarping station. Cake Breaker : q Check the operation by observing the action of the paddle conveyor tossing the press cake whilst transporting it to the depericarper. q Check and record the full operational load of the Cake breaker conveyor drive motor and record on the check lists. q Take samples of the mixture of fibre and nuts at the end of the Cake breaker conveyor and have these samples analyzed immediately. q The appearance of the mixture should be of loose, fluffy fibre and clean nuts. q Observe the entry of the material into the depericarper and the obstruction caused by the hanger bearings of the Cake breaker conveyor and the final screw at the end of the conveyor.


13

q Where the conveyor is fitted with a steam jacket, check the fittings and the effectiveness of this steam heating.

Depericarping : q Check the motor load of the fibre cyclone fan under full operational load conditions and record the results. q Perform the same for the polishing drum and the nut transport conveyors, pneumatic transport, elevators etc. Record all findings. q Observe the separation of fibre and nuts by taking samples of the nuts before and after the polishing drum and samples of fibre after the fibre cyclone outlet, before being mixed with other materials in the boiler fuel conveyors. q Analyze the samples immediately and record the results.

q If found necessary, adjust the throat opening of the depericarper to achieve the optimum separation of fibre and nuts under full pressing operating capacity and not/mark the settings of this adjustable throat. q If adjustments are made, recheck all the motor loads again on fans, conveyors etc.

2.19 Kernel Recovery. q Check the effectiveness of the transport of nuts from the polishing drum to the drying silos / storage bins. Record the full load Amperes of the drive motors for conveyors, fans etc.

Nut Polishing Drum. q Check the effectiveness of the polishing drum. Are the nuts polished ?. the adjustment of drum speed may be required. q Take samples of nuts before the nut bin and analyze immediately for moisture content of nuts, broken nuts and kernel and dirt etc. in this nut material.

Nut Dryer. q Check the performance of the nut dryer, record temperatures, fan motor loads, etc.


14

q If a grading drum/system is installed, take samples of nuts before and after the grading. q Analyze immediately the compare and record the results.

Nut Cracker. q Take samples before entering the crackers and analyze immediately, including the moisture content of the nuts. q Check the feed regulating devices into the crackers and record the electric motor load of the nut crackers when in full operation. q Approximate throughput can be calculated by feeding nuts at an established rate into a bag or container of 50 kilograms and measure the time it takes to fill this bag or container. q Take samples after the crackers and analyze this “cracked mixture” immediately for whole nuts, broken nuts with shell adhering, whole kernels, broken kernels and shell content. q Calculate the shell nut ratio.

Dry separation system ( winnowing ) q Check the performance of the primary and secondary separating columns by taking samples after each column and analyzing these immediately for contents in a similar way as described above. q From the analysis results, calculate the effectiveness of the separating columns. q If found necessary, adjust the column throats / damper to achieve the optimum separation under the full load conditions. q After each adjustment samples must be taken, analyzed and recorded and the position of the adjustable throat openings must be marked and recorded. q Take samples if the “final” kernel to the kernel dryers and analyze immediately for admixture, moisture and F.F.A content.

Hydro-claybarth separartion system. q If a clay bath or hydro cyclone is used to further separate the remainder of the cracked mixture, follow the manufacturer’s instructions/recommendations to achieve the most efficient separation.


15

q Take samples before and after this equipment to analyze immediately and assess the effectiveness. Record the results. q Observe the transportation of the shell and dirt components to the boiler fuel conveyor system. Check and record the electrical load on all motors used in this system and record the full operational Amperes on the checklists.

2.20 Fuel Supply To Boilers. q Observe the mixture of fibre and shell before entering the boiler fuel distributing conveyors. q Take samples and analyze to calculate the fibre : shell ratio.

2.21 Water Treatment. q Check and observe the water intake and pumps, and measure the electrical load and record. q Check and observe the raw water treatment in flocculation tank and water clarifier basin or tank. q Check and observe the operation of the raw water filters and the cleaning thereof by back washing and /or air scouring. Record the performance and the operational procedures noted. q Check and observe the operation of the chemical dosing pumps, the quantities of chemicals used and the type of chemicals used. Also record the water usage. q Check and observe the demineralization plant operation, take samples before and after the process and have these analyzed. Compare and record the results and assess the effectiveness of the treatment q Take boiler feed water and boiler blow down samples and have these analyzed. q From the results of the analyses noted above, assess or calculate the effectiveness and the performance of the water treatment system as a whole and for the boiler water section specifically.


16

2.22 Power House. q Check and observe the operation and the load of the Diesel driven electric power generating sets. Record all the main switch board readings on separate sheets, recordings to be taken every half hour. q Record the incoming steam pressure and the back pressure at the back pressure vessel every half hour throughout the operating period. q Record all temperatures, pressures and load of the Turbine driven electrical power generating sets. Record all main switch board readings on separate sheets, recordings to be taken every half hour. q Ensure that the TIME is correctly recorded since this will relate to the readings/recordings made from the boiler equipment and will later be used for the assessment/calculation of the overall steam generating/electrical power generating balance.

2.23 Effluent ponding treatment system. q During these test runs, the effluent ponds will only be filling up and their performance cannot as yet be assessed. q Samples of the effluent going into the ponds must however be taken and analyzed to establish the input into the ponding system. q An estimate of the flow rate into the ponds is also to be made. q Proper checking of the performance and effectiveness of the ponds should start after the normal hydraulic retention time calculated for the ponds has elapsed, i.e. after 30 and 60 days of operation. q The main checking at this initial stage is the performance of the cooling tower, recycling pumps, aerators and the flow pattern, findings must be recorded.

2.24 Laboratory. q Each team must be responsible for the analyzing and calculating of the results of the samples their team has taken.


17

q In this way there will be 3 sets of analyses of the same machinery and equipment, but done at different times, under different conditions and observed/checked by different people. q At the end of the endurance test period, the analyses must be checked and calculated by each team and a full report made of the teams overall findings and observations. q These reports must from the basis of the control and processing standards that are to be set and maintained during the “Take over certification test” and the rest of the operating life span of the mill. The sample test and laboratory report sheet in shown in Appendix.

2.25 Crude palm oil Storage. q During the test period, tanks will only be filling up, but tank fittings, temperature control etc., can be checked and recorded. q A note must be made of the method used to calibrate the storage tanks and the figures obtained should be checked/compared against actual oil weighing. q At the end of the 5 day test period, Team A should check and sort all data gathered by the teams and coordinate the laboratory test results. This can be done on day 6, when team A is not involved in the endurance test. q Team B will continue to check the whole mill on the first shift during day 6 q Team A will continue to check the whole mill on the second shift during day 6


3

18

FINALIZATION.

After completion of these test periods, all data and results from all the teams and the laboratory analysis are to be tabled in a general meeting with all participants. (The check list can be used as the guide for the agenda of this meeting). All problems identified must be discussed and recorded in the minutes, even if the problem has already been solved during the test periods. The meeting will ensure that the equipment identification list and the electric motor lists are complete with all data that is required and make these lists available for future reference.

3.1 Process Control And Monitoring Indicators Enclosed are the appendices showing the suggested layout for the control and monitoring indicators to be calculated for each of the five day @ 5 hours test period and for each shift of the two day @ sixteen hours endurance test periods. These reports are to be tabled at the final meeting and analyzed together with the check lists produced by the teams and the individual analysis data calculated by the Laboratory analysts. These reports will also form the basic layout for the future reporting on direct mill performance and should be incorporated into the overall mill monthly reports. The universally recognized system of judging the overall efficiency of the milling operation is to calculate the EXTRACTION efficiencies by the “known losses”. Refer to the sample of the Extraction efficiencies form enclosed in the following page. The “comments /notes /remarks” sections should have notes on individual items, whilst the General Comment section provides space for comments on the overall utilization, losses or quality parameters. At the end of the meetings and if overall consensus and agreement is reached, the new factory should be certified by the participants of the tests and the meetings as “operational”. Any non operational areas, or not yet fully operational areas (such as for instance effluent or storage tanks etc.) must be specified and excluded from such certification.


19

SAMPLE OF THE EXTRACTION EFFICIENCIES FORM.

FOR CRUDE PALM OILL : % OIL EXTRACTED TO FFB ---------------------------------------------------------------------- x 100% % OIL EXTRACTED + TOTAL OIL LOSS TO FFB

Where the total oil loss is the sum of : -

to F.F.B

-

to F.F.B

-

to F.F.B

-

to F.F.B

A = % loss of kernel in shell

-

to total kernel

B = % loss of kernel in cyclone fibre

-

to total kernel

C = % loss of kernels in final cleaning

-

to total kernel

% oil loss in empty bunch and stalks % oil loss in press fibre % oil loss in nuts % oil loss in total from clarification (This should calculated to > or +/- 92%)

FOR PALM KERNEL : % EFFICIENCY KERNEL EXTRACTION = 100 – A – B – C Where :

(This should calculate to > or +/- 92%)


4

20

TAKING OVER AND CERTIFICATION TEST. Once the new mill has been certified as operational in accordance with the test and commissioning programme as set out above, the official hand over – take over certification test can proceed. The procedure for this Supervision is suggested to be as : a:

Site visits by the Consultant (frequency depending on circumstances, but not less than once per calendar month ).

b:

Liaison meetings with contractor, preferably at the time of the site visit.

c:

Advice/recommendations for possible improvements, modifications etc.

Operational procedures as applicable to each individual mill (in view of the different types of equipment installed) will be set out in liaison with the client and consultant and printed in the form of a “Manual for Factory Operations” for the mill in question. The layout of these procedures will follow the order of the listing of the stations / equipment as per the checklist produced for the Taking over certification test.

PERUNDING AME SDN BHD – Consulting Engineers. 25 th January 1999.

PERUNDING AME SDN BHD - Consulting Engineers.

1

TRAINING AND MANPOWER

Please refer to the attached “ Training Management and Staff for Palm Oil Mill ”. The detailed training programme will be formulated in liaison with the client, once the basis for such a programme has been set out by the Consultant. Organizational structure and a Manpower Development Plan will be closely linked to the above and thus must await the availability of the training programme.

MASTER LIST OF MACHINERY


ITEM

DESCRIPTIONS

QTY

UNIT

POWER / KW Unit Total

SPEED RPM

PROPOSED 45 MT FFB PER HOUR IN THE FIRST STAGE AND FUTURE EXTENSION TO 90 MT FFB PER HOUR OIL PALM MILL.

1

FRUIT RECEPTION

1.1

Weighbridge

1

1.2

F.F.B. Loading Ramp & Hopper C/w Hydraulic System

20

bays

5.5 x 2

11

1.3

FFB Scraper bar conveyor with covered walkway

2

Nr

7.5

15

1.4

Cage Transfer Carriage No.1

1

Nr.

5.5

5.5

1.5

FFB Cages

42

Nr.

0

0

1.6

Rail Tracks

8

Lines

0

0

2

STERILISING STATION

2.1

Mobile Rail piece

6

Nr

0

0

2.2

Sterilisers - 2 DOOR TYPE

3

Nr.

0

0

2.3

Steriliser Auto Program Control

3

Nr

2.2

6.6

2.4

Steriliser Catwalk

1

Lot

0

0

2.5

Blow off Silencer

3

Nr.

0

0

2.6

Winches

6

Nr.

11

66

2.7

Idler Bollard

8

Nr.

0

0

2.8

Condensate Blow-down Chamber

3

Nr.

0

0

2.9

Steriliser condensate sump pump

2

Nr.

3

6

2.10

Steriliser Condensate Recovery Tank

1

Nr.

0

0

2.11

Clarification waste water sump pump

2

Nr.

3

6

2.12

Clarification waste water sludge tank

1

Nr.

0

0

2.13

Skimmed oil - collection tank

1

Nr.

0

0

2.14

Skimmed oil - pumps

2

Nr.

2.2

2.2

2.15

Acid oil collection Tank

1

Nr.

0

0

2.16

Acid oil drumming pump

1

Nr

2.2

2.2

2.17

Transfer carriage system at Loading Ramp

1

Nr.

7.5

7.5

Page 1 of 18

25

1460

1460

1460

1460

Perunding AME Sdn Bhd / 25 Jan. 99 / NW.


ITEM

3

DESCRIPTIONS

QTY

UNIT


SPEED RPM

THRESHING STATION

3.1

Cage Tippler machine

1

Nr.

7.5

7.5

3.2

FFB conveyor cum auto feeder for tippler

1

Nr.

7.5

7.5

3.3

FFB cross conveyor to Thresher No.2

1

Nr

5.5

5.5

46

3.4

Thresher No.1 with bottom screw conveyor complete with platform, handrails & walkways Drum drive Bottom screw conveyor

1

Nr.

1

18

18

25

1

3

3

46

3.5

Recycled Bunch Elevator

1

Nr.

5.5

5.5

56

3.6

Bunch crasher with feed chute

1

Nr

22

22

3.7

Thresher No.2 for recycle bunches with bottom screw conveyor with platform, handrail & walkway Drum drive Bottom screw conveyor

1

Nr.

3.8 a b c

Empty bunch conveyor ( 3 sections ) with support Horizontal section No.1 Inclined section Horizontal section No.2

1

3.9

E.B. Hopper c/w Hydraulic system

8

a b

a b

4

2 to 10

1

18

18

25

1

3.75

3.75

46

1

5.5

5.5

46

1 1

7.5 5.5

7.5 3.75

46 46

bays

7.5

7.5

46

lot

PRESSING STATION

4.1

Fruit Elevator

2

Nr.

5.5

11

46

4.2

Fruit distribution conveyor c/w chutes and doors

1

Nr.

3.75

3.75

46

4.3

Fruit Return Conveyor complete with chute

1

Nr.

3.75

3.75

46

4.4

Press station structure complete with platform handrails and walkways.

1

lot

0

0

0

4.5

Hot water tank for press station

1

Nr.

4.6

Digester - type 3500 kg cap.

3

Nr.

22

66

28

4.7

Twin Screw Presses - type P15 complete hydraulics

3

Nr.

30

90

16

4.8

Crude oil collection gutter in SS

1

Lot

0

0

4.9

Desanding tank ( sand trap )

1

Nr.

0

0

4.10

Sand removal conveyor for sand trap

1

Nr.

3.75

3.75

46

4.12

Sand removal elevator with screen buckets

1

Nr.

3.75

3.75

56

4.13

Hopper with support for sand waste

1

Nr.

0

0

4.14

Vibrating screen - 60" Circular - double deck type complete with ms structure, platform & walkway

2

Nr.

3.75

7.5

4.15

Screen Waste Conveyor

1

Nr.

2.2

2.2

4.16

Crude Oil Tank with auto steam heating, insulation etc.

1

Nr.

0

0

4.17

Crude Oil Transfer Pumps with auto level switch

2

Nr.

3.75

7.5

4.18

Crude Oil diluation control system

1

Nr.

Page 2 of 18

56

1460



ITEM

5

DESCRIPTIONS

QTY

UNIT


SPEED RPM


5.1

Vertical Clarifier with stirrer, insulation & cladding

1

Nr.

3.75

3.75

25

5.2

Heating tank with pumps

1

lot

2 x 2.2kw

4.4

1460

5.3

Sludge settling tank with SS liner

1

Nr

0

0

5.4

Crude oil tank with SS liner

1

Nr.

0

0

5.5

Pumps for sludge tank

2

Nr.

2.2

4.4

5.6

Steel structure for decanter & Vacuum dryer platform complete with handrails, supports & walkways

1

lot

0

0

5.7

Desanding multi-cyclone unit & pumpset

1

Set

2.2

2.2

5.8

Sludge balance tank of SS

1

Nr.

0

0

5.9

3 Phase Decanter

1

Nr.

30

30

5.10

Solid waste Conveyor for Decanter sludge

1

Nr

2.2

2.2

5.11

Hopper for solid waste

1

Nr

0

0

5.12

Light Phase Tank with pumpset

1

Nr.

2.2

2.2

1460

5.13

Heavy Phase Tank with pumpsets

1

Nr.

2.2

2.2

1460

5.14

Balance tank with SS liner

1

Nr.

0

0

5.15

Steel Structure for Clarification Station with 1 ton maintenance chain block

1

lot

0

0

5.16

Sludge Separator complete unit

1

Nr.

15

15

5.17

Oil Heater Tank with Pumpset c/w Level switch

1

Nr.

3.75

3.75

5.18

Oil Purifier

2

Nr.

7.5

15

5.19

Vacuum Oil Dryer with vacuum & transfer pumps

1

Nr.

2x 7.5

15

5.20

Hot Water Tank with auto steam heating

1

Nr.

0

0

5.21

Sludge Fat pit pumpsets

3

Nr

3.75

11.25

5.22

Sludge oil recovery tank

1

Nr

0

0

5.23

Pumpsets for sludge oil & Effluent waste

2

Nr

3.75

7.5

5.24

Acid oil tank

1

Nr

1

Nr.

11

11

1

Lot

1

1

6

1460

56

DEPERICARPING STATION

6.1

Cake Breaker Conveyor c/w Supporting Structures and Platform

6.2

Depericarping System Consists Of:-

a)

Depericarping Column c/w Adjustable Damper and Supporting Structures

Page 3 of 18

62



ITEM

DESCRIPTIONS

QTY

UNIT


SPEED RPM

b)

Ducting To Cyclones And Fan

1

Lot

0

c)

Fibre Cyclone

1

Nr.

0

d)

Air lock c/w Drive and mounting rollers for easy removal

1

Nr.

2.2

2.2

e)

Fan complete with Motor

1

Nr.

56

56

6.3

Depericarper Damper Control System

1

Nr.

6.4

Nut Polishing Drum

1

Nr.

5.5

5.5

30

6.5

Nut conveyor No.1

1

Nr

3.75

3.75

56

6.6

Nut Elevator No.1

1

Nr.

3.75

3.75

56

6.7

Destoning System Consists Of:-

a)

Separating & Expansion column with Supporting Structures

1

Lot

0

0

b)

Ducting From Column To Cyclone and Fan

1

Lot

0

0

c)

Cyclone

1

Nr.

0

0

d)

Air lock ( Inlet feed ) c/w drive

1

Nr.

2.2

2.2

30

e)

Airlock ( Nuts ) c/w drive

1

Nr.

2.2

2.2

30

f)

Cyclone

1

Nr.

g)

Air Lock ( Cyclone ) c/w Drive

1

Nr.

2.2

2.2

h)

Fan complete with motor

1

Nr.

25

25

6.8

Destoner Damper Control System

1

Nr.

6.9

Nut conveyor No.2

1

Nr

3.75

3.75

56

56

7

30

0 30

KERNEL RECOVERY STATION

7.1

Nut Conveyor No.3

1

Nr.

2.2

2.2

7.2

Nut Silos

2

Nr.

0

0

7.3

Nut feed conveyor to elevator

1

Nr.

3.75

3.75

7.4

Nut Elevator

1

Nr.

5.5

5.5

7.5

Nut grading drum

1

Nr.

2.2

2.2

56

7.6

Nut feed conveyor to ripple mills

1

Nr.

2.2

2.2

56

7.7

Nut cracking rippler mills

4

Nr.

5.5

22

30

7.8

Cracked mixture conveyor

1

Nr.

2.2

2.2

56

7.9

Cracked mixture elevator

1

Nr

3.75

3.75

46

Page 4 of 18



ITEM

7.10

DESCRIPTIONS

QTY

UNIT


SPEED RPM

Cracked mixture dry separation system consist of :

a)

Air lock c/w Drive

2

Nr.

2.2

4.4

b)

Winnowing Column c/w Adjustable Damper

1

Lot

1

1

c)


1

Lot

0

d)

Cyclone 1st stage

1

Nr.

0

e)

Airlock ( cyclone ) c/w Drive

1

Nr.

2.2

2.2

f)

Fan c/w Motor

1

Nr.

11

11

g)

Winnowing Column Damper Control System

1

Nr.

h)

2nd stage Winnowing Column c/w Adjustable Damper

1

Nr.

1

1

30

30

I)


1

Nr.

0

j)

Cyclone 2nd stage

1

Nr.

0

k)

Airlock ( cyclone ) c/w Drive

1

Nr.

2.2

2.2

l)

Fan c/w Motor

1

Nr.

11

11

m)

Winnowing Column Damper Control

7.11

Cracked Mixture Conveyor

1

Nr.

2.2

2.2

56

7.12

Kernel conveyor

1

Nr.

2.2

2.2

56

7.13

Hydrocyclone 3 stage type c/w pumps

2

Nr.

2 x 15

60

7.14

Wet Shell Pneumatic Transport System

30

a)

Airlock c/w Drive

1

Nr.

2.2

2.2

b)

Fan c/w Motor

1

Nr.

7.5

7.5

c)

Ducting From Fan to Cyclone

1

Nr.

0

d)

Cyclone

1

Nr.

0

7.15

Wet Kernel Elevator

1

Nr.

5.5

5.5

46

7.16

Wet Kernel Conveyor

1

Nr.

5.5

5.5

56

7.17

Kernel Silo c/w Fan and Feeder

2

Nr.

11

22

7.18

Dry Kernel Conveyor

1

Nr.

3.75

3.75

56

7.19

Kernel Winnowing System Consist Of:30

a)

Airlock c/w Drive

2

Nr.

2.2

4.4

b)

Column, air duct and cyclone

1

lot

0

0

c)


1

Nr.

11

11

Page 5 of 18

30



ITEM

7.20

DESCRIPTIONS

QTY

UNIT

SPEED RPM

Kernel Pneumatic transport system

a)

Air lock with drive motor

2

Nr

b)

Air duct & cyclone

1

lot

c)


1

7.21

Distribution conveyor on top of bulk silos

7.22

Kernel Bulk Silo c/w discharge Doors & Vent Fan

8


2.2

4.4

Nr

11

11

1

Nr

3.75

3.75

3

Nr

3 x 18

54

0

0

BOILER HOUSE

8.1

Shell Bunker with steel structure

1

Nr.

8.2

Boiler fuel distribution conveying system

1

lot

Fuel conveyor I Fuel conveyor II ( double deck )

1

Nr

7.5

7.5

56

1

Nr

7.5

7.5

56

8.3

Ground Feed Tank

1

Nr.

0

0

8.4

Boiler feed water treatment plant, consist of : 2

Nr.

3.75

7.5

Nr.

0

0

a b

a

Softener Booster Pump

b

Deaerator Feed Tank c/w Insulation and supporting Structure

c

Deaerator Tank Pump c/w low level alarm

2

Nr.

15

30

d

Duplex Water Softener

1

Nr.

1

1

e

Chemical Dosing Pump c/w dosing tank

2

Nr.

0.33

0.66

f

Vacuum Deaerator

1

Nr.

0

0

g

Deaerator Extraction Pump

1

Nr.

15

15

Water tube Boiler - 35,000 kg / hr @ 20.8 bar complete with the following : FD Fan Secondary draught Fan Induced draught Fan Soot blower system Feed water pump - electric Feed water pump - steam turbine Controls

2

Nr

2 2 2 2 3 3 3

Nr Nr Nr Nr Nr Nr Nr

60 11 45 7.5 30 30 1

120 22 90 15 90 0 1

8.6

Fuel Disposal conveyor with supporting structure

1

Nr.

7.5

7.5

56

8.7

Fuel Return Elevator

1

Nr.

5.5

5.5

46

8.8

Boiler Blowdown Chamber

1

Nr.

0

0

8.9

Ash Removal Conveyor

1

Nr.

3.75

3.75

8.5 a b c d. e f g

Page 6 of 18

46



ITEM

9

DESCRIPTIONS

QTY

UNIT


POWER PLANT

9.1

Turbo Alternator. 1200 kw

1

Nr.

9.2

BPR Pressure Controller

1

set

0

9.3

Back Pressure Receiver c/w Insulation, Operating Platform

1

Nr.

0

9.4

Exhaust silencer

1

Nr

0

0

9.5

Diesel skid tank with pumpset

1

Nr.

3.75

3.75

9.6

Diesel day tank

1

Nr

9.7

Diesel genset 150 kw

1

Nr.

0.33

0.33

9.9

Diesel genset 350 kw

2

Nr.

0.33

0.66

9.10

Air compressor for pneumatic system

1

Nr

15

15

15

15

10

0.5

0.5

PALM OIL STORAGE & CPO LOADING SHED

10.1

CPO Storage Tanks - 2000mt cap.

2

Nr

10.2

CPO transfer pumps

2

Nr

10.3

CPO inspection bridge structure

1

Nr

11

N - RAW WATER TREATMENT PLANT

11.1

Raw Water Clarifier

1

Nr.

0

11.2

Clarified water concretesettling tank

1

Nr.

0

11.3

Clear Water Pump c/w Level Switch

2

Nr.

11

22

11.4

Chemical dosing pumps & mixing tanks

3

Nr

0.33

1

11.5

Pressure Sand Filters

2

Nr.

0

0

11.6

Water transfer pumps

2

Nr

15

30

11.7

Water Storage Tank with structure

1

Nr.

11.8

Chlorination System with dosing pumps

1

Nr.

12

0 0.33

0.33

FIRE PROTECTION EQUIPMENT & SYSTEM

12.1

Hose reel points

8

Nr

12.2

Fire Hydrant

4

Nr

12.3

Emergency Diesel Pump

1

Nr

12.4

Extinguishers & Apparels

a b c

SPEED RPM

Lot

CO2 type extinguishers Dry powder extinguishers Asbestors blanket and gloves

6 8 2

Page 7 of 18

Nr Nr Nr



ITEM

13

DESCRIPTIONS

QTY

UNIT


SPEED RPM

MISCELLANEOUS

13.1

Central Monitoring, Alarm & Control System

13.2

Coupling, belt & pulley guards

1

Lot

13.3

Maintenance Platform for Conveyor & Elevator Drives

1

Lot

13.4

Effluent Recycling Pumps c/w Float switch

2

Nr.

15

30

1460

13.5

Surface Aerators

4

Nr.

7.5

30

1460

1

Lot

14

Lot

3

PIPING, VALVES & FITTINGS The cost shall include pipes, elbows, tees, reducers, flanges, nipples, coupling, steam traps, sight glasses, sockets, gauges, meters, air vents, sniffer valves, air release valves, safety valves, blinds, insulation, pipe supports and etc.for the following services:-

14.1 a)

14.2

Raw Water Piping:Water Clarifier to Overhead Water Tank

Cold Water Piping:-

a)

Overhead Water Tank To Plant/Equipment

1

Lot

b)

Ring Main within Factory Building with 50mm as main and 25mm as down comer installed @ 18m c/c c/w valves

1

Lot

c)

To Factory Office

1

Lot

d)

To Workshop

1

Lot

e)

To Canteen/Toilet/Locker Room

1

Lot

14.3

Steam Piping:-

a)

High Pressure From Boiler to Engine Room

1

Lot

b)

High Pressure From Boiler to Vacuum Ejectors, Turbine Feed Water Pump

1

Lot

c)

Low Pressure From Turbine to Back Pressure Receiver

1

Lot

d)

Low Pressure to and Within Sterilisation Station

1

Lot

e)

Low Pressure to and Within Steam Plant

1

Lot

f)

Low Pressure to and Within Main Process Building

1

Lot

g)

Low Pressure to and Within Clarification Station

1

Lot

h)

Low Pressure to and Within CPO Storage Tanks

1

Lot

Page 8 of 18



ITEM

DESCRIPTIONS

QTY

UNIT

1

Lot

14.4

Steam Condensate Piping

14.5

Sludge Oil Piping:-

a)

Within Press Station

1

Lot

b)

Within Clarification Station

1

Lot

14.6

SPEED RPM

Crude Oil Piping:-

a)

Press station within & to Clarification station

1

Lot

b)

Within Clarification Station

1

Lot

c)

Clarification To CPO Tanks

1

Lot

d)

CPO Tanks To Unloading Shed

1

Lot

1

Lot

14.7

Compressed Air To Control Valve

14.8

Diesel Oil Piping

14.9

Effluent piping from Sludge pit to the ponds

approx. 500

M

14.10

Effluent piping from sump to recycle pumps to Acidification Ponds

1 Approx. 200

Lot M

A

Total power installed for operating machinery

B

Allowing a load diversity factor of 65 % to operate the mill at 45 mt FFB per hour.

C

Complex street lighting and domestic use

D


CONNECTED LOAD

1531.08

Power supply : 1. Steam Turbo Alternator 2. Diesel engine Alternator 3. Diesel engine Alternator

1 unit 2 units 1 unit

Page 9 of 18

x 0.65

1200 kW 350 kW 150 kW

1531.1 kW 995 kW

Total

55 kW 1050 kW

Total

2050 kW


Appendix B Sheet 1 of 1

COMMISSIONING CHECK LIST OF OIL PALM MILL This check list may not contain all of the machinery, data or items required for a specified design of an oil palm mill but should be used as a basis for a general check list during testing & commissioning of the machinery, equipment and plant for further development such as processing reports and maintenance programme. ITEM

STATION / LOCATION

A.

Reception area

01.

Weighbridge

02.

Check

Loading ramp

BRIEF NOTES

ITEMS TO CHECK

:

condition of mill internal roads

:

Condition, operational procedures

:

recording methods, accuracy

:

condition, operational procedures

:

fruit spillage, overall cleanliness

03.

Railtracks

:

overall condition

04.

Transfer tracks

:

overall condition, operational procedures

05.

Marshalling yard

:

type/condition of cage moving device

06.

a) Cages

:

number operational

:

number under repair

:

total number available

:

number operational

:

total number available

:

condition, operational procedures

:

chart recorders

:

door wear and door joints

:

door safety devices/measure

:

wear plates/internal railtracks

:

hinged railpieces

:

Condensate drainage

:

condition silencer/pit

:

condition valves, pipes, etc.

:

thermal insulation

:

pressure, cycle times (door open/door close)

:

sequence of usage, automatic system operation

:

check roof, rafters, columns, floor

b) Bogies

07.

Capstans & Ropes

B.

Sterilization :

08.

Sterilizers

Check

Operation

09.

Building GENERAL COMMENT : CHECKED BY :

DATE :


COMMISSIONING CHECK LIST OF OIL PALM MILL

C 10.

REMARKS

Crane & Thresher : Crane / Tippler: condition of

:

Beam

:

hoist cables Drum / tippler

11.

tipping chains

:

power cables

:

feeding device, RPM

:

thresher drum, RPM

:

bar clearance, spider arms

:

threshing action, effectiveness

:

count 100 bunches

:

all drive units, chains and sprockets

:

machinery guards

Thresher : condition of

12.

:

Unstripped bunch count check

D.

Empty bunch disposal system or incinerating :

13.

EB conveyors. condition of

:

Chains, scraper bars, sprockets etc. Drive units

14

Incinerator

:

Chutes etc.

:

Incinerator roofs

:

Incinerator grates

:

External and internal brickwork

:

Method of operation, sequence of usage

GENERAL COMMENT :

CHECKED BY :

DATE :



E.

Extraction Station :

15.

Conveyor

16. 17.

18.

check

:

Condition of bottom fruit conveyors

Elevator

:

fruit elevator chains and buckets

Top fruit conveyor

:

top fruit conveyors

:

feed chutes

:

return fruit conveyors

:

drive units and machinery guards

:

overall condition shaft, arms, wearplates,

Return fruit conveyor check

19.

REMARKS

Digestors

pinion & rack valve and feed chute

check 20.

Presses

:

Steam heating, injection system & control

:

Temperatures

:

average throughput

:

general performance (visual)

:

all drive units and machinery guards

:

Condition of worm screws, cage, cones, seals, bearings, drive shaft, press body.

:

Hot water spraying system. Auto hydraulic system. all drive units and machinery guards

F

Crude oil :

21.

Gutter

22. 23.

24.

check

:

crude oil gutters and tank

Crude oil tank

:

tank operating temperature

Vibrating screens

:

Type

:

condition and operation

:

solids carry over/effectiveness

:

dilution rates (at screens)

:

tank heating type (closed coil or live steam)

:

type, condition, method of operation

:


Crude oil pumps check

GENERAL COMMENT :

CHECKED BY :

DATE :



G.

Clarification Station :

25.

Clarifer tank

check

REMARKS

:

clarifier tank operation, levels and temperatures

:

underflow composition and oil content

:

pure oil skimming and operational procedures

26.

Sludge tank

:

sludge tank operation

27.

Decanters

:

feedrates, feed temperature, electric loading

:

overall condition

:

Capacity, feed temperature, electric loading

:

type used, sequence of usage, condition

:

Capacity, feed temperature, electrical loading,

28.

29.

Oil Purifier

Sludge centrifuges

nozzle size, type used, sequence of usage, condition 30.

Vacuum Dryer

:

Capacity, feed temperature, vacuum, electrical loading, condition

31.

Piping, fittings, flow meters

:

valves, pipelines and fittings

:

overall condition/operation

:

station working temperature

:

station overall cleanliness

:

special tools for centrifuges (available / condition)

:


GENERAL COMMENT :

CHECKED BY :

DATE :



H.

Depericarper Station :

32.

Cake breaker conveyor

:

condition/operation

33.

Primary depericarper

:

ducting condition

Fan

:

fan condition, electrical loading

Fibre cyclone

:

fibre cyclone condition

Air lock

:

rotary sluice condition

:

nut/fibre separation effectiveness

:

condition chains / buckets

:

electrical load

:

drives and machinery guards

:

overall condition, cleanliness

:

average loading , operating temperatures

:

heaters, filters, fans

:

cleaning frequency

34.

Nut elevators

check

I. 35.

Kernel Recovery Station : Nut silos

check

36.

Nut grading drums

:

drum condition, drive, machinery guards

37.

Nut cracking

:

feeding rates and methods

:

overall cracker condition

:

cracker loading (electrical)

:

cracker effectiveness

38.

Uncracked nut conveyor

:

uncracked nut return, quantity, where

39.

Dry separation system

:

Same checks for 1st & 2nd winnowing system

40

REMARKS

Feed conveyor

Condition of feed conveyor & drive

Ducting

Ducting condition

Fan

Fan operation & condition

Cyclone

Cyclone condition

Air lock

Air lock condition

Hydro cyclones

:

drum condition

:

Pumps condition

:

water supply and waste discharge method

GENERAL COMMENT : CHECKED BY :

DATE :


COMMISSIONING CHECK LIST OF C.P.O. MILLS

I 40.

REMARKS

Continue - Kernel recovery : Hydro cyclone Separation effectiveness

41

Clay bath separators

:

overall operation, clay condition, qty.

:

Clay condition , gravity tests,

check

Pump condition Vibrating trays or drum condition

42

Shell conveyor

:

water supply and discharge, clay recover

:

conveyor/elevator condition

:

recovery rate

Check 43

Drive & gearmotor

Kernel winnowing system

Separation effectiveness Blow or fan condition

44

Kernel transport system

Condition of conveying system Or pneumatic system

Check 44.

Kernel silo / Bulk storage

Check

J.

Boilerhouse :

44

Fuel conveyors Fuel

45

Excess fuel conveyor

Drives : gearmotor / fan or blower :


:

average loading, operating temperatures

:

heaters, fan, filters

:

cleaning frequency

:

conveyors, belts, etc.

:

vibrating screen, secondary separation

:

check fuel storage space

:

stored fuel condition, shell content, dryness etc.

:

distribution of fuel, firing method Same checks as above

GENERAL COMMENT :

CHECKED BY :

DATE :



46.

Boiler Plants

REMARKS

Type of Boiler Capacity per hour (MCR) :

operating pressure

:

operating procedures

:

Operating frequency (period before change over)

cleaning interval

check : condition of

47.

Boiler feed pumps

:

Furnace

:

Tubes

:

chimney and soot collectors

:

firing equipment

:

fans, draught reg. and doors

:

furnace and grate (visual)

:

gauge glasses, indicators

:

other instrumentation checks & calibration

:

Frequency of regeneration

:

condition pipelines, valves etc.

:

Elect. & turbine drives conditions

:

treated water storage system/quantity Record usage of chemicals etc. chimney temperatures

:

ash and soot removal procedures

:

chemical dosing equipment condition.

K.

Boiler Feed water plant :

48.

Chemical dosing equipment

Chemical dosing equipment condation

49.

Feed water pumps

Feed water pump s conditions

50.

Deserator plant

: :

Deaerator condition, operation, temperature manual/automatic/modulated feed supply

GENERAL COMMENT :

CHECKED BY :

DATE :


COMMISSIONING CHECK LIST OF OIL PALM MILL L.

Raw-water Treatment Plant

:

51.

Raw water intake pumps

:

52.

Intake Building

:

53.

Pipe line to mill

:

54.

Clarifier tank

:

55.

Sand filter

Filter condition

56.

Pumps

Condition of pumps, seal, impeller etc

57.

Treatment plant building

REMARKS

condition raw and treated water chemicals used, quantities methods of dosing etc. frequency of cleaning

M.

Engine Room :

58.

Diesel drive alternators

59.

Steam turbine drive alter.

:

steam turbine / alternator condition

60.

Electrical switchboard

:


:

condition of switch gear

:

condition of instrumentation

:

condition of pipelines, valves, fittings

:

condition of instrumentation, gauges, etc.

:

operational methods, pressures

:

condition of safety equipment

:

condition, loading, operation

:

recording methods logbooks etc.

:

frequency of machine rotation/usage

:

availability of safety devices etc.

:

overall cleanliness

61.

62.

Back pressure vessel

Air compressors General

Diesel engine / Alternator condition

GENERAL COMMENT :

CHECKED BY :

DATE :


COMMISSIONING CHECK LIST OF OIL PALM MILL OTHER GENERAL MILL AREAS : N.

Effluent ponding system

63.

Sludge / Fat pits.

Condition of sludge pits / ponds

64.

Sludge oil recovery tank

Any trace of oil in pond and estimated amount

65.

Transfer pumps

Screens, drains, pumps

66.

Pipe line to ponds

Aeration devices, overflow alarms etc.

67.

Mixing / cooling ponds

Safety measures etc.

68.

Anearobic ponds

69.

Faculatative ponds

70.

Stablisation pond

71

Recycling pumps

72

Mechanical Aerators

O.

Laboratory :

73.

Equipment

:

Chemicals used, correctness

:

sub sampling room, recording methods

:

Sampling methods, analysis methods

:

raw data results, data interpretation

:

Accuracy, overall cleanliness

:

oil tank temperature recording

CPO Tanks

:

Method of calibration, measuring devices

Dispatch pumps

:

Condition of tanks, pipelines, valves etc.

:

Method of dispatch, security etc.

:

Tank cleaning interval

:

Condition of Bulking Silos, heating Vent etc.

:

Method of dispatch, security etc.

:

Cleaning interval

P.

Produce storage :

74.

Crude Palm Oil

75.

Check

Palm Kernel.

76.

Acid Oil tank ( High FFA )

Condition of tank, pipeline, pumps Method of dispatch, security etc

GENERAL COMMENT :

CHECKED BY

DATE

REMARKS



Q.

General & Administration

:

REMARKS

Check condition / availability

Perimeter fencing Station and factory lighting Security

R.

Lightning protection

:

Workshop equipment, material

:

Stores and spare part stock

:

Staff and labour housing

:

Water supply Electricity supply Housing availability

:

Overall power requirement

: :

S.

Staff and labour

:

Manager / Engineer Assistant manager

:

Shift staff

:

Shift labour

:

Workshop staff

:

Workshop artisans

:

Workshop labour

:

Stores staff

:

Administrative staff

:

GENERAL COMMENT :

CHECKED BY :

 22nd , January 1999 / Noel Wambeck.

DATE :

Appendix C

ELECTRIC MOTOR LIST 1. Prepare an electric motor list, according to the code numbers of the machinery and add the particular details for each motor, i.e.: Example : LR1

PS1

No. motor Name Type Frame type Power Speed kW Amps Starter Total number Usage

No. motor Name Type Frame Power Speed KW Amps Starter Total number Usage

: : : : : : : : : : :

: : : : : : : : : : :

----------------------Crompton Parkinson Flanged mounted --------AC 3 phase 415V, Hz 50. 1500 R.P.M. 3kW 15Amp DOL 10 Loading ramp door drive

----------------------Elektrim Foot mounted --------3 phase, 380-415V, 1500 R.P.M. 30kW. 45Amp. star-delta starter 3 Digestor drive Etc., etc.

2. A suitable computer programme, which can either be purchased (and then usually needs modifications to suit the particular application) or be developed on site. 3. The motor list must have columns to record the “no load” and the “full operational load” electric current expressed in Amperes. 4. The completed lists should be copied and made available to each member of the test and commissioning team.

SPECIFICATIONS FOR MACHINERY

WEIGHBRIDGE

SPECIFICATION SHEET PROJECT NAME

DATE:

13-May-00

MACHINE NAME PROJECT CODE

OIL PALM MILL

ROAD WEIGHBRIDGE

DELIVERY DRAWING NO.

PREPARED BY

NW

REVISION No. LOCATION RECEPTION

ITEM No. QUANTITY / UNITS

GENERAL

A1 1

Scope of works include the unloading, safe keeping , assist in the installation, testing and commissioning. PROPRIETARY ITEM TO BE SUPPLIED BY THE CLIENT.

Function:

Weighing of FFB on delivery and dispatch of CPO and kernel.

SPECIFICATIONS

One (1) Load cell road weighbridge ( Pitless ) for operation on electronic system.

Capacity

50,000 kg

Platform

12 m x 3 m x 12.5 m ms constructed platform and skid resistant

Weighing system

PITLESS - Load cell weighbridge

Weight display

Electronic Digital Indicator with read out 0 to 50,000 kg x 10 kg

Power load

2000 watts 230 volts 50 hz AC single phase.

Electronic Printer:

Laser ink jet type printer

Recording

The following features shall be included. i) Interfaces with indicator to provide digital indication and print gross, tare and nett weight, vehicle registration number, date, time, consecutive number and code for type of product. ii) Push button for testing. iii) Error indication.

Uninterruptible Power

A reliable U.P.S. system shall be provided to serve as a back up for at least 2 hours in the event of a power failure.

Tickets

5000 copies of tickets in triplicate printed to the approved format.

P.C Computer

(Interface with indicator ) Intel 500 MHz Max pro Pentium processor with pre-installed Microsoft Windows 95 and Office 2000 shall be provided

Page 1 of 2

WEIGHBRIDGE


DATE:

13-May-00


OIL PALM MILL

ROAD WEIGHBRIDGE


PREPARED BY

NW



A1 1

Sheet 2.

Keyboard

The keyboard shall be full size with the Standard QWERTY layout with all alpha, numeric, punctuation and mathematical symbol characters.

Memory / Cache

Shall be adequate of at least 128 MB to cater for the required program to effect the use of the computer for weighbridge and the requirements of the General office use and print out format.

Colour monitor / Display

17" Sony SVGA colour monitor

Printers

Good quality printer with A4 paper sheet tray one for A3 paper Alternative for colour printer should also be included in the offer.

Drives

8.2 GB Hard drive, 3.5" 1.44 Floppy disk drive, 44x CD - ROM drive

Internal Fax / Modem

Motorola 33.6 kbps

Software program

Special Note

a. Weighbridge Ticket printing program with printing for. Daily, weekly and monthly summary of tonnage by product, suppliers, vehicles, etc. b. Fraud proof (please give details). c. Anti virus & protection 1. All equipment shall be ‘tropicalised and rodent proof. 2. Calibration and testing shall be provided 3. It is the responsibility of the supplier to arrange with the Weights and Measures Department for the stamping of Weighbridge. Stamping fees will be borne by the Employer. In addition to the documents as required, the supplier will supply 10 sets of weighbridge tickets 30 days after award of tender and 4 copies of all approvals and test certificates upon delivery or 3 months prior to commissioning whichever is earlier.

General

Contractor shall provide design details of the equipment for the consultant's approval before fabrication.

Page 2 of 2

RAIL TRACKS AND SLEEPERS


DATE:

13-May-00


OIL PALM MILL

RAIL TRACKS & SLEEPERS

DELIVERY

PREPARED BY

NW


DRAWING NO.


A2 8 SETS

GENERAL

Scope of works include the fabrication, delivery, erection & installation, commissioning handing over and guarantee

Function

For conveying fully loaded 7.5 MT FFB cages from the FFB Hopper to the Steriliser Cage transfer carriage and than to the Tippler, whereas the empty cage is conveyed back to the FFB Hopper.

Construction

As per drawing

SPECIFICATIONS

Eight ( 8 ) Lines Rail Tracks including Sleepers as follows : The tracks shall be constructed from standard mild steel rail bar, mounted and welded to MS channel sleepers, set at 800 mm c/c which shall be laid onto the prepared RC floor ( RC floors shall be provided by the civil works contractor ) The rails shall have section not less than 90mm x 82mm x 42mm and weighing approx. 22 kg per meter with wheel space of 800 mm gauge. It shall cater for the complete 90 metric tonnes FFB per hour operation of the Mill spanning the complete length of the fruit reception area to the end of the steriliser bay of which 2 are return tracks in accordance to the drawings. The complete railtrack system shall be laid, aligned, levelled and well anchored before casting into concrete such that the top of the rails is flush with the concrete floor. The rail system shall be properly anchored to prevent settlement thus avoiding derailment of the 7.5 MT FFB cages during operation. Suitable drains shall be provided to ensure that water is not trapped in the rail system.

General

Contractor shall provide design details of the rail system for the Consultant's approval before fabrication. The contractor shall check during the installation with the civil contractor who will provide assistance in completing the works for the marshalling yard area.

Page 1 of 1

FFB HOPPERS


DATE:

13-May-00


OIL PALM MILL

FFB LOADING RAMP & HOPPERS


PREPARED BY

NW



A3 8 SETS

GENERAL

Scope of works include the manufacture, erection & installation commissioning, handing over and guarantee

Function:

To receive, store and load FFB into FFB CAGES

SPECIFICATIONS

Fifteen ( 15 ) bays FFB Hoppers complete with hydraulic system as follows :

Type: Capacity: Slope: Construction Material: Construction Details: Door operation:

Sloping ramp c/w hydraulic operated doors 30 doors x 15 tonnes FFB = 450 MT FFB. not less than 27 deg. As per drawings As per drawings Hydraulic type, vertical stroke( top down) c/w individual lever control located at FFB hopper's platform as per drawings

Hydraulic System:

Consist of hydraulic pump, oil tank, cylinders, tubing, lever control releif valve, pressure gauges, pump strainer, check valve and all the necessary accessories for completion operation of units of 15 doors. The tank shall be interconnected.

Powerpack Reservoir Pump

Double unit 80 litres Fix displacement low noise gear type, 23 litres/min @ 250 Bar

Relief valve

Direct acting type, 120 litres/min adjustable from 0-100 Bar

Cylinder:

piston type, 915mm stroke 200 bar rated pressure 300 bar static pressure Heavy duty construction with welded cap and easily removalbe head with air bleeding plugs at both end 63mm ID and 78 mm OD barrel

Piston road: Mounting: Directional Control Valve: Tubing:

38mm diameter rod heat treated steel hard chrome plated Female clevis both ends.

Motor:

11kw = 5.5kw x 2 Vendor to advise .

Detail Drawings

Contractor to provide detail drawing for approval by the consultant

Individual valve for each door seamless cold drawn hydraulic tubing, 235 N/m2 minimum yeild strength. Flaxible hoses to be 2 -wire braided high pressure type.

Page 1 of 1

415V 50 Hz TEFC IP 55 Class F

HORIZONTAL CONVEYOR


DATE:

13-May-00


OIL PALM MILL

HORIZONTAL CONVEYOR

DELIVERY

PREPARED BY

NW

REVISION No. LOCATION

DRAWING NO.

RECEPTION


A4 1 unit

GENERAL

Scope of works include the manufacture, delivery & installation commissioning, handing over and guarantee .

Function:

To convey FFB from the Loading ramp and controlled feed into the cross cage feed conveyor

SPECIFICATIONS

One (1) unit Horizontal Conveyor suitable for 90mt FFB per hour operation complete with steel structure, covered walkway, handrails and ladders

Type:

Conveyor chain with scrapper plate

Capacity:

90mt FFB per hour

General Arrangment:

As per drawing

Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate:

Steel c/w hardened steel flanged rollers, 150 mm pitch, 9000 kg breaking load Mild steel or equivalent Mild steel or equivalent 12T, 150 mm pitch, grey iron Mild steel 6 mm minimum thickness or equivalent

Basic Dimension: Width: Length: Inclination: Conveying Section: Shaft Speed: Transmission Sprocket Ratio: Drive: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:

1200 mm 45 m Horizontal Top 25 rpm 1.00 Geared motor coupled conveyor shaft by tarnsmission chain & sprocket 1450 25 6876 <

Page 1 of 4

rpm rpm Nm (min) 1.5

HORIZONTAL CONVEYOR


DATE:

13-May-00


OIL PALM MILL

HORIZONTAL CONVEYOR

DELIVERY

PREPARED BY

NW


DRAWING NO.

RECEPTION


A4 1 unit

Sheet 2.

Motor:Power: Type:

18 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

APPROVED MAKES

Specified or Equivalent.

Motor: Gear reducer: Coupling: Conveyor & Transmission chain, sprocket Bearing:

Crompton Parkinson, ABB Brook, Brush, ELEKTRIM SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold Renold, Tsubaki, PC SKF, FAG, NTN

OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devises c/w take-up bearings

Page 2 of 4

CAGE FEED CONVEYOR


DATE:

13-May-00

PREPARED BY

NW


OIL PALM MILL

CAGE FEED CONVEYOR

DELIVERY


DRAWING NO.

ITEM No.

A5

QUANTITY / UNITS

1 unit

GENERAL


Function:

To convey FFB from the horizontal conveyor and controlled feed into the FFB cages lined up in front of the sterilizer bay area

SPECIFICATIONS

One (1) unit Cage feed Conveyor suitable for 90mt FFB per hour operation complete with steel structure, covered walkway, handrails and ladders

Type:

Conveyor chain with scrapper plate

Capacity:

90mt FFB per hour

General Arrangment:

As per drawing

Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate:

Steel c/w hardened steel flanged rollers, 150 mm pitch, 9000 kg breaking load Mild steel or equivalent Mild steel or equivalent 12T, 150 mm pitch, grey iron Mild steel 6 mm minimum thickness or equivalent

Basic Dimension: Width: Length: Inclination: Conveying Section: Shaft Speed: Transmission Sprocket Ratio: Drive: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:

1200 mm 30 m Horizontal Top 25 rpm 1.00 Geared motor coupled conveyor shaft by tarnsmission chain & sprocket 1450 25 2865 <


Page 1 of 2

CAGE FEED CONVEYOR


DATE:

13-May-00

PREPARED BY

NW


OIL PALM MILL

CAGE FEED CONVEYOR

DELIVERY


DRAWING NO.

ITEM No.

A5

QUANTITY / UNITS

1 unit

Sheet 2.

Motor:Power: Type:

7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

APPROVED MAKES



Crompton Parkinson, ABB Brook, Brush, ELEKTRIM SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold Renold, Tsubaki, PC SKF, FAG, NTN


Page 2 of 2

CAGE TRANSFER CARRIAGE No. 1


DATE:

13-May-00

PREPARED BY

NW


OIL PALM MILL

TRANSFER CARRIAGE MACHINE No.1


GENERAL


ITEM No.

A6

QUANTITY / UNITS

1

Scope of works include the fabrication, supply, delivery, erection & installation testing, commissioning, hand over and guarantee. The concrete pit to house the equipment shall be constructed by others.

SPECIFICATIONS

One (1) unit of Transfer Carriage Machine for handling 2 fully loaded cages of 7mt FFB each. The installation shall be in a r.c. pit next to the loading ramp.

Construction

As per drawing in accordance to details by contractor

Details of the Cage Transfer Carriage : Capacity Width Span

2 Units FFB cages per load of 7MT FFB each PER TRANSFER 6,000 mm approx. 44 metre to span 8 sets railtracks

Long Travel Speed

Fast Speed = 50 m / min Medium Speed = 12 m / min Micro Speed = 0.5 m / min

Cage Transfer

Shall be driven by chain system

Handling Capacity

Calculated at 12 cages per hour ( Vendor to advise )

Control System

System to enclose in close cabin via joystick controller and push button.

Drive Motor

2 x 7.5kw TEFC, IP 55 Class F ( Vendor to advise )

Power Supply

415V / 3ph / 50 Hz with 230 V control voltage. Flexible cable of 80 metre length of PVC flat cable system

Size of Conductor

4 core 10 mm 2 flat cable.

Requirement

Contractor to provide design detail of the equipment offered for consultant's approval before fabrication.

Page 1 of 2

WINCH BOLLARDS


DATE:

13-May-00


OIL PALM MILL

PREPARED BY

WINCH & BOLLARDS

DELIVERY

NW


DRAWING NO.


GENERAL

A7 4

Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee

Function:

To winch 7 mt FFB Cages and bollard to act as idler for winching along the railtracks and loading into the steriliser.

SPECIFICATIONS

Four ( 4 ) units Winch (Capstan ) and Six (6) units Bollards as follows :

Type: Pulling Capacity: Arrangement: Construction Details:

Vertical drum motor driven steel rope winch 60 mt load ( 7 x 7 tonnes fully loaded FFB cages) As per drawing As per drawing

Construction Material: Drum: Shaft: Frame: Rope:

Cast iron EN16 Steel Mild steel Steel of 50m length (600 KN breaking strength)

Drum Speed: DriveSystem:

25 rpm Motor directly coupled to gear reducer by flexible coupling and gear reducer coupled to winch main shaft

Gear box: Input speed: Output speed: Output torque: Design Service Factor:

1450 rpm 25 rpm 5730 Nm (min) > 1.5

Motor:Power: Type:


APPROVED MAKES


Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:

Crompton Parkinson, Brush, ABB brooks, Elektrim SEW, HANSEN, RENOLD, EPG ELECTROPOWER Fenner (Fenaflex) Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

Page 1 of 1

CAGES and BOGIES


DATE:

13-May-00


OIL PALM MILL

BOGIES & CAGES

DELIVERY

PREPARED BY REVISION No.

LOCATION RECEPTION

DRAWING NO.

ITEM No.

A8

QUANTITY / UNITS

49

GENERAL

Scope of works include the manufacture, delivery, installation commissioning, handing over and guarantee.

Function:

To contain FFB for sterilisation process

SPECIFICATIONS

Forty Nine (49 ) units Cage & Bogies of the intergral type suitable for operation on 22kg gauge railtrack.

Capacity: Construction Details:

7.5 MT FFB per cage. As per drawings

Construction Material:Frame: Wheel: Bush : (with lubricating groove)

Axle: Casing:

Mild steel 4 nos. Cast Steel Phosphorous Bronze having the following chemical contents: BS 1400 PB2; 11.2% - 13% Tin; 0.3% max Zinc; 0.5% max Lead; 0.25%-0.6% Nickel; 0.5% Copper; 85% EN 9 steel Mild steel

Basic Dimensions: Cage Diameter: Wheel Dia: Wheel Base: End Plate/end plate: Pin to Pin centre: Painting:

NW

2,400 400 800 4,000 4,200

mm mm mm mm mm

2 coats of Apexior No.1

Page 1 of 2

+0.00 mm - 3.00 mm clearance

STERILISER CATWALK

SPECIFICATION SHEETS PROJECT NAME

MACHINE NAME

DATE:

13-May-00

STERILISER CATWALK PROJECT CODE :

OIL PALM MILL

REVISION NO:

DELIVERY DRAWING No.

LOCATION STERILIZER STATION

NW

Item No.

C4

Quantity

1 set

GENERAL

Scope of works include the manufacture, erection & installation commissioning, handing over and guarantee.

Function:

For use in operation and maintenance of steriliser valves

SPECIFICATIONS

One Lot ( 1 ) Sterilser Catwalk complete with control platform, handrails & staircase to span 3 steriliser vessels as follows :

Basic Dimensions: Construction Details: Construction Material:-

As per drawings As per drawings Mild steel

PROVISION

Provision shall be made for future expansion of the catwalk to span 2 more sterilisers and a total of 5 Sterilisers.

OTHER REQUIREMENTS 1. Handrailing shall be 40 dia. m.s black pipe 2. Kick plate of 100mm high x 6mm thick to be provided along the platform 3. Stairways at both ends of the catwalk.

Page 1 of 1

1

PREPARED BY:

Mobile Rail Piece


DATE:

13-May-00


OIL PALM MILL

MOBILE RAIL PIECE

DELIVERY

PREPARED BY

NW


DRAWING NO.

STERILISER STATION


B 1. 2

GENERAL

Scope of works include the manufacture,delivery, erection & installation commissioning, handing over and guarantee.

Function:

To act as a bridge for FFB CAGES to move in / out of the Sterilisers

SPECIFICATIONS

Two ( 2 ) units Mobile Rail Piece as follows : Note : 2 units for operation of double door sterilizer

Basic Dimensions: Construction Details:

As per drawings As per drawings

Construction Material Frame: Wheel: Bushing: Shaft:

Mild steel 4 nos. Cast Steel As per drawing Mild steel

Page 1 of 1

STERILISER


DATE:

12-Aug-98


OIL PALM MILL

PREPARED BY

STERILISERS

DELIVERY

NW


STERILISER STATION

DRAWING NO.

ITEM No.

B2

QUANTITY / UNITS

GENERAL Scope

Function:

Scope of works include the design, fabrication, delivery, erection & installation, testing & Certification, commissioning, handing over and guarantee To sterilise FFB using steam as sterilising medium

SPECIFICATIONS Quantity Design & Construction Code: General Arrangement & Asembly: Capacity: Outside Dia. S.H.L: Plate thickness: Type of welds: Material Standard:

TWO (2) units Sterilisers- 2 door type as follows : BS 5500 or ASME for un-fired pressure vessel as per drawings 7 Cages of 7MT FFB each 2,700 mm 30,000 mm(excludng door collar) Length 15 mm Min. Double V-butt welds Carbon steel Grade 151 to BS 1501 Pt.1

Working Pressure: Working Temperature: Compliance with local regulation: Tolerance In term Of Straightness:

3.5

kg/cm2 (dry saturated steam)

150 Yes 10

o

C

mm (maximum deviation)

Nozzle:Users Steam inlet Steam exhaust Condensate Outlet Safety Valves Temperature gauge Pressure gauge Pressure Controller Cages rail:

size (mm) 150 200 100 80 1/2" BSP 1/2" BSP 1/2" BSP

Protrusion (mm) 150 150 150 150

qty 2 1 6 2 2 2 1 800 mm

Flange PN 16 PN 16 PN 16 PN 16

Material API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40

c/c using 100 x 75 x 10 thk ms angle

Steam spreader:

To be provided at the top of the steriliser

Saddles:

To fit snugly into steriliser body with no open gap, equally spaced, one saddle at the center remains fixed and the rest allowed to slide on 63mm solid steel bar during expension

Insulation.

The entire shell shall be lagged with a 50 mm thick rock wool blanket and covered with 22 gauge embossed aluminium sheet cladding. All the necessary supports, rings, strips, fittings, etc. are to be provided.

Wear Liners Location: Material: Thickness: Tell-tale hole:

180 deg. at bottom halves throughtout mild steel 9 mm to be provided on each bottom section of steriliser shell

Page 1 of 2

2

STERILISER


DATE:

12-Aug-98


OIL PALM MILL

PREPARED BY

STERILISERS

DELIVERY

NW


STERILISER STATION

DRAWING NO.

ITEM No.

B2

QUANTITY / UNITS

Sheet 2.

Steriliser Doors Type: Safety device: Qty: Working Pressure:

2

Quick opening/closing, rotating ring To be provided against accidental opening when under pressure 2 for each steriliser kg/cm2 (dry saturated steam)

3.5

Working Temperature: O.D: Design & Construction Code: Compliance with local regulation:

o 150 C 2,700 mm BS 5500 or ASME for un-fired pressure vessel Yes

Features and Accessories:

-Swingjib assembly, ball bearing type and broadly spaced pivot -Rotating locking ring c/w operating ratchet -Rebated door seals -Door and steriliser mating faces fitted with machined stainless steel (EN 58J Gr 316) ring -Handle and operating gears for easy opening and closing

Wear Plate:

4.5 mm

stainless steel 304 throughtout

Testing Type: Pressure: Code & Regualations:

Hydrostatic 1.5 x design pressure BS 5500 or ASME for un-fired pressure vessel and local authorities

Requirements. The following shall be provided:Two (2) 150 mm diameter pressure gauge of 0 - 7 kg/cm2 (100 psi) mounted one at each end of the vessel. Testing

After completion of installation the steriliser shall be hydrostatically tested to 7.03 kg/cm2 (100 psi) and shall satisfy the Machinery Department Regulations in all repsects.

Painting

After the staisfactory completion of tests the external surface of the steriliser shall be wire brushed and painted with two coats of heat resistant paint. The interior shall be wire brushed and painted with two coats of approved Apexior No.1.

General


Page 2 of 2

STERILISER AUTO PROGRAM CONTROL


DATE:

13-May-00


OIL PALM MILL

STERILISER AUTO PROGRAM CONTROL SYSTEM

DELIVERY


LOCATION STERILISER STATION

DRAWING NO.


GENERAL

Scope of works include the unloading, safe keeping, erection installation. assist in testing & commissioning. PROPRIETARY EQUIPMENT TO BE SUPPLIED BY CLIENT.

SPECIFICATIONS

One ( 1 ) unit Sterilizer Auto Program Control System for operation with 3 Sterilisers - 2 door type 2700mm dia x 25.2M

The System

Each steriliser shall be fitted with control valves and programmer to permit automatic sterilisation of the FFB and consists of:-

Manual over-ride operation

NW

A.

Programmer controller c/w control valves of 150 mm- Steam Inlet 200mm - steam exhaust and 150mm - condensate together with pressure switches and necessary accessories.

B.

A safety interlock switch for the steriliser door.

C.

Circular pressure/temperature recorder of pressure/temperature range of 4.0 kg/cm2 and 0 - 200 degree C respectively. The recorder shall indicate a 24 hours cycle. Each pressure/temperature recorder shall be supplied with 200 sheets of spare charts.

D.

The system shall include provision to enable all three ( 3 ) sterilisers to operate individually or synchronised to permit sequential operation in pairs or all sterilisers together. System shall be able to do single, double or tripple peak.

All valves shall be equipped with a manual over-ride to permit operation: a.

In the event of failure of the automatic system

b.

In the event of failure of the pneumatic system. The steam inlet control valve shall be designed to fail ‘shut’, all other valves to be design to fail ‘open’. The valves shall be rotary type with an eccentric mounted disc and teflon seal ring. The seal ring must be pressure assisted to provide good shut of characteristic. The valve actuator shall be pneumatic diaphragm actuator type with a top mounted handwheel. The handwheel shall be used only when there is a breakdown of the automatic system.

Material of construction

Material of construction of the valve shall be cast iron body, cast steel disc and 316 (EN 58J) stainless steel shaft. Generally all valves and actuators shall be of low maintenance cost design.

Safety Devices

The control system shall be complete with safety devices to prevent any steam from entering the steriliser if the steriliser door is opened. The safety devices shall include at least pneumataic kick-off as well as an electrical kick-off device.

Page 1 of 2

B3 1

STERILISER AUTO PROGRAM CONTROL


DATE:

13-May-00


OIL PALM MILL

STERILISER AUTO PROGRAM CONTROL SYSTEM


PREPARED BY

NW

REVISION No. LOCATION STERILISER STATION


B3 1

Sheet 2. Instrument Panel

A free standing type instrument panel complete with an incoming electrical switch designed to code IP 55 to house the control and instruments.

Indicating Lights & Stop Button

Indicating lights for the starting of each programme and compeltion of the cycle should be provided and provision should be made for stoppage of the sterilising cycle should this become necessary. All the pneumatic and electrical connections from the control panel to the control valves, etc. shall be included. Instrument air to be taken from the air compressor. All necessary air pressure regulators and fittings should be included.

Air Compressor

An air compressor capacity 600 litres/min at a delivery pressure of 7 kg/cm2 and equipped with receiver tank, relief valves, pressure gauge, air hose, pressure differential sensor for automatic stop/start, , etc. shall be provided. It shall be electrically driven, single stage and air cooled.

Manuals

Equipment drawings, installation and operating instruction, spare parts list and specification shall be provide upon commissioning.

Requirement


Page 2 of 2

BLOW-OFF CHAMBER


DATE:

12-Aug-98


BLOW OFF CHAMBER and SILENCER

OIL PALM MILL

DELIVERY

PREPARED BY

NW


DRAWING NO.


GENERAL

Scope of works include the manufacture, dlivery,erection & installation, commissioning, handing over and guarantee.

Function:

To act as silencer during blowing-off of steam from STERILISER

SPECIFICATIONS

Three ( 3 ) Units Steriliser Blow-Off Chamber & Silencer

Construction Details:

As per drawing

Construction Material

Mild steel

Basic dimensions: Base diameter

1,200

mm

Outlet

510

mm

Manhole

450

mm square

Mounting:

12 nos 15mm dia x 300 mm long holding down bolt

Flanges:

To BS 4504 PN 16

Page 1 of 1

B4 3

CONDENSATE BLOW-DOWN


DATE:

13-May-00


OIL PALM MILL

PREPARED BY

BLOW DOWN CHAMBER

DELIVERY

NW


DRAWING NO.


GENERAL Scope

Scope of works include the manufacture, delivery & installation commissioning, handing over and guarantee.

Function:

To receive steriliser condensate from STERILISERS before discharging to the CONDENSATE PIT and to act as silencer

SPECIFICATIONS Quantity

TWO ( 2 ) units Condensate blow-down chamber as follows :


As per drawings

Construction Material

Mild steel

Basic dimensions: Base: Outlet Manhole

1500 970 450

mm square mm mm

Mounting:

12 nos 15mm dia x 300 mm long holding down bolt

Internal Baffles:

4 nos. 4.5mm plates

REQUIREMENTS Contractor to provide details & drawings for Consultants approval before fabrication.

Page 1 of 2

B5 2

CONDENSATE RECOVERY TANK

SPECIFICATION SHEET DATE:

PROJECT NAME

13-May-00


OIL PALM MILL

CONDENSATE TANK

DELIVERY



DRAWING NO.


GENERAL Scope


Function:

To recover oil from steriliser condensate


One ( 1 ) unit Steriliser Condensate Recovery Tank as follows :

Brief Descriptions:

A conical bottom and cylindrical top section supported by steel sections, elevated from ground level. An adjustable skimmer is to be provided for skimming oil at the top layer. Overflow pipe for sludge underflow to be provided.

Capacity: Basic Dimensions: Construction Details:

100 m3 As per drawings As per drawings

Construction Material:-

Mild steel Mild steel Mild steel S.S 304 Sch 40 Pipe (inside tank only) ERW Sch 40 Mild steel ERW Sch 40 Mild steel

Tank: Skimer Funnel: Skimer Handle: Skimer Pipe: Overflow Pipe: Ladder & Catwalk: Heating coils: Support: Nozzles:-

Users Size (mm)Qty skimmed oil drain overflow steam in steam out steam in steam out hot water in Flanges:

NW

100 80 150 50 50 25 25 25

2 2 2 1 1 1 1 1

Flange PN 10 PN 10 PN 10 PN 16 PN 16 PN 16 PN 16 PN 10

Protrusion Material (mm) 150 ERW Sch 40 150 ERW Sch 40 150 ERW Sch 40 150 ERW Sch 40 150 ERW Sch 40 150 ERW Sch 40 150 ERW Sch 40 150 ERW Sch 40

Raised face to DIN 2526

Page 1 of 1

B6 1

CONDESATE PIT PUMP


DATE:

13-May-00

MACHINE NAME OIL PALM MILL

PROJECT CODE

PREPARED BY

CONDENSATE PIT PUMP

DELIVERY

NW


DRAWING NO.

ITEM No.

B7

QUANTITY / UNITS

GENERAL Scope

Scope of works include the manufacture, delivery & installation commissioning, handing over and guarantee. To pump condensate water to the effluent treatment system

Function

SPECIFICATION Two ( 2 ) units Steriliser Condensate Pit Pump complete with flanged drive motor, coupling and level switch as follows : ( one unit in operation and one unit on standby ) Type

Centrifugal, self-priming, end-suction - Vertical mount

Connection

BS 4504 PN 10

OPERATING DATA Capacity Medium

90 m3 per hour Steriliser Condensate o

( for 90mt FFB per hour operation )

Temperature Specific Gravity

100 0.9

C

Viscousity Delivery Head Speed NPSH available

0.08 420 1450 3

CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling Level Switch: Drive:

Cast Iron GG25 S.S AISI 304 S.S AISI 304 Mechanical S.S AISI 304 Flexible Magnetic type, stainless steel float and rod, counter weight Motor directly coupled with flexible coupling

Ns/m2 kPa RPM (Max) m liquid

Motor:Power: Type:

5.5 kw TEFC 4-pole, S.C, IP 55, Class F Ins., 415V / 3-Ph / 50 Hz

APPROVED MAKES

Specified or Equivalent

Pump: Motor:

SIHI, KSB, Warman, Southern Cross or equivalent Crompton Parkinson, Brush, ABB Brook

Coupling: Bearing: Level switch:

Fenner (Fenaflex) or equivalent SKF, FAG Mobrey, BESTA

OTHER REQUIREMENTS 1. Vendor to provide technical details, cataloques, performance curve and etc.

Page 1 of 1

2

ACID OIL TANK

SPECIFICATION SHEET DATE: ######

PROJECT NAME MACHINE NAME PROJECT CODE

OIL PALM MILL

ACID OIL TANK

DELIVERY



DRAWING NO.


GENERAL Scope

Scope of works include the manufacture, erection & installation commissioning, handing over and guarantee.

Function:

To receive skimmed oil from Steriliser condensate recovery tank

SPECIFICATIONS Quantity Capacity: Construction Details: Construction Material: Nozzles:

One ( 1 ) Acid Oil Tank as follows : 8 m3 As per drawing Mild steel

Users drain pump suction overflow vent

Size (mm) Flange 50 PN 10 50 PN 10 50 PN 10 50 PN 10

Protrusion (mm) 150 150 150 150

Material ERW Sch 40 ERW Sch 40 ERW Sch 40 ERW Sch 40

Monkey ladder from ground level to tank top to be provided Tank plate thickness: Flanges:

NW

6

mm

Raised face to DIN 2526

Page 1 of 1

B8 1

ACID OIL PUMP


DATE:

13-May-00


OIL PALM MILL

ACID OIL DRUMMING PUMP SET

PREPARED BY




GENERAL Scope


Function

Decanting of acid oil from the collection tank and filling of drums

SPECIFICATION Quantity

Two ( 2 ) units Acid oil drumming Pumpset as follows:

Type

Centrifugal, End-suction - Vertical mount

Connection

Raised face flange to DIN 2526PN 10

OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Deleivery Head Speed NPSH available

15 mt per hour Acid oil 100 oC 0.9 0.08 Ns/m2 100 kPa 1450 RPM (Max) 3 m liquid

CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling Drive: Motor:Power: Type: Level switches:

APPROVED MAKES Pump: Motor: Coupling: Bearing: Level switch:

NW

Cast Iron GG25 S.S AISI 304 S.S AISI 304 Mech seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling to the pump 2.2KW ( Vendor to advise ) TEFC 4-pole, S.C, IP 55, Class F Ins., 415V / 3-Ph / 50 Hz Magnetic type with stainless steel float, stainless steel rod and counter weight Specified or Equivalent SIHI, KSB, Warman, Southern Cross Crompton Parkinson, Brush, ABB Brooks, Elektrim Fenner (Fenaflex) SKF, FAG Mobrey, BESTA


Page 1 of 1

B9 2

TRANSFER CARRIAGE


DATE:

13-May-00


OIL PALM MILL

PREPARED BY

CAGE TRANSFER CARRIAGE No.2


REVISION No. LOCATION FRUIT HANDLING


GENERAL Scope

Scope of works include the unloading, safe keeping, assist in the installation, testing & commissioning.

Function:

To transfer 1 FFB Cages per transfer from Steriliser railtracks to tippler railtrack


One ( 1 ) unit Cage transfer Carriage as follows : Note that the Equipment and RC pit will be provided by others.

Brief Description:

Consists of mainframe resting on 4 wheels that travel along the pits on railtrack. The drive wheels (at diagonal positions) are driven by hydraulic motors which receive hyadrualic oil from hydraulic pack. The cages are moved in and out of the car by drag chain conveyor mounted on the car main frame. The movement of the chain is by hydraulic motor which receives the oil from the same hydraulic pack. Sizing of hydraulic system shall be by the Contractor.

FFB Cage Data:Capacity: Hook to Hook: Cage Diameter: Wheel Dia: Wheel Base: End Plate/end plate: Full Wt:

7 tonnes FFB 4,400 mm 2,400 mm 404 mm 700 mm 4,000 mm 9,000 kg

CONSTRUCTION & MATERIAL Type: Size: Arrangment: Capacity: Loading

Pit and fully hydraulic operated 1 no. 7 tonnes FFB cages at one time transfer Generally as per drawing 15 cages / hr 10 tons ( cage + 7 tons FFB )

Basic Dimensions: Width: Carriage Length: Pit depth: Long Travel Speed:Fast: Medium: Creep:

To suit cage size and operating platform 1,200 mm 50 m/min 12.5 m/min 0.5 m/min

Long Travel Drive:

By hydraulic motors fixed on carriage wheels at diagonal position

Wheel Diameter:

Vendor to advice

Cage In/Out Speed:

NW

15 m/min

Page 1 of 2

C1 1

TRANSFER CARRIAGE


DATE:

13-May-00


OIL PALM MILL

PREPARED BY

CAGE TRANSFER CARRIAGE No.2




Continue ………. Cage In/Out Transfer: Control System:

Construction Material:Frame: Platform and Catwalk: Wheel: Cabin Roof:

NW

C1 1

Sheet 2.

By conveyor chain & hook system operated by hydraulic motor Via joysticks controller and push button, located in an enclosed cabin mounted on the Carriage together with hydraulic pack

Mild steel Mild steel chequered plate 4 nos. Cast Steel Spandek

Hydraulic System:

Consist of hydraulic pump, oil tank, hydraulic motor, tubing, lever control, releif valve, pressure gauges, pump strainer, check valve and all the necessary accessories for complete operation

Power Cable to Hydraulic Pack: Motor:Power: Type:

P.V.C insulated flat flexible cable c/w hanger and supports

APPROVED MAKES

Specified or Equivlent

Motor: Hydraulic System: Bearing: Chain:

Crompton, Parkinson, Brush, ABB Brooks, Elektrim Rextroth or Vickers SKF, FAG, NTN Renold, Tsubaki and PC chain

2 x 7.5kw ( Vendor to advice ) TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

OTHER REQUIREMENTS 1. Vendor to furnish technical specifications, drawings and catalogues of equipment 2. Handrailing of mild steel 40dia. black pipe to be provided for platfrom 3. Hydraulic equipments and accessories shall be of standard model and commonly available 4. Carriage position locks by mean of hydraulic cylinders or other means to be provided 5. The scope of supply shall also include hyadraulic pack, PVC insulated flat flexible, control panel, hyadrualic tubing and equipments 6. Power supply to the control panel is excluded 7. Mode of operation shall be semi-auto with limit switches to control each mode

Page 2 of 2

WINCH and BOLLARDS


DATE:

13-May-00


OILPALM MILL

WINCH & BOLLARDS

DELIVERY

PREPARED BY

NW


DRAWING NO.


C2 4 sets

GENERAL Scope


Function:

To winch FFB Cages from the sterliser & along the railtracks

SPECIFICATIONS

Four ( 4 ) Sets Winch / Capstan and Six (6) Bollards as follows :

Type: Pulling Capacity: Arrangement: Construction Details:

Motor driven steel rope winch 60 Tons = 7 cages x 7 tonnes fully loaded FFB cages As per drawing As per drawing

CONSTRUCTION MATERIAL Drum: Shaft: Frame: Rope: Drum Speed: DriveSystem:

Mild steel EN16 Steel Mild steel Steel of 50m length (600 KN breaking strength) 25 rpm Motor directly coupled to gear reducer by flexible coupling and gear reducer coupled to winch main shaft


1450 rpm 25 rpm 5730 Nm (min) > 1.5

Motor:Power: Type:

15 KW ( Vendor to advise ) TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:

Specified or Equivalent. Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, HANSEN, RENOLD, EPG ElectroPower Fenner (Fenaflex) Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

Requirement

Contractor to provide drawing with full details of offered equipment

Page 1 of 1

TIPPLER


DATE:

13-May-00


PROJECT CODE

FFB CAGE TIPPLER

DELIVERY

PREPARED BY

NW


DRAWING NO.


GENERAL Scope


Function:

To rotate FFB cage and discharge into hopper than to FRUIT FEEDING CONVEYOR

SPECIFICATIONS Quantity Type: Capacity: General Arrangement: Construction Details:

One (1) unit Tippler complete with drive as follows : Rotating To handle 7MT FFB Cage As per drawing As per drawing

CONSTRUCTION MATERIAL Frame & Structures Sprocket Drive Chain:

Mild steel Mild steel Steel c/w hardened steel rollers or equivalent

Final Speed: Tippler Control: Drive System:

2 rpm Hydraulic control lever Hydrualic power pack drives a hydraulic motor directly coupled to a gear box. The output shaft of the gearbox is fitted with duplex sprocket which in turn drives the tippler through chain and sprocket.


# rpm 20 rpm # Nm (min) < 1.5

Motor:Power: Type: Hydraulic System:

8 KW Vendor to advise TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Consist of hydraulic pump, oil tank, hydraulic motor, tubing, lever control, releif valve, pressure gauges, pump strainer, check valve and all the necessary accessories for complete operation

Chain & Sprocket: Pitch Type

50 mm Duplex

Page 1 of 2

C3 1

TIPPLER


DATE:

13-May-00


OIL PALM MILL

FFB CAGE TIPPLER


PREPARED BY

NW



C3 1

Sheet 2. APPROVED MAKES Motor: Gear reducer: Coupling: Chain: Bearing: Hydraulic Equipment:

Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold , EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki and PC Chain SKF, FAG, NTN Rextroth or Vickers

OTHER REQUIREMENTS:1. Vendor to furnish technical specifications, drawings and catalogues 2. Tippler supports to be provided and bolted securely on foundation 3. Tippler shall be able to rotate at 180o 4. Lever control to be located near Tippler

Page 2 of 2

FRUIT FEED CONVEYOR


DATE:

13-May-00


PROJECT CODE

FRUIT FEED CONVEYOR

DELIVERY

PREPARED BY

NW


DRAWING NO.


GENERAL Scope


Function:

To convey sterilised fruit bunches from TIPPLER to Thresher


One (1) unit Fruit Feed Conveyor with drive as follows :

Type: Capacity: Construction Details:

S - type conveyor with scrapper plate on twin flanged roller chain 45 MT FFB PER HOUR. As per drawings

CONSTRUCTION MATERIAL Chain: Drag Plate: Frame: Sprocket: Wear Plate:

Steel c/w hardened steel flanged rollers, 150 mm pitch, 15,000 kg breaking load Mild steel or equivalent Mild steel or equivalent 12T, 100 mm pitch, grey iron Mild steel 6 mm minimum thickness or equivalent

Basic Dimension: Width: Length: Inclination: Conveying Section: Shaft Speed: Drive:

1,200 mm Check drawing approx. 18o Top 5-10 rpm Variable speed reducer coupled to conveyor shaft by transmission chain & sprocket

Gear box: Input speed: 1450 rpm Output speed: 2 to 10 rpm Output torque: 14,925 Nm (min) Design Service Factor: < 1.5 Motor:Power: Type:


Page 1 of 2

C4 1

FRUIT FEED CONVEYOR


DATE:

13-May-00


OIL PALM MILL

PREPARED BY

FRUIT FEED CONVEYOR

DELIVERY

NW


DRAWING NO.


C4 1

Sheet 2. APPROVED MAKES


Motor: Gear reducer: Coupling:

Crompton Parkinson, ABB Brook, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold

Conveyor & Transmission chain, sprocket Bearing:

Renold, Tsubaki SKF, FAG, NTN

OTHER REQUIREMENTS 1. Mild steel outlet chute to be provided at the end of the conveyor 2. Drive end shaft fitted with flange bearings 3. Non-drive end shaft to be fitted with chain tensioning devises c/w take-up bearings 4. Vendor to provide full specification, drawings and catalogues of components.

Page 2 of 2

TOIP FEED CONVEYOR


DATE:

13-May-00


PROJECT CODE

PREPARED BY

TOP FEED CONVEYOR

DELIVERY

NW

REVISION No. LOCATION THRESHING STATION

DRAWING NO.


GENERAL Scope

D1 1


Function:

To convey empty bunches from Tippler fruit feed conveyor to any of the Thresher


Type: Capacity: General Arrangment: CONSTRUCTION MATERIAL Chain: Drag Plate: Frame: Sprocket: Wear Plate:

One (1) unit Horizontal Top feed Conveyor suitable for handling 90MT FFB per hour as follows: Conveyor chain c/w scrapper plate 30,000 kg / hr of empty bunches As per drawing

Steel c/w hardened steel rollers, 100 mm pitch, 8000 kg breaking load Mild steel or equivalent Mild steel or equivalent 12T, 100 mm pitch, grey iron Mild steel 6 mm minimum thickness or equivalent

Basic Dimension: Width: Length: Inclination: Conveying Section: Shaft Speed: Transmission Sprocket Ratio: Drive:

760

mm mm

Horizontal Top 25 rpm 1.00 Geared motor coupled conveyor shaft by tarnsmission chain & sprocket

Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:


APPROVED MAKES Motor: Gear reducer: Coupling:

Specified or Equivalent. Crompton Parkinson, ABB Brook, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold


Renold, Tsubaki, PC

1450 25 2865 <


SKF, FAG, NTN

OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devises c/w take-up bearings Page 1 of 2

THRESHER STRUCTURE


DATE:

13-May-00


PROJECT CODE

THRESHER MACHINE

DELIVERY

PREPARED BY

NW


DRAWING NO.

ITEM No. QUANTITY

GENERAL Scope


Function:

To thresh sterilised fruit bunches


One (1) Thresher with platform, supporting structure, handrails stairways and drive as follows: Rotating Drum 45 MT FFB PER HOUR. As per drawing As per drawing

CONSTRUCTION MATERIAL Shaft: Boss: Rim: Frame: Supporting struct : Plaform Handrail: Structure bolts & nuts:

EN 16 Steel Carbon steel Carbon steel Carbon steel Mild steel Mild steel chequered plate of 6mm thick 40mm dia.black pipe High tensile

Drum Speed: Drum Basic Dimension: Drive System:

22 rpm 2,100 mm 6,300 mm

Diameter Length

Motor coupled to gear reducer by fliud coupling and gear reducer output shaft connected to thresher shaft by triplex chain / sprocket system

Gear box: Input speed: Output speed: Output torque: Overhung load: Design Service Factor: Sprocket:Ratio: Type: Motor:Power: Type:

1450 rpm 25 rpm 8404 Nm (min) To be within the permissible limit depending on the sprockets used for further speed reduction > 1.5 (min) 1.14 Triplex 18kw

( Vendor to advise )

TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

Page 1 of 2

D2 1

THRESHER STRUCTURE


DATE:

13-May-00


OIL PALM MILL

THRESHER MACHINE


PREPARED BY

NW


ITEM No. QUANTITY

D2 1

Sheet 2. APPROVED MAKES



Crompton Parkinson, ABB Brook, Brush, Elektrim Sew, HANSEN, SEW, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold Renold, Tsubaki SKF, FAG, NTN

OTHER REQUIREMENTS:1. Vendor to furnish details drawing and specifications of selection of gear reducers, fluid coupling, chain and sprockets 2. Inlet and outlet chute made from 6mm thk. m.s plate shall be provided

Page 2 of 2

BOTTOM SCREW CONVEYOR


DATE:

13-May-00


PROJECT CODE

PREPARED BY

BOTTOM SCREW CONVEYOR

DELIVERY

NW


DRAWING NO.


GENERAL Scope

Scope of works include the manufacture, delivery & installation commissioning, handing over and guarantee

Function:

To convey fruitlets from THRESHER to Fruit Elevator

SPECIFICATIONS One (1) Bottom Screw Conveyor as follows : Type: Size: General Arrangement: Construction Details:

Full flight screw 600 mm dia. As per drawing As per drawing

Construction Material: Casing: Wear plate:

Screw Shaft: Hanger bearing: Conveyor Speed: Drive System:

Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L, Gr.B Sch 80 pipe Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled with flexible coupling to the shaft.

Gear box: Input speed: 1450 rpm Output speed: 56 rpm Output torque: 640 Nm (min) Design Service Factor: > 1.5 Motor:Power: Type:

3.75 kw TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

APPROVED MAKES



Crompton Parkinson, ABB Brook, Brush SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold Renold, Tsubaki SKF, FAG, NTN

OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at both end of the conveyor 4. Conveyor shall be mounted on rollers and able to slide sideway for easy removal during maintainance 5. Contractor to provide detail drawing and specification of equipment offered.

Page 1 of 1

D 3. 1

HORIZONTAL E.B.C


DATE: 13-May-00 MACHINE NAME HORIZONTAL EMPTY BUNCH CONVEYOR

OIL PALM MILL

PROJECT CODE

PREPARED BY

DELIVERY

NW


DRAWING NO.


GENERAL Scope


Function:

To convey empty bunches from THRESHER to EMPTY INCLINED BUNCH CONVEYOR


One (1) unit Horizontal Empty Bunch Conveyor suitable for handling 90MT FFB per hour as follows:

Type: Capacity: General Arrangment:

Conveyor chain c/w scrapper plate 30,000 kg / hr of empty bunches As per drawing

CONSTRUCTION MATERIAL Chain: Drag Plate: Frame: Sprocket: Wear Plate:

Steel c/w hardened steel rollers, 100 mm pitch, 8,000 kg breaking load Mild steel or equivalent Mild steel or equivalent 12T, 100 mm pitch, grey iron Mild steel 6 mm minimum thickness or equivalent

Basic Dimension: Width: Length: Inclination: Conveying Section: Shaft Speed: Transmission Sprocket Ratio: Drive:

760

mm mm

Horizontal Top 25 rpm 1.00 Geared motor coupled conveyor shaft by transmission chain & sprocket



APPROVED MAKES Motor: Gear reducer:

Specified or Equivalent. Crompton Parkinson, ABB Brook, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectroPower

Coupling:

Fenner (Fenaflex) , Renold

Conveyor & Transmission

Renold, Tsubaki, PC

chain, sprocket Bearing:

SKF, FAG, NTN

1450 25 2865 <


OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings Page 1 of 2

D4 1

HORIZONTAL E.B.C

SPECIFICATION SHEET PROJECT NAME PROJECT CODE

DATE: 13-May-00 OIL PALM MILL

MACHINE NAME HORIZONTAL EMPTY BUNCH CONVEYOR


PREPARED BY

NW



4. Non-drive end shaft to be fitted with chain tensioning devises c/w take-up bearings

Page 2 of 2

D4 1

UNSTRIPPED BUNCH ELEVATOR


DATE:

13-May-00

MACHINE NAME


OIL PALM MILL

PROJECT CODE

PREPARED BY

DELIVERY

NW


DRAWING NO.


D5 1

GENERAL Scope

Scope of works include the manufacture, delivery & installation commissioning handing over and guarantee.

Function:

To convey unstripped bunches from H.E.B Conveyor to Thresher No.2


One ( 1 ) unit Unstripped Bunches Conveyor as follows : Double conveyor chain c/w buckets 90 MT FFB per hour. As per drawing As per drawing

CONSTRUCTION MATERIAL Casing: Sprocket Bucket: Chain rail: Wear plate: Chain: Drive: Shaft Speed: Transmission Sprocket Ratio:

Mild steel with 6mm minimum thickness 12T, 150 mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 150mm pitch 15000 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 25 rpm 1

Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:

1450 25 2865 >


Power: Type:


Motor:-

APPROVED MAKES



Crompton Parkinson, ABB Brooks, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

OTHER REQUIREMENTS 1. Miantenance door shall be provided at the elevator booth 2. Top cover shall be bolted for ease of maintenance 3. Take-up bearing with adjustable bolt and screw shall be provided at the bottom booth for chain tightening 4. Mild steel outlet chute shall be provided 5. Plumber block bearing shall be fixed at the top booth

Page 1 of 1

THRESHER No. 2


DATE:

13-May-00


PROJECT CODE

PREPARED BY

THRESHER MACHINE No.2

DELIVERY

NW


DRAWING NO.


GENERAL Scope

D6 1

Scope of works include the manufacture, delivery & installation, commissioning, handing over and guarantee.

Function:

To thresh unstripped bunches


One ( 1 ) unit Thresher No.2 for Unstipped Bunches as follows:

Type: Capacity: General Arrangement: Construction Details:

Rotating Drum 90MT FFB per hour As per drawing As per drawing

CONSTRUCTION MATERIAL Shaft: Boss: Rim: Frame & Structure: Drum Speed: Drum Basic Dimension: Drive System:

Gear box: Input speed: Output speed: Output torque: Overhung load: Design Service Factor:

EN 16 Steel Carbon steel Carbon steel Carbon steel 22 rpm 2,200 mm diameter 5,000 mm length Motor coupled to gear reducer by fliud coupling and gear reducer output shaft connected to the thresher shaft by triplexchain / sprocket system

1450 rpm 25 rpm 8404 Nm (min) To be within the permissible limit depending on the sprockets used for further speed reduction < 1.5 (min)

Sprocket:Ratio: Type:

1.14 Triplex

Power: Type:


Motor:-

APPROVED MAKES Motor: Gear reducer: Coupling:

Specified or Equivalent Crompton Parkinson, ABB Brook, Brush Elektrim SEW, HANSEN, SEW, Renold, EPG ElectroPower. Fenner (Fenaflex) , Renold


Renold, Tsubaki SKF, FAG, NTN

OTHER REQUIREMENTS:1. Vendor to furnish selection of gear reducers, fluid coupling, chain and sprockets 2. Inlet and outlet chute made from 6mm thk. m.s plate shall be provided Page 1 of 4

BOTTOM FRUIT CONVEYOR

SPECIFICATION SHEET PROJECT NAME PROJECT CODE

DATE: OIL PALM MILL

MACHINE NAME BOTTOM FRUIT CONVEYOR FOR THRESHER No.2


PREPARED BY

ITEM No.

GENERAL Scope

Scope of works include the manufacture, delivery & installation, commissioning, handing over and guarantee.

Function:

To convey fruitlets from Unstripped Bunch Thresher to the fruit Elevator Via Bottom cross conveyor.


One (1) Bottom Fruit Conveyor as follows :

Type: Size: General Arrangement: Construction Details:



NW


QUANTITY / UNITS

CONSTRUCTION MATERIAL Casing: Wear plate:

13-May-00

Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L, Gr.B Sch 80 pipe Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled with flexible coupling to the shaft.

Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:


APPROVED MAKES


Motor: Gear reducer: Coupling: Conveyor & Transmission

Crompton Parkinson, Brook, Brush SUMITOMO, HANSEN, Renold Fenner (Fenaflex) , Renold Renold, Tsubaki


SKF, FAG, NTN

1450 rpm 56 rpm 938 Nm (min) > 1.5

OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at both end of the conveyor 4. Conveyor shall be mounted on rollers and able to slide sideway for easy removal during maintainance

Page 1 of 1

D7 1

BOTTOM CROSS FRUIT CONVEYOR


DATE:

13-May-00


OIL PALM MILL

PREPARED BY

BOTTOM CROSS CONVEYOR

DELIVERY

NW


THRESHING STATION

DRAWING NO.

ITEM No.

D8

QUANTITY / UNITS

GENERAL Scope

Scope of works include the manufacture, delivery & installation, commissioning, handing over and guarantee 12 months.

Function:

To convey fruitlets from Thresher bottom fruit conveyor to fruit elevator


One ( 1 ) unit Bottom Cross Fruit Conveyor as follows :




Screw Shaft: Hanger bearing: Conveyor Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:

Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughoutthe conveyor extended a least 100mm above the centerline of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L, Gr.B Sch 80 pipe Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled with flexible coupling to the shaft. 1450 56 938 <



APPROVED MAKES


Motor: Gear reducer:

Crompton Parkinson, ABB Brook, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectrolPower

Coupling:

Fenner (Fenaflex) , Renold

Conveyor & Transmission

Renold, Tsubaki


SKF, FAG, NTN

OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at both end of the conveyor 4. Conveyor shall be mounted on rollers and able to slide sideway for easy removal during maintainance

Page 1 of 1

1

INCLINED E.B.C


DATE:

13-May-00


OIL PALM MILL

INCLINE EMPTY BUNCH CONVEYOR

DELIVERY

PREPARED BY

NW


EMPTY BUNCH DISPOSAL SYSTEM

DRAWING NO.


E1 1

GENERAL Scope


Function:

To convey empty bunches from the horizontal bunch conveyor to the empty bunch hoppers.


Type: Capacity: General Arrangment: Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate: Inclination: Conveying Section: Shaft Speed: Transmission Sprocket Ratio: Drive:

One ( 1 ) unit Inclined Empty Bunch Conveyor complete with covered walkway, handrails, chutes, steel structure and drive shall be suitable for handling 90mt FFB per hour opration.

Conveyor chain with scrapper plate 25,000 kg / hr of empty bunches As per drawing

Flanged roller chain of 150mm pitch of Cast steel or equivalent, 8000 kg breaking load Mild steel section Mild steel 12T, 150mm pitch grey cast iron Mild steel 6 mm minimum thickness 15 deg. Top 15 rpm 1.67 Geared motor coupled conveyor shaft by tarnsmission chain & sprocket


11 KW Vendor to advise TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

APPROVED MAKES


Motor: Gear reducer: Coupling: Drag Chain: Bearing:

Crompton Parkinson, Brush, ABB Brook, Elektrim SEW, HANSEN, Renold, EPG Electropower Fenner (Fenaflex) or equivalent Renold, Tsubaki, PC Chain SKF, FAG

1450 25 4202 <



Page 1 of 1



DATE:

13-May-00


PROJECT CODE

PREPARED BY


DELIVERY

NW

REVISION No. LOCATION EMPTY BUNCH DISPOSAL SYSTEM

DRAWING NO.


GENERAL Scope

E2 1

Scope of works include the manufacture, delivery & installation, commissioning handing over and guarantee.

Function:

To convey unstripped bunches from H.E.B Conveyor to Thresher No.2


One ( 1 ) unit Unstripped Bunches Conveyor as follows :


Double conveyor chain c/w buckets 90 MT FFB per hour. As per drawing As per drawing

Construction Material: Casing: Sprocket Bucket: Chain rail: Wear plate: Chain:

Mild steel with 6mm minimum thickness 12T, 150 mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 150mm pitch 15000 kg breaking load

Drive: Geared Motor coupled to elevator shaft by chain & sprocket Shaft Speed: 25 rpm Transmission Sprocket Ratio: 1 Speed Reducer: Input speed: 1450 rpm Output speed: 25 rpm Output torque: 2865 Nm (min) Design Service Factor: > 1.5 Motor:Power: Type:



Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower

Coupling: Transmission Chain: Conveyor Chain: Bearing:

Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG


Page 1 of 1

BUNCH CRUSHER


DATE:

13-May-00


OIL PALM MILL

PREPARED BY

BUNCH CRUSHER


NW


ITEM No.

E3

QUANTITY / UNITS

1

GENERAL Scope

Scope of works include the manufacture, supply, installation, erection, testing commissioning, handing over and guarantee

Function:

Crushing of the bunches for the removal of fruitlets and dewatering of bunches


One ( 1 ) unit Bunch Crusher complete with support, chutes and drive, as follows:

Unit Capacity

12MT Bunches per hour. ( 45mt FFB per hour )

Diamension Weight

Approx 2,500 kg

CONSTRUCTION MATERIAL Construction

Drive system

Robust construction with parts in contract with bunch from special wear resistance steel. The drive system shall consist of a motor coupled to gearmotor with pulley and belt transmission. An arrangement with the use of a fluid coupling can also be considered.

Motor

Approx. 22kw 415 V 3 Ph 50 HZ TEFC IP55 Class F

APPROVED MAKES Motor: Gear reducer: Coupling: Conveyor & Transmission chain, sprocket Bearing:

Specified or Equivalent. Crompton Parkinson, ABB Brook, Brush, Elektrim Sew, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold Renold, Tsubaki SKF, FAG, NTN

OTHER REQUIREMENTS:1. Vendor to furnish details drawing and specifications of selection of gear reducers, fluid coupling, chain and sprockets 2. Inlet and outlet chute made from 6mm thk. m.s plate shall be provided

Page 1 of 1

TOP EMPTY BUNCH CONVEYOR


DATE:

13-May-00


PROJECT CODE

PREPARED BY


DELIVERY

NW


DRAWING NO.


GENERAL Scope


Function:

To convey empty bunches from Inclined EB Conveyor to the EB Hoppers.


One (1) unit Top Empty Bunch Conveyor suitable for handling 90MT FFB per hour as follows:

Type: Capacity: General Arrangment: Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate: Basic Dimension: Width: Length:

Conveyor chain c/w scrapper plate ### kg / hr of empty bunches As per drawing

Steel c/w hardened steel rollers, 100 mm pitch, 6800 kg breaking load Mild steel or equivalent Mild steel or equivalent 12T, 100 mm pitch, grey iron Mild steel 6 mm minimum thickness or equivalent

Inclination:

mm mm Horizontal

Conveying Section:

Top

Shaft Speed:

25

Transmission Sprocket Ratio: Drive:

1.00 Geared motor coupled conveyor shaft by tarnsmission chain & sprocket


760

rpm

1450 rpm 25 rpm 2865 Nm (min) < 1.5

Motor:Power: Type:


Page 1 of 2

E4 1



DATE:

13-May-00


OIL PALM MILL



PREPARED BY

NW



E4 1

Sheet 2. APPROVED MAKES Motor: Gear reducer: Coupling: Conveyor & Transmission chain, sprocket Bearing:

Crompton Parkinson, ABB Brook, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold Renold, Tsubaki, PC SKF, FAG, NTN


Page 2 of 2

Empty bunch Hoppers


DATE:

13-May-00


OIL PALM MILL

EMPTY BUNCH HOPPERS STRUCTURE

&

PREPARED BY

DELIVERY

NW


DRAWING NO.

EMPTY BUNCH DISPOSAL SYSTEM

ITEM No.

E5

QUANTITY / UNITS

16

GENERAL Scope

Scope of works include the design, manufacture, delivery & installation commissioning, handing over and guarantee.

Function:

To receive, store and unload empty bunches into trucks.


Sixteen ( 16 ) bay Empty Bunch hoppers as follows : The hopper shall be of mild steel construction and doors will be operated hydraulically.

Type: Capacity: Slope: Construction Material: Construction Details: Door operation:

Sloping ramp c/w hydraulic operated doors 10,000 kg per Hopper 27 deg

Hydraulic type, vertical stroke( top down) c/w individual lever control located at hopper's platform as per drawings

Hydraulic System:

Consist of hydraulic pump, oil tank, cylinders, tubing, lever control, releif valve, pressure gauges, pump strainer, check valve and all the necessary accessories for completion operation of each 16 sets of doors. The tank shall be interconnected.

Powerpack: Reservoir: Pump

Double unit 80 litres capacity with epoxy coating Fix displacement low noise gear type, 23 litres/min @ 250 Bar

Relief valve

Direct acting type, 120 litres/min adjustable from 0-100 Bar

Cylinder:

piston type, 915mm stroke 200 bar rated pressure 300 bar static pressure Heavy duty construction with welded cap and easily removable head with air bleeding plugs at both end

Piston road: Mounting: Directional Control Valve: Tubing:

38mm diameter rod heat treated steel hard chrome plated Female clevis both ends.

Motor:

Individual valve for each door seamless cold drawn hydraulic tubing, 235 N/m2 minimum yeild strength. Flaxible hoses to be 2 -wire braided high pressure type. 2 x 5.25 kw TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

Detail Drawings

Contractor to provide detail drawing for approval by the consultant Page 1 of 2

FRUIT ELEVATOR


DATE: 13-May-00 MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED BY

FRUIT ELEVATOR

DELIVERY

NW


DRAWING NO.

PRESS STATION


GENERAL Scope

Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee 12 months.

Function:

To convey loose fruits from THRESHER CONVEYOR to TOP DISTRIBUTING CONVEYOR


Two ( 2 ) unit Fruit Elevator.


Double conveyor chain c/w buckets 45 MT FFB per hour. As per drawing As per drawing

Construction Material: Casing: Sprocket Bucket: Chain rail: Wear plate: Chain:

Mild steel with 6mm minimum thickness 12T, 150 mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 150mm pitch, 15000 kg breaking load

Drive: Shaft Speed: Transmission Sprocket Ratio:

Geared Motor coupled to elevator shaft by chain & sprocket 25 rpm 1


1450 25 2865 >


Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:

7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent. Crompton Parkinson, Brush, ABB Brooks , Elektrim SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG


Page 1 of 1

F1 2

FRUIT FEED CONVEYOR


DATE:

13-May-00


OIL PALM MILL

FRUIT FEED CONVEYOR

PREPARED BY


NW

REVISION No. LOCATION PRESS STATION


F 2. 1

GENERAL Scope

Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee.

Function:

To convey loose fruit from FRUIT ELEVATOR to Digesters

SPECIFICATIONS Quantity Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:

One ( 1 ) unit Fruit feed conveyor as follows : 45 MT FFB per hour. Full flight screw 600 mm dia. As per drawing As per drawing Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor

Screw Shaft: Shaft joint: Hanger bearing:

Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup

Conveyor Speed: Drive System:

56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling



APPROVED MAKES


Motor: Gear reducer: Coupling: Bearing:

Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold,HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN

1450 rpm 56 rpm 938 Nm (min) > 1.5

OTHER REQUIREMENTS:1. Four ( 4 ) mild steel outlet chutes c/w rack & pinion sliding doors with chain operated to be provided at inlet to 3 digesters and blank space. 2. One mild steel chute to be provided at the end of the conveyor to recycle the excess fruit to FRUIT ELEVATOR 3. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 4. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust Page 1 of 2

FRUIT FEED CONVEYOR


DATE:

13-May-00


OIL PALM MILL

FRUIT FEED CONVEYOR


PREPARED BY

NW



5. Top of the conveyor shall be covered with 3mm thk m.s plate

Page 2 of 2

F 2. 1

RETURN FRUIT CONVEYOR


DATE:

13-May-00


OIL PALM MILL

PREPARED BY


DELIVERY


DRAWING NO.


GENERAL Scope

Scope of works include the Design, manufacture, delivery installation, commissioning, handing over and guarantee.

Function:

To convey excess loose fruit from Fruit Feed Conveyor to Fruit Elevator

SPECIFICATIONS Quantity Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:

Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:

NW

One (1) unit Return Fruit Conveyor as follows : 45 MT FFB per hour. Full flight screw 600 mm dia. As per drawing As per drawing

Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling 1450 56 640 >



APPROVED MAKES



Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold,HANSEN, EPG ElectroPower

Coupling: Bearing:

Fenner (Fenaflex), Renold FAG, SKF, NTN

OTHER REQUIREMENTS:1. One inlet appreture for the overflow of digested material to be conveyed to the fruit elevator. 2. One MS chute flange to be provided at the end of the conveyor for attachment of the return fruit chute to the elevator. 3. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 4. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust Page 1 of 2

F 3. 1



DATE:

13-May-00


OIL PALM MILL



PREPARED BY

NW



5. Top of the conveyor shall be covered with 3mm thk m.s plate cover.

Page 2 of 2

F 3. 1

Recycle Chute


DATE:

13-May-00


OIL PALM MILL

RECYCLE CHUTE

DELIVERY

PREPARED BY

NW


DRAWING NO.

PRESS STATION

ITEM No.

F 4.

QUANTITY / UNITS

1

GENERAL Scope

Scope of works include the Design, manufacture, delivery, installation, commissioning, handing over and guarantee

Function:

To convey excess loose fruit from Fruit Feed Conveyor to Fruit Elevator


One ( 1 ) unit Recycle Chute of mild steel

General Arrangement: Construction Details: Construction Material: Casing: Supports :

As per drawing As per drawing Mild steel of 6mm minimum thickness M. S. Channels & Angle iron

Page 1 of 1

DIGESTER


DATE:

13-May-00


OIL PALM MILL


PREPARED

DIGESTER ( 3500 m3 )

REVISION No. PRESS STATION


GENERAL Scope

Function: SPECIFICATIONS Quantity Unit Capacity

Diamension CONSTRUCTION MATERIAL Construction

F5 3

Scope of works include the unloading at site, safe keeping installation, assist in testing and commissioning. Digestion of loose fruitlets before screw press oil extraction.

Three ( 3 ) units Digesters as follows : 15MT Fresh Fruit Bunches ( FFB ) per hour. or not less than 3,500 liters per hour. approx. 4000 mm H x 1300 mm D

The cylindrical portion shall have a 12mm thick mild steel shell with a 9mm thick mild steel liner. The shell insulated with rockwool at density of 90 kg / m2 and covered with 22 gauge embossed stainless steel sheet. Heating by steam injection and control by a thermostatic valve. Chute from digester to screw press to be fabricated from 4 mm thick stainless steel sheet with sight glass, flanged door oil filled pocket for temperature gauge.

Drive system

Motor is connected to a fluid drive coupling and then to the vertically mounted gear reducer as shown in the drawing.

Motor

approx. 22kw 4 pole, TEFC, IP 55 class F 415 V 3 phase 50 Hz.

Gear reducer

Ratio 40:1 service factor 1.5 ( min )

APPROVED MAKES




Page 1 of 1

TWIN SCREW PRESS


DATE:

13-May-00


OIL PALM MILL

PREPARED

TWIN SCREW PRESS ( TYPE P15)

DELIVERY

REVISION No.

DRAWING NO.

ITEM No.

PRESS STATION

QUANTITY / UNITS

F 6. 3

GENERAL Scope

Scope of works include the unloading at site, safe keeping, insatallation assist in testing and commissioning.

Function:

The extraction of crude palm oil by screw pressing.


Three ( 3 ) units Twin Screw Presses as follows :

Unit Capacity

15MT Fresh Fruit Bunches ( FFB ) per hour.

Diamension Weight

Approx. 4600mm L x 1100mm W x 1400mm H Approx 4,500 kg


Robust construction with parts in contract with press mash & fibre from special wear resistance steel.

Strainer & Cage

The holes of the strainer and press cage shall have taper holes no larger than 3 x 2 mm with 6 mm C/C and the cage plate of 12 mm thickness supported by ribs.

Drive system

The drive system of he twin screw press shall consist of a motor directly coupled to a gearmotor with pulley and belt transmission to the drive shaft of the screw press. An arrangement with the use of a fluid coupling can also be considered.

Motor

Approx. 22kw 415 V 3 Ph 50 HZ TEFC IP55 Class F

Hydraulic Cone Control

The hydraulic cone control shall be automatic with the cones sliding in and out, maintaining a consistent pressure. The feedback of the pressure in the main hydraulic motor drive shall be used to control the hydraulic cylinder driving the adjustable cones and its motion shall stepless.

Preformance

a. b. c. d.

Oil loss on press fibre shall not exceed 7% Oil / Dry matter Oil loss on Nuts shall not exceed 1% Oil / Dry matter Broken Nuts in press fibre shall not exceed 12% NOS in Sludge shall not exceed 10% Oil / Dry matter.

APPROVED MAKES




Page 1 of 1

PRESS STRUCTURE


DATE:

13-May-00


OIL PALM MILL

PRESS STRUCTURE


PREPARED REVISION No.

'PRESS STATION


GENERAL Scope

Scope of works include the Design, manufacture, delivery Installation, commissioning, handing over and guarantee.

Function:

To support equipment which include 4 presses, 4 digesters, digester feed conveyor, fruit return conveyor, Hot water tank and Oil launder.


Lot - Press Structure with platform and necessary stairways.

Plateform

The chequered plates for the platform shall be 6 mm thick and toe plate of 100mm x 6 mm

Stairways

The chequered plates are to be secured to the supporting structure by stitch welding and all necessary stairways shall be provided as shown in the drawing.

Chain Block

At the top of the structure a cross beam with a 3 ton chain block shall be provided for maintenance of the digester & Press.

General Arrangment: Construction Details: Construction Material: Structures: Plaform Handrail: Structure bolts & nuts:

As per drawing As per drawing

Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe High tensile

OTHER REQUIREMENTS 1. Handrail of 40 mm black pipe shall be 900mm high with intermediete poles at 2000 c/c 2. 100mm high kick plate to be provided around the platform 3. Hoist beam and 3 ton chain block shall be installed as shown in the relevant drawings

Page 1 of 2

F 7. 3

CRUDE OIL COLLECTION GUTTER


DATE:

2-Oct-98


OIL PALM MILL

CRUDE OIL GUTTER

DELIVERY

PREPARED NW REVISION No.

LOCATION PRESS STATION

DRAWING NO.

ITEM No.

F 8.

QUANTITY / UNITS

GENERAL Scope

Scope of works include the Design, manufacture, delivery, installation, commissioning, handing over and guarantee .

Function:

To collect crude oil ex-SCREW PRESSES and channel it to Sand trap


One ( 1 ) Crude Oil Collection Gutter as follows : The cude oil pipe shall be a stainless steel pipe of 200 mm dia. It shall have sufficient gradient to allow a full flow and drainage of the crude oil mixture. The outlet oil drain from the digester and press drain funnel and interconnecting pipes to crude oil gutter shall be included. Provision for hot water and steam blowing of the crude oil gutter.

General Arrangment:

As per drawing


As per drawing

Construction Material:

PIPE S.S AISI 304

Thickness:

4.5 mm

Size:

200 mm Dia.

Page 1 of 1

1

SAND TRAP


DATE:

13-May-00


OIL PALM MILL

PREPARED

SAND TRAP TANK

DELIVERY

REVISION No.

DRAWING NO.

ITEM No.

PRESS STATION

QUANTITY / UNITS

GENERAL Scope Function:

NW

F 9. 1

Scope of works include the Design, manufacture, delivery, installation, testing, commissioning and guarantee. To receive oil from CRUDE OIL GUTTER and trap the sand

SPECIFICATIONS Quantiry

One ( 1 ) Sand Trap as follows : The sand trap tank shall have a capicity of approximately 7 m 3 and of vertical cylindrical construction. Internal buffling shall be provided to allow for non-turbulent flow of crude oil to the top of the tank whereby allowing the sand and heavy solid particles to settle to the bottom. The crude oil overflow pipe shall be connected to the crude oil tank.

Capacity: Basic Dimensions:

7 m3 As per drawing

Construction Material:Tank:

Mild steel

Close Steam Coil:

50mm dia. S.S 304 seamless sch 10S

Nozzles:Protrusion qty 1 1 1 1 1

Purpose Drain Overflow Steam inlet Cond.Outlet Hot water

Size (mm) 80 150 50 50 25

Tank plate thickness: Flanges:

6 mm Raised face to BS 4504

Page 1 of 1

(mm) 150 150 150 150 150

Flange PN 10 PN 10 PN 16 PN 16 PN 10

Material API 5L Gr B Sch 40 API 5L Gr B Sch 40 SS 304 Sch 10S SS 304 Sch 10S GI Class C BS 1387

CIRCULAR VIBRATING SCREEN


DATE:

13-May-00


OILPALM MILL

PREPARED

CIRCULAR VIBRO SIEVE SCREEN

DELIVERY

NW

REVISION No. 'PRESS STATION

DRAWING NO.


F 10 2

GENERAL Scope

Scope of works include the Design, manufacture, delivery, installation, testing commissioning and guarantee.

Function:

Screening of crude oil before clarification process.


Two ( 2 ) units Circular Vibrating screens as follows :

Type

Double deck circular vibro sieve screens.

Screen area

not less than 1.6 m2

Diameter

60 inchs.

Unit Capacity

:

CONSTRUCTION AND MATERIAL. Construction

Diluted crude oil of equivalent to 16 m3 / h

Bottom supporting assembly supported by springs which shall give the required vibrations.

The cylindrical deck body (wetted part) to fabricated from stainless steel 304 (EN 58B) or equivalent. The first and second deck shall be equipped with mesh 20 and 40 stainless steel screen respectively Variable weights at the lower end of the motor shaft for varying the amplitude of vertical vibration. Variable weights at the upper end of the motor shaft for varying the horizontal conveying so as to screen solids to the periphery for discharge

The design fittings of the sieve screen shall be so as to facilitate easy assembling and dismantling of the screen box for screen cloth changes, cleaning and inspection

Contractor shall provide details of and specify vibrating screen make, type, model, country of origin, capacity , motor etc… Vibro Motor.

3.75 kw 415 V, 3 phase 50 Hz TEFC, IP 55 Class F

APPROVED MAKES




Page 1 of 1

VIBRATING SCREEN STRUCTURE


DATE:

13-May-00


OIL PALM MILL

PREPARED

VS STRUCTURE




GENERAL

Scope of works include the design, fabrication, delivery, installation, testing, commissioning and guarantee.

Function:

To support 2 circular vibrating screens

SPECIFICATIONS General Arrangment: Construction Details: Construction Material: Structures: Plaform Handrail:

NW

As per drawing As per drawing Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe

OTHER REQUIREMENTS 1. Handrail shall be of 40mm black pipe, 900mm high with intermediete poles at 2000 c/c 2. 100mm high kick plate to be provided around the platform

Page 1 of 1

F 11. 2

SCREEN WASTE CONVEYOR


DATE:

13-May-00


OIL PALM MILL

PREPARED

SCREEN WASTE CONVEYOR

DELIVERY

NW


PRESS STATION

DRAWING NO.

ITEM No.

F 12

QUANTITY / UNITS

GENERAL Scope


Function:

To convey vibrating screen reject of solid waste to FRUIT ELEVATOR.


One ( 1 ) unit Screen Waste Conveyor as follows :


Full flight screw 300 As per drawing As per drawing


Screw Shaft: Hanger bearing: Conveyor Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:

mm dia.

Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Stainless steel 304 of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Motor directly coupled to speed reducer by flexible coupling 1450 56 375 >




Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold, HANSEN

Coupling: Bearing:


OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at drive end of the conveyor 4. Roller thrust bearing shall be fitted at discharge end

Page 1 of 1

1

CRUDE OIL TANK


DATE:

13-May-00


OIL PALM MILL

PREPARED

CRUDE OIL TANK

DELIVERY

NW


DRAWING NO.

PRESS STATION

ITEM No.

F 13.

QUANTITY / UNITS

1

GENERAL Scope

Scope of works include the Design, manufacture, delivery, installation commissioning, handing over and guarantee.

Function:

To receive oil from VIBRATING SCREEN


One ( 1 ) unit Crude oil tank as follows :

Capacity: Basic Dimensions: Construction Details:-

7 m3 As per drawing As per drawing

Construction Material:Tank: Close Steam Coil: Live steam injection: Insulation: Nozzles:-

Stainless steel 4.5mm plate 25mm dia. S.S 304 seamless sch 10S 25mm dia. S.S 304 seamless sch 10S 80mm thk Rockwool c/w 0.7mm thk aluminium cladding

Purpose drain pump suction vent hot water inlet crude oil inlet steam inlet steam condensate recycle Flanges:

Size (mm) 80 80 150 25 200 50 50 50

Qty 3 3 1 3 1 3 3 1

Raised face to BS 4504

Page 1 of 1

Protrusion Flange PN 10 PN 10 PN 10 PN 10 PN 10 PN 16 PN 16 PN 10

(mm) 150 150 150 150 150 150 150 150

Material API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 SS 304 SCH10S SS 304 SCH10S API 5L SEAMLESS SCH40

CRUDE OIL PUMP



PROJECT CODE

OIL PALM MILL

PREPARED

NW

CRUDE OIL PUMP DELIVERY


DRAWING NO.


GENERAL Scope


Function

To transfer the crude oil to the clarification station


Two ( 2 ) units Crude Oil Pump as follows :

Type Connection

Centrifugal, End-suction Raised face flange to BS 4504 PN 10


45 Crude Oil 90 0.9 0.1425 35 1450 3

MT / hr o

C

Ns / m2 m liquid RPM (Max) m liquid

CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling Level Switches:

Cast Iron GG25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Magnetic type, with stainless steel float & rod and counter weight Motor directly coupled with flexible coupling to the pump

Drive: Motor:Power: Type:

approx. 3.75 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

OTHER REQUIREMENTS

1. Vendor to provide technical details, cataloques, performance curve and etc.

Page 1 of 1

F 14 2

OVERHEAD HOT WATER TANK


DATE:

13-May-00


OIL PALM MILL

PREPARED

HOT WATER TANK


NW



F 15 1

GENERAL Scope


Function:

Heating tank of water for extracted crude oil dilution


One ( 1 ) unit Overhead Hot water tank as follows :


4 m3 As per drawing As per drawing

Construction Material:Tank: Close Steam Coil: Live steam injection: Insulation: Level switch Control

Stainless steel 4.5mm plate 25mm dia. S.S 304 seamless sch 10S 25mm dia. S.S 304 seamless sch 10S 80mm thk Rockwool c/w 0.7mm thk aluminum cladding Level limit switch for feed water inlet Thermostatic control valve for steam coil

Nozzles:Purpose vent hot water inlet and outlet steam inlet

Flanges:

Size (mm) 150 25 50 25

Qty 1 3 1 3


Page 1 of 1


Protrusion (mm) 150 150 150 150

Material API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 SS 304 SCH10S

SAND TRAP CONVEYOR



PROJECT CODE

OIL PALM MILL

PREPARED

SAND TRAP CONVEYOR

DELIVERY


DRAWING NO.


GENERAL Scope

Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.

Function:

TO convey trap sand for disposal


One ( 1 ) unit Sand trap Conveyor No. 1 as follows :

Capacity: Type: Size: General Arrangement: Construction Details:

1,000 kg / hr of sand material Full flight screw 200 mm dia. As per drawing As per drawing


Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:

NW

Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling 1450 56 375 >



APPROVED MAKES



Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold, HANSEN, EPG ElectroPower

Coupling: Bearing:


OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate Page 1 of 2

F 16 1

STRAINER BUCKET ELEVATOR


DATE:

13-May-00


OIL PALM MILL

BUCKET ELEVATOR

DELIVERY

PREPARED

NW


PRESS STATION

DRAWING NO.


GENERAL Scope

Function:

F 17. 1

Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee. Conveyor to drain the solid waste in buckets, while in motion and thereafer unloading onto trailer or truck for field disposal.


One (1) Bucket Elevator ( strainer ) complete with drive as folows:


Double conveyor chain c/w buckets 1,000 kg material per hour. As per drawing As per drawing

Construction Material: Casing: Sprocket Bucket: Chain rail: Wear plate: Chain: Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:

Mild steel with 6mm minimum thickness 12T, 100mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 100mm pitch. 3600 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 25 rpm 1 1450 25 1000 >




Specified or Equivalent. Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, HANSEN, Renold, EPG ElectroPower




Page 1 of 1

AUTO DILUTION SYSTEM


DATE:

13-May-00


OIL PALM MILL

PREPARED

CRUDE OIL DILUTION SYSTEM

DELIVERY

NW


DRAWING NO.

ITEM No.

F 18.

QUANTITY / UNITS

GENERAL Scope

Scope of works include the unloading, safe keeping, installation supervision assist in the testing and commissioning.

Function

Controlled dilution of raw CPO and water for effective clarification


One (1) Crude Oil Dilution System as follows:-

Construction

The Automatic Crude Oil Dilution system shall handle viscous slurry nature of crude oil at temperature range: 70 C - 90 C. It shall be of proven make and currently in operation. The Automatic Crude Oil Dilution System consists of PID controller that automatically modulates 50mm hot water valve to dilute crude oil to pre-set density. Crude oil from buffer tank is gravity feed and pass through density cell for continuously crude oil density.

Scope of supply shall include: 1

Density cell c/w positive cell fluid retainer and signal conditioning.

2

Microprocessor based controller with PID control and I/P conversion.

3

50mm dia. modulating control valve for hot water.

4

Crude Oil R.S.G. recorder.

5

Installation & Operating instructions, service manual and buffer tank drawing.

6

Testing and commissioning.

Page 1 of 1

1

WATER COLLECTION TANK


DATE:

13-May-00


OIL PALM MILL

PREPARED

WATER COLLECTION TANK

DELIVERY

NW


PRESS STATION

DRAWING NO.

ITEM No.

F 19.

QUANTITY / UNITS

GENERAL Scope

Scope of works include the Design, manufacture, delivery, installation commissioning, handing over and guarantee.

Function:

Tank to collect condensate water from all equipment and piping system


One ( 1 ) unit Water Collection tank as follows :

Capacity: Basic Dimensions:

2.25 As per drawing

Construction Details:-

As per drawing

m3

Construction Material:Tank: Insulation: Level switch

Mild steel 5mm plate 80mm thk Rockwool c/w 0.7mm thk aluminum cladding Level limit switch for level control

Nozzles:Purpose

Size (mm)

Qty

Flange

Protrusion (mm)

Material

Water inlet

50

3

PN 10

150 API 5L SEAMLESS SCH40

and outlet

50

1

PN 10

150 API 5L SEAMLESS SCH40

Flanges:


Page 1 of 1

1

PUMP SET - WATER COLLECTION TANK.


DATE:

13-May-00


OIL PALM MILL

PUMP FOR WATER COLLECTION TANK

DELIVERY

PREPARED

NW


DRAWING NO.


F 20 2

GENERAL Scope

Scope of works include the Design, manufacture, delivery , installation commissioning, handing over and guarantee.

Function

To recycle the condensate water to the Hot water tank crude oil dilution tank, vibrating screen and clarification station.


Two ( 2 ) Pump set with level switch for water collection tank as follows : Note : One unit on standby.

Type Connection Control

Centrifugal, End-suction Raised face flange to BS 4504 PN 10 Level switch

OPERATING DATA Capacity Medium Temperature Specific Gravity Deleivery Head Speed NPSH available

15 WATER 100 1 30 1450 3

MT / hr o

C

m liquid RPM (Max) m liquid

CONSTRUCTION Casing Impeller Shaft Coupling Level Switches:

Cast Iron GG25 S.S AISI 304 S.S AISI 304 Flexible Magnetic type, with stainless steel float & rod and counter weight Motor directly coupled with flexible coupling to the pump

Drive: Motor:Power: Type:

approx. 3.75 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz


Page 1 of 2

VERTICAL CLARIFIER


DATE:

13-May-00


OIL PALM MILL

PREPARED

VERTICAL CLARIFIER

DELIVERY

NW


DRAWING NO.



G 1. 1

GENERAL Scope

Scope of works include the Design, Fabrication, delivery, installation, testing commissioning and guarantee.

Function:

Static separation of crude oil from sludge


One ( 1 ) unit Vertical Clarifier Tank as follows :

Capacity: Basic Dimensions : Construction Details:-

120 As per drawing As per drawing

Construction Material:Tank body: Close Steam Coil: Open Steam Coil: Skimmer: Sludge Underflow Pipe: Hot water Coil: Stirrer: Baffles: Supporting Structures: Insulation:

Mild steel cylindrical section and SS 304 conical section 50mm dia. S.S 304 seamless sch 10S 50mm dia. S.S 304 seamless sch 10S S.S 304 S.S 304 seamless sch 10S 50mm dia. S.S 304 seamless sch 10S S.S 304 S.S 304 Mild steel 50mm thk Rockwool c/w 0.7mm thk aluminium cladding

Nozzles:Users Drain Sudge Overflow Oil outlet Vent Hot water in Steam in Cond. out crude oil in Rec.oil in Temp.Gauge Temp.Controller

Size mm 100 150 150 100 50 50 50 80 65 3/4" BSP 3/4" BSP

Qty 1 1 1 1 1 2 1 1 1 1 1

Manhole

as per drawing

Stirrer

as per drawing

Flanges:

m3


Page 1 of 2

Flange Protrusion Material mm PN 10 150 API 5L Gr B, seamless Sch 40 PN 10 150 SS 304 Sch 10S PN 10 150 API 5L Gr B, seamless Sch 40 PN 10 150 API 5L Gr B, seamless Sch 40 PN 10 150 SS 304 Sch 10S PN 16 150 SS 304 Sch 10S PN 16 150 SS 304 Sch 10S PN 10 150 SS 304 Sch 10S PN 10 150 SS 304 Sch 10S 100 100

PURE OIL TANK


DATE:

13-May-00


OIL PALM MILL

PREPARED

PURE OIL TANK

DELIVERY

NW

REVISION No. LOCATION CLARIFICATION STATION

DRAWING NO.


G 2. 1

GENERAL Scope

Scope of works include the Design, Fabrication, delivery installation, testing, commissioning and guarantee.

Function:

To receive oil from VERTICAL CLARIFIER

SPECIFICATIONS Quantity Capacity: Basic Dimensions: Construction Details:-

One ( 1 ) Unit Pure Oil Tank as follows : 30 m3 As per drawing As per drawing

Construction Material:Tank body: Steam Coil: Cover: Insulation:

Mild steel 50mm dia. API 5L,Gr B seamless sch 40 Mild steel 50mm thk Rockwool c/w 0.7mm thk aluminium cladding

Nozzles to be provided:Users drain oil inlet vent steam inlet cond.oulet oil outlet temp.gauge temp.control

Size (mm) 100 150 100 50 25 100 3/4" BSP 3/4" BSP

Qty 1 1 1 1 1 1 1 1

Flange PN 10 PN 10 PN 10 PN 16 PN 16 PN 10

Protrusion (mm) Material 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 80 API 5L, Gr B Sch 40 seamless 80 API 5L, Gr B Sch 40 seamless

Flanges:


Level Indicator:

Mechanical type with SS float and string

Page 1 of 1

SLUDGE TANK


DATE:

13-May-00


OIL PALM MILL

PREPARED

SLUDGE OIL TANK

DELIVERY

NW


DRAWING NO.


GENERAL

Scope of works include the Design, Fabrication, delivery installation, testing , commissioning and guarantee

Function:

To receive Sludge phase from VERTICAL CLARIFIER

SPECIFICATIONS

One ( 1 ) unit Sludge Tank as follows :




Mild steel SS AISI 304 seamless sch 10S Mild steel 50mm thk Rockwool c/w 0.7mm thk aluminium cladding

G 3. 1

m3

Nozzles to be provided:Users drain sludge inlet vent steam inlet cond.oulet sludge outlet temp.gauge temp.control Flanges: Level Indicator:

Size (mm) 100 150 100 50 25 100 3/4" BSP 3/4" BSP

Qty 1 1 1 1 1 1 1 1


Protrusion (mm) Material 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 SS 304 seamless Sch 10S 150 SS 304 seamless Sch 10S 150 SS 304 seamless Sch 10S 80 API 5L, Gr B Sch 40 seamless 80 API 5L, Gr B Sch 40 seamless

Raised face to BS 4504 Mechanical type with SS float and string

Page 1 of 1

DESANDING CYCLONE


DATE:

13-May-00


OIL PALM MILL

PREPARED

MULTI DESANDING CYCLONE

DELIVERY

NW


DRAWING NO.

ITEM No.

G 4.

QUANTITY / UNITS

1

GENERAL Scope

Scope of works include the design, manufacture, delivery installation supervision, testing, commissioning and guarantee. The installation on elevated platform will be provided by others.

Function:

desanding of crude oil before clarification process.


One ( 1 ) Desanding cyclone system, delivered in module assembly, mounted in a m.s. frame complete with 3 cyclones control valves, connecting pipes, booster pump, solids collecting tank and control unit to be link with PLC and Central Control station via the LAN networking. The starter board, local switch and air supply will be provided by others

Capacity

45 m3 Sludge mixture per hour with solid contents of 15%

Performance

Removal of sand and solid mattter above 50 micron of not less than 75% of the total input sand and solid matter, operating at full capacity. Vendor to provide details on wear parts and running hours

Discharge head Scope of supply

3 kg / cm3 a. b. c. d. e. f. g. h. I. j. k.

Desanding cyclone assembly, mounted in m.s. frame Auto program control unit Set of control valves Solid matter collecting tank with water flushing system. Booster feed pump Set of piping connections and fixtures. Set of standard tools Set of standard spares Flow indicator Installation & Operation instruction, service and parts manuals Testing, commissioning and training of 3 operators

Page 1 of 2

DESANDING CYCLONE


DATE:

13-May-00


OIL PALM MILL

MULTI DESANDING CYCLONE


PREPARED

NW


ITEM No.

G 4.

QUANTITY / UNITS

1

Sheet 2.

Material for Cyclones

Abrasion resistance ceramic

System for discharge of dirt

Discharge via a stainless steel collecting tank

Control Panel

Control panel using microprocessor- based control for operation.

Control Valve

Mark Control, Valtac, Keystone, bailey, Kitasawa or equivalent

Booster pump motor

3.75 kw 415V / 3-Ph / 50Hz Contractor to provide detail requirements

Test on completion :

Samples shall be taken for the inlet feed and outlet discharged material and analysed for quality and quantity of solid matter. The results shall be statistically analysed by taking the mean average and standard deviation.

Approved Makes


Valves

Mark Control, Valtac, bailey, Kitasawa, Keystone, Klinger

Motor

Brook Crompton, ABB, Brush, Marelli

Pump

SIHI, Vogel, KSB, Grundfos, Robuschi, Allen Gwynnes, Ajax

Requirement

Contractor to provide design details of equipment offered for consultant's approval before fabrication.

Page 2 of 2

PRE - CLEANER PUMP


DATE:

13-May-00


OIL PALM MILL

PREPARED

SLUDGE OIL TRANSFER PUMP




GENERAL Scope

Scope of works include the Purchase, delivery, installation testing, commissioning and guarantee.

FUNCTION

To pump the sludge oil from the sludge oil tank to the multi desanding cyclone

SPECIFICATIONS. Quantity Type Connection

Two ( 2 ) units Sludge Oil Transfer Pumps as follows: Centrifugal, End-suction BS 4504 PN 10


45 Sludge Oil 105 0.86 0.1425 30 1450 3

CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling DriveSystem: Motor:Power: Type:

APPROVED MAKES Pump: Motor: Coupling: Bearing: Mechanical seal:

NW

m3 per hour of Sludge Oil o

C

Ns/m2 m liquid RPM (Max) m liquid

Cast Iron GS-C25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling approx. 3.75 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent KSB, SIHI, Robuschi, Warman or equivalent Crompton Parkinson, Brush, ABB Brooks, Elektrim Fenner (Fenaflex), Renold SKF, FAG, NTN Crane, Burgman

OTHER REQUIREMENTS:1. Vendor to provide technical details, cataloques, performance curve and etc.

Page 1 of 1

G 5. 2

SLUDGE BUFFERTANK


DATE:

13-May-00


OIL PALM MILL

PREPARED

SLUDGE OIL TANK

DELIVERY

NW



DRAWING NO.


G 6. 1

GENERAL Scope

Scope of works include the Design, Fabrication, delivery, installation, testing commissioning and guarantee.

Function:

Buffer tank to feed the decanter or sludge separator


One ( 1 ) unit Sludge buffer tank as follows : 3 4 m As per drawing As per drawing


Stainless steel 304, 3mm thick SS AISI 304 seamless sch 10S Mild steel 50mm thk Rockwool c/w 0.7mm thk aluminium cladding

Nozzles to be provided:Uses drain sludge inlet vent steam inlet cond.oulet sludge outlet temp.gauge temp.control Flanges: Level Indicator:

Size (mm) 100 80 100 50 25 100 3/4" BSP 3/4" BSP

Qty 1 1 1 1 1 1 1 1


Raised face to BS 4504 Mechanical type with SS float and string

Page 1 of 1

Protrusion (mm) Material 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 SS 304 seamless Sch 10S 150 SS 304 seamless Sch 10S 150 SS 304 seamless Sch 10S 80 API 5L, Gr B Sch 40 seamless 80 API 5L, Gr B Sch 40 seamless

SLUDGE SEPARATOR


DATE:

13-May-00


OIL PALM MILL

SLUDGE SEPARATOR

DELIVERY

PREPARED

NW



DRAWING NO.

ITEM No.

G 7.

QUANTITY / UNITS

GENERAL Scope

1

Scope of works include the unloading at site, safe keeping, installation assist in testing and commissioning. Centrifugal Separation and recovery of Oil from Sludge from the under flow of the sludge tank or working in series with the decanter.

Function:


One ( 1 ) Sludge Separator in module form complete with interconnecting pipes, valves and fittings ready for start up.

Material to process Capacity

Sludge with 15% NOS from underflow of CS tank 36 m3 per hour ( Rate at 0.8 of 45 MT FFB per hour )

Capacity of each Separator Input feed rate

Performance will be based on operating without Decanter. 9 m3 Crude oil & Sludge mixture per hour

Discharge head

3 kg / cm3

CONSTRUCTION All bowl parts in contact with oil or sludge shall be in stainless steel. System for Cleaning:

The nozzle holders shall be easily removable from the outside without dismantling the centrifuge. A cleaning system shall be provided that the bowl internals can be cleaned by intermittent flushing without dismantling the unit.

Scope of supply: a. b. c. d. e. f. g.

Motor complete with fluid coupling Set of flexible connections 2 Sets of Special tools for maintenance Set of standard spares Complete automated cleaning system Flowmeter for incoming sludge 3 Sets of Installation, Operation & Service Manual

Operation of the automated cleaning system at regular intervals shall necessitate cleaning of the bowl parts by dismantling of the centrifuge after only 150 hours of operation. For sludge as the processing medium the waste water ex separator shall have an oil loss not exceeding 12% oil/Nos. Motor

11kw 415V, 3Ph, 50 HZ 4-pole, TEFC, Class F, IP 55 ( Vendor to advise )

Page 1 of 1

3 PHASE DECANTER


DATE:

13-May-00


OIL PALM MILL

DECANTER ( 3 PHASE )

DELIVERY

PREPARED

NW


DRAWING NO.

ITEM No.

G 8.

QUANTITY / UNITS

1

GENERAL Scope

Scope of works include the unloading at site, safe keeping, installation, assist in testing and commissioning.

Function:

Separation of Oil, Light phase and Sludge from Raw Sludge oil from the underflow of the CS tank


One ( 1 ) unit 3 Phase Decanter System complete in module form as follows : The unit shall be supplied complete with inter-connecting pipes, valves and fittings ready for start up.

Capacity

15 m3 Sludge oil with 20% NOS per hour

Discharge head

3 kg / cm3

CONSTRUCTION MATERIAL Construction:

All decanter parts in contact with oil or sludge shall be in s.s. AISI 306 and scroll conveyor with tips protected with tungsten carbide tiles. The works for the Mechnical Contractor shall also include the following : a. b. c. d. e. f. g. h.

Mounting and Installation of the decanter equipment Flow meter and regulated with an isolating valve. A 75mm solenoid valve to shut off the feed when power is cut Connections of a 50mm socket for hot water feed. Steel structure with platform, handrailings, stairways and ladder. A 3 ton chain block mounted on a overhead I-beam for maintenance Suitable discharge chutes for solid waste to conveyor. Drawing and detail specification of mounting platform & structure

Power

45kw 415V 3phase 50 HZ TEFC IP55 Class F Vendor to advise details of power requirements.

Requirements

Contractor to co-ordinate with equipment supplier for full details

Page 1 of 1

DECANTER WASTE CONVEYOR


DATE:

13-May-00


OIL PALM MILL

CONVEYOR ( DECANTER SOLID )

DELIVERY

PREPARED

NW


DRAWING NO.

ITEM No.

G 9.

QUANTITY / UNITS

GENERAL Scipe

1

Scope of works include the Design, Fabrication, delivery, installation, testing, commissioning and guarantee

Function:

To convey decantered solid waste material to hopper for field disposal.

SPECIFICATIONS Qunatity Capacity Type: Size: General Arrangement: Construction Details:

One (1) unit Screw Conveyor for decanter solid waste as follows: 6000 kg solid waste per hour ( 90mt FFB per hour ) Full flight screw 300 mm dia. As per drawing As per drawing



Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Stainless steel 304 of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Motor directly coupled to speed reducer by flexible coupling


1450 56 640 >


Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:

3.75 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold, HANSEN, EGP ElectoPower Fenner (Fenaflex), Renold FAG, SKF, NTN

OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at drive end of the conveyor 4. Roller thrust bearing shall be fitted at discharge end

Page 1 of 1

DECANTER LIGHT PHASE TRANSFER PUMP


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

LIGHT PHASE TANK & PUMP DELIVERY


DRAWING NO.

ITEM No.

G 10.

QUANTITY / UNITS

GENERAL Scope

1

Scope of work include the Design, Fabrication, delivery, installation, testing, commissioning and guarantee.

Function

To receive the underflow from the decanter

SPECTIFICATION Quantity Tank Volume Material Construction

One ( 1 ) units Decanter Light Phase Tank & Transfer Pump 200 litres Stainless Steel As per drawing

Pump Type Connection

Centrifugal, End-suction Raised face flange toBS 4504 PN 10


15 M3 per hour. Sludge Oil - Light phase o 99 C 0.9 Ns/m2 0.0798 20 m liquid 1450 RPM (Max) 3 m liquid

CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling DriveSystem:

Cast Iron GS-C25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling

Motor:Power: Type: APPROVED MAKES Pump: Motor: Coupling: Bearing:

approx. 3.75kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent. KSB, SIHI, Robuschi, Warman Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, FAG, SKF


Page 1 of 1

DECANTER HEAVY PHASE TRANSFER PUMP


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

DECANTER HP TRANSFER PUMP DELIVERY


DRAWING NO.

ITEM No.

G 11.

QUANTITY / UNITS

GENERAL Scope

Scope of work include the Design, Fabrication, delivery installation, testing, commissioning and guarantee.

Function

To receive the heavy phase liquid from the decanter

SPECTIFICATION Quantity Type Connection

Two ( 2 ) units Decanter Heavy Phase Transfer Pump Centrifugal, End-suction Raised face flange toBS 4504 PN 10


15 Sludge Oil 90 0.9 0.0798 20 1450 3



M3 per hour. o

C



approx. 3.75kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

Robuschi, Warman Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, FAG, SKF


Page 1 of 1

2

SLUDGE SETTLING TANK


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

SLUDGE SETTLING TANK DELIVERY


DRAWING NO.


G 12. 1

GENERAL Scope

Scope of works include the Design, fabrication, delivery installation, testing, commissioning and guarantee.

Function:

To receive sludge from various tank for recovery of Oil


One ( 1 ) unit Sludge / Oil recovery settling Tank as follows : 3 m 20 As per drawing As per drawing

Construction Material:Tank body: Steam Coil: Open channel:

Mild steel API 5L Gr B seamless Sch 40 Mild steel

The following nozzles to be provided:-

Users drain pump inlet steam inlet

Size (mm) 80 80 50

Qty

Flange PN 10 PN 10 PN 16

Protrusion (mm) Material 150 API 5L Gr B seamless Sch 40 150 API 5L Gr B seamless Sch 40 150 API 5L Gr B seamless Sch 40

Flanges:

Raised face toBS 4504

Requirement

Contractor to provide full details for approval by consultant.

Page 1 of 1

SLUDGE SETTLING TANK PUMP


DATE:

13-May-00


OIL PALM MILL

PREPARED

SETTLING TANK PUMP

DELIVERY

NW



DRAWING NO.


GENERAL Scope

Scope of works include the Design, fabrication, delivery installation, testing, commissioning and guarantee

Function

To pump the recovered oil from the Sludge settling tank

SPECIFICATIONS Quantity Type Connection

Two ( 2 ) units Recovery Oil Pump as follows: Centrifugal, End-suction BS 4504 PN 10


15 Crude Oil 90 0.86 0.1425 20 1450 3

mt/hr o

C


CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling DriveSystem: Level Switch:

Cast Iron GS-C25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling Mercury type with SS float and rod

Motor:Power: Type:

2.2 kw ( Vendor to advice ) TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

APPROVED MAKES


Pump: Motor: Coupling: Bearing: Mechanical seal: Level switch:

Robuschi, Warman or equivalent Crompton Parkinson, Brush Fenner (Fenaflex), Renold SKF, FAG, NTN Crane, Burgman Mobrey, BESTA


Page 1 of 2

G 13. 2

OIL HEATER TANK


DATE:

13-May-00


OIL PALM MILL

PREPARED

OIL HEATER TANK

DELIVERY

NW



DRAWING NO.


G 14. 1

GENERAL Scope

Scope of works include the Design, Fabrication, delivery installation, testing, commissioning and gurantee.

Function:

To heat the Clean CPO before Vacuum drying process.

SPECIFICATIONS Quantity Capacity: Basic Dimensions:

One ( 1 ) unit Oil heater Tank as follows: 3 1.5 m 1 m (W) x 1 m (L) x 1.5 m (H)

Construction Material:Contruction Tank body: Steam Coil: Level switch

Stainless steel 4mm thick sheet ( AISI 304 ) API 5L Gr.B Seamless Sch 40 Mercury type with ss float and rod.

The following nozzles to be provided:Users drain steam inlet cond.outlet pump inlet Flanges:

Size (mm) 50 50 25 50


Protrusion (mm) 150 150 150 150


Page 1 of 1

Material API 5L Gr.B Seamless Sch 40 API 5L Gr.B Seamless Sch 40 API 5L Gr.B Seamless Sch 40 API 5L Gr.B Seamless Sch 40

OIL PURIFIER


DATE:

10-Oct-99


OIL PALM MILL

PREPARED

OIL PURIFIER

DELIVERY


DRAWING NO.


GENERAL Scope

Scope of works include the unloading at site, safe keeping installation, assist in testing and commissioning.

Function:

Clarification of the crude oil by removing dirt from oil.


Two ( 2 ) unit Oil Purifiers as follows :

Unit capacity

:

6,000 liters per hour of crude palm oil

System for separation

High speed centrifuge with solids ejecting disc stack type

Discharge system

Sliding bowl bottom automated to discharge at regular intervals by a discharge programme. The intervals for discharge shall be easily variable by setting the timing device.

Material of construction

All parts in contact with oil shall be in stainless steel.

Scope of supply

Unit shall be completed with the following:Flanged motor Built-on feed pump Set of flexible connections Set of standard tools Set of standard spares Flow indicator Thermometer Strainer Automatic discharge system Installation instruction, service and operation manuals

Test on completion :

Samples shall be taken for the inlet feed and outlet waste water and analysed for oil content. The results shall be statistically analysed by taking the mean average and standard deviation.

Performance

Dirt content of purified oil not more than 0.01%

Motor

NW

:

Approx. 7.5kw 4 pole TEFC, IP55 Class F 415V, 3-Ph , 50Hz

OTHER REQUIREMENTS : 1. Vendor to provide technical details, catalogues, performance curve etc ……..

Page 1 of 1

G 15. 2

OIL HEATER PUMP


DATE:

13-May-00


OIL PALM MILL

PREPARED

CPO TRANSFER PUMP

DELIVERY

NW



DRAWING NO.


GENERAL Scope

Scope of work include the Design, Fabrication, delivery, installation, testing, commissioning and guarantee.

Function

To heat the Oil before Vacuum drying process


Two( 2 ) unit CPO Transfer Pump as follows :

Type Connection

Centrifugal, End-suction Raised face flange toBS 4504 PN 10


15 Sludge Oil 90 0.9 0.0798 20 1450 3



M3 per hour. o

C



approx. 3.75kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Robuschi, Warman Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, FAG, SKF


Page 1 of 1

G 16. 2

VACUUM OIL DRYER


DATE:

10-Oct-99


OIL PALM MILL

PREPARED

NW

VACUUM OIL DRYER DELIVERY


DRAWING NO.


ITEM No.

G 19.

QUANTITY / UNITS

1

GENERAL Scope


Function:

Drying of Purified CPO by removing the moisture


One ( 1 ) Vacuum Oil Dryer as follows :

Capacity

15 metric ton per hour of Crude Palm Oil


Constructed from mild steel and conforming to the latest standards for pressure vessels standards for and Factories & Machinery Regulations. Vacuum provided by means of mechnical pump.

Vacuum Pump

Motor Scopeof supply

Type: Multi-stage centrifugal, horizontal Contruction: cast iron casing and impeller Sealing: mechanical seal Capacity: As per vaccum dryer Head: shall be able resistance of 100 mm pipe, 300m long, 4 elbows, 11kw 415V/3Ph/50Hz, S.C TEFC, Class F Ins., IP 55 Vacuum dryer vessel with spray nozzle assembly, sight glasses, vacuum pressure gauge, float type liquid level control valve, illumination of the intervals of the dryer Feed tank with stainless steel float. Multi-stage Vacuum Pump Transfer oil pump c\w motor, coupling and base plate. Certification from the Factories and Machinery Department.

Performance

Moisture content in dried oil does not exceed 0.09% at 90oC.

Tests on completion

Samples shall be taken at hourly interval for inlet and outlet oil and analysed for moisture content. The results shall be statistically analysed by taking the mean average and standard deviation

Page 1 of 1

HOT WATER TANK


DATE:

10-Oct-99


OIL PALM MILL

PREPARED

HOT WATER TANK

DELIVERY

NW



DRAWING NO.


G 20 1

GENERAL Scope


Function:

To provide hot water for dilution purposes


One ( 1 ) unit Hot Water Tank as follows :



Construction Material:Tank: Steam Coil: Insulation:

Mild steel Carbon steel seamless Sch 40 50mm thk Rockwool c/w 0.7mm thk aluminium cladding

m3

The following nozzles to be provided:Users

Size

Protr'n

Qty

Flange

1 1 1 1

PN 10 PN 10 PN 10 PN 10

Material

mm Water inlet Water outlet Overflow Drain Temp.gauge Temp.controller Flanges:

100 150 100 150 80 150 80 150 3/4" BSP with copper pocket 3/4" BSP with copper pocket Raised face to BS 4504

Page 1 of 2

GI Class C to BS 1387 GI Class C to BS 1387 GI Class C to BS 1387 GI Class C to BS 1387

CLARIFICATION STRUCTURE


DATE: 10-Oct-99 MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED

NW

CLARIFICATION STRUCTURE DELIVERY DRAWING NO.



G 21 1

GENERAL Scope


Function:

To support equipment, tanks and vessels


General Arrangment: Construction Details: Construction Material: Structures: Plaform Handrail: Structure bolts & nuts: Chain block beam

One ( 1 ) unit Clarification Steel structure with Chain block, and roller for maintenance of centrifugal equipment, stairways platform, walkways, handrails and ladder. As per drawing As per drawing

Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe High tensile steel Mild steel I beam to suit

OTHER REQUIREMENTS 1. Handrail shall be 40 mm black pipe 900mm high with intermediete poles at 2000 c/c 2. 100mm high kick plate to be provided around the platform 3. A 3 ton Chain block c/w I-beam shall be provided for maintenance of Separators and Purifier

Page 1 of 1

SLUDGE PIT PUMP



PROJECT CODE

OIL PALM MILL

PREPARED

NW

SLUDGE PIT PUMP DELIVERY


DRAWING NO.

ITEM No.

G 22

QUANTITY / UNITS

GENERAL Scope

Scope of works include the purchase, delivery, installation testing, commissioning and guarantee.

Function:

To pump Oil from Sludge pit to the Sludge recovery tank


Two ( 2 ) units Sludge pit pump as follows : Centrifugal, self-priming, Vertical mount Raised face flange to BS 4504


30 Crude Oil 100 0.9 0.0798 200 1500 3


Cast Iron GG-25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling

MT/hr o

C

Ns/m2 Kpa RPM (Max) m liquid


approx. 3,75 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Robuschi, Warman, CK Pump Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, SKF, FAG


Page 1 of 1

2

SLUDGE RECOVERY TANK


DATE:

10-Oct-99


OIL PALM MILL

PREPARED

NW

SLUDGE OIL RECOVERY TANK DELIVERY



DRAWING NO.

ITEM No.

G 23.

QUANTITY / UNITS

1

GENERAL Scope


Function:

To recover oil from clarification and other process waste water


One ( 1 ) unit Sludge Oil Recovery Tank as follows : A conical bottom and cylindrical top section supported by steel sections, elevated from ground level. An adjustable skimmer is to be provided for skimming oil at the top layer. Overflow pipe for sludge underflow to be provided.

Capacity: Basic Dimensions: Construction Details:

150 As per drawings As per drawings

m3

Construction Material:Tank: Skimer Funnel: Skimer Handle: Skimer Pipe: Overflow Pipe: Ladder & Catwalk: Heating coils: Support:

Mild steel Mild steel Mild steel S.S 304 Sch 40 Pipe (inside tank only) API 5L Gr.B Sch 40 Mild steel S.S 304 Sch 10S Pipe Mild steel

Nozzles:Users skimmed oil drain overflow steam in steam out steam in steam out hot water in Flanges:

Size (mm)

100 80 150 50 50 25 25 25

Qty 2 2 2 1 1 1 1 1 Raised face to BS 4504

Page 1 of 1

Flange

Protrusion

PN 10 PN 10 PN 10 PN 16 PN 16 PN 16 PN 16 PN 10

(mm) 150 150 150 150 150 150 150 150

Material API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40

CAKE BREAKER CONVEYOR


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

CAKE BREAKER CONVEYOR DELIVERY

REVISION No. LOCATION DEPARICARPER STATION

DRAWING NO.


GENERAL Scope

Scope of works include the manufacture, delivery & installation testing, commissioning, handing over and guarantee

Function:

To break up pressed cake from SCREW PRESSES and convey to the DEPRICARPING COLUMN


One ( 1 ) unit Cake Breaker Conveyor complete with supports and inspection walkway with handrails and ladders.

Type:

Paddle c/w short section of auger conveyor at the end of the conveyor to act as airlock 45 MT FFB per hour. 700 mm

Capacity: Diameter: Construction Material: Shaft:

Paddle: Casing: Top cover: Hanger Bearing:

SANVIK low alloy steel pipe, supported by thrust roller bearing at lower end and hanger bearing at 2.5m c/c along the conveying section Mild steel paddle with H.T.S rod or equivalent Mild steel minimum thickness 6mm or equivalent Steel mesh for the entire conveyor Railko bush c/w cast iron housing, grease nipple and cup protuding out of the conveyor casing

Thrust Bearing:

To be fitted at the drive-end

Shaft to shaft jointer:

Solid mild steel

Screw (auger):

Mild steel screw 6mm minimum thickness welded to mild steel solid shaft

Connecting piece to Depricarper Column: Inclination: Conveyor Speed: Drive: Variable Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:

Canvas c/w mild steel holder rings o 6 69 rpm Geared motor directly coupled by flexible coupling 1450 69 1038

rpm rpm Nm (min)

<

1.5


7.5 KW Vendor to advise. TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, SEW, EPG ElectroPower Fenner (Fenaflex), Renold SKF, FAG, NTN

OTHER REQUIREMENTS:1. Wear plate thickness 6mm minimum to be provided 2. Side plate of minimum 300mm high to be provided for the entire length of the conveyor except at the full flight screw section 3. Conveyor supporting structures c/w platform , walkways, stairways and handrails are to be provided 4. Detail design by the contractor shall be first approved by the consultant before fabrication.

Page 1 of 1

H 1. 1

DEPRICARPING SYSTEM

SPECIFICATION SHEETS PROJECT NAME PROJECT CODE

DATE: OIL PALM MILL

MACHINE NAME DEPARICARPER WINNOWING SYSTEM

PREPARED

DELIVERY

13-May-00 NW


DRAWING NO.


GENERAL Scope


Function:

To separate the nut and fibre using air separation method


One ( 1 ) Depericarping system complete with : Separation column, support, ducting and adjustable damper, fibre cyclone, airlock, fan

Separation capacity:

45 MT FFB per hour.

Depricarping Column General Arrangement: Construction Details: Construction Material:

As per drawing As per drawing Mild steel

Ducting General Arrangement: Construction Details: Construction Material: Basic Dimensions:

As per drawing As per drawing Mild steel Diameter: Thickness

600 6

mm mm

Fibre Cyclone General Arrangement: Construction Details: Construction Material:


Wear liner:

4.5mm thk to be provided at the inlet volute of the cyclone

Page 1 of 2

H 2. 1

DEPRICARPING SYSTEM


DATE:

PROJECT CODE

OIL PALM MILL

MACHINE NAME DEPARICARPER WINNOWING SYSTEM

PREPARED

DELIVERY

13-May-00 NW


DRAWING NO.


H 2. 1

Sheet 2. Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:

Rotary vane 1 As per drawing As per drawing Mild steel 600 mm 30 rpm Motor directly coupled to speed reducer by flexible coupling

Motor:Power: Type:


Fan Type: Flowrate: Static Pressure:

Cetrifugal 42,000 150

Construction Material: Casing: Impeller: Shaft: Pulley:

Mild steel Carbon steel (self-cleaning type) Carbon steel Cast iron

Speed: Drive System:

m3/hr mm wg

Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by fluid coupling then to belt and pulley To be provided Floor Common baseframe to be provided

Belt guard: Type of Mounting: Baseframe: Motor:Power: Type:

approx. 36 kw - Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

APPROVED MAKES


Motor: Fan: Coupling: Bearing:

Crompton Parkinson, Brush Novenco, James Hawden, Chicago Transfluid, Renold, Fenner NTN, SKF, FAG

OTHER REQUIREMENT Contractor to provide detail design for approval by consultant.

Page 2 of 2

DEPERICARPER CONTROL SYSTEM


DATE:

13-May-00


OIL PALM MILL

PREPARED

DAMPER CONTROL SYSTEM

DELIVERY

NW


DRAWING NO.

DEPARICARPER STATION

ITEM No.

H 3.

QUANTITY / UNITS

GENERAL Scope

Function


1

Scope of works include the unloadfing, safe keeping, assisting in the testing installation and commissioning. System to monitor and control of kernel or Nuts losses in the fibre cyclone by controlling the air flow rate in the Depericarper Column.

One (1) Depericarper Damper Control System as follows:-

The control shall be based on the following process variables : a. Number of Presses in operation b. Predetermined separation air velocity in the Depericarper column.

The supply shall consist of : 1. PLC unit system. The PLC shall be link to the Central control station via LAN networking 2. Damper pneumatic actuator 3. Air flow meter. The air flow meter shall measure the air flow rate and compare it with the set value. It will sent a signal to the PLC which in turn automatically adjust the damper accordingly to the set value of the air flow rate. 4. Installation & Operating instructions, service manual and buffer tank drawing. 5. Testing, commissioning and training of operator.

Manuals


General


Page 1 of 1

NUT POLISHING DRUM


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

NUT POLISHING DRUM DELIVERY



DRAWING NO.


GENERAL Scope

Scope of works include the design, fabrication, delivery installation, testing and guarantee.

Function:

To polish nuts from DEPERICARPER COLUMN


One ( 1 ) unit Nut Polishing Drum complete as follows :


Rotating Drum 9,000 kg/hr of nuts As per drawing As per drawing

Construction Material: Shaft: Hub: Drum Casing: Frame & Structure: Basic Dimensions: Drum Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor:

EN 16 Steel Carbon steel Carbon steel Carbon steel 1,200 mm dia. 4,500 mm long 25 rpm Geared motor coupled to drum shaft by spocket and chain drive 1450 25 2101 <

rpm rpm Nm (min) 1.5 (min)

Motor:Power: Type:


APPROVED MAKES



Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, SEW, EPG ElectroPower Fenner (Fenaflex), Renold SKF, FAG, NTN

Page 1 of 1

H 4. 1

INCLINE NUT CONVEYOR


DATE:

13-May-00


OIL PALM MILL

PREPARED

INCLINED NUT CONVEYOR

DELIVERY

NW


DRAWING NO.



H5 1

GENERAL Scope


Function:

To transfer nuts from NUT POLISHING DRUM to destoning system


One ( 1 ) unit Inclined Nut Conveyor as follows :

Type:

Full flight screw with round casing only at the end of the conveyor

Capacity General Arrangement: Construction Details:

7,500 As per drawing As per drawing

Construction Material: Diameter: Conveyor Speed: Drive System:

Mild steel 300 mm 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling


APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:

1450 56 375 <

kg nuts per hour.



Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, SEW, Renold, Benzler SALA Fenner (Fenaflex), Renold NTN, SKF, FAG

OTHER REQUIREMENTS : 1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearing to be fitted at drive end of the conveyor. 3. Roller thrust bearing to be fitted at discharge end of the conveyor 4. Saddle supports to be provided

Page 1 of 1

DESTONING SYSTEM


DATE:

13-May-00


OIL PALM MILL

DESTONING SYSTEM

DELIVERY

PREPARED

NW



DRAWING NO.


H 6. 1

GENERAL Scope

Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee

Function:

To separate the nut and stone using air separation method


One ( 1 ) Destoning System consisting of : Expansion column, support, ducting, nut discharge chute, cyclone, airlock and fan

Capacity: Separation & Expansion Column General Arrangement: Construction Details: Construction Material:

9,000 kg / hr of nut


Ducting General Arrangement: Construction Details: Construction Material: Basic dimensions: Diameter: Thickness:

450 6

Cyclone General Arrangement: Construction Details: Construction Material: Basic dimensions:

As per drawing As per drawing Mild steel As per drawing

Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Speed: Drive System: Motor:Power: Type:

As per drawing As per drawing Mild steel mm mm

Rotary vane 1 As per drawing As per drawing Mild steel 300 mm 30 rpm Motor directly coupled to speed reducer by spocket & chain 2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

Page 1 of 2

DESTONING SYSTEM


DATE:

13-May-00


OIL PALM MILL

PREPARED

DESTONING SYSTEM

DELIVERY

NW



DRAWING NO.


H 6. 1

Sheet 2. Fan Type:

Centrifugal 20,404 m3/hr 250 mm wg

Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System:

Mild steel Carbon steel Carbon steel Cast steel Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by fluid coupling then by belt and pulley To be provided

Belt guard:

Type of Mounting: Baseframe: Motor:-

Floor Common baseframe to be provided Power: Type:

Approx. 22 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

Supporting Structures Construction details: Material:

as per drawing mild steel

APPROVED MAKES



Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, SEW, EPG Electropower

Fluid Coupling: Bearing: Fan: Transmission Belt:

Fenner (Fenaflex), Renold, Transfluid NTN, SKF, FAG Novenco, James Hawden, Chicago Fenner

Page 2 of 2

DESTONER DAMPER CONTROL SYSTEM


DATE:

13-May-00


OIL PALM MILL

DESTONER DAMPER CONTROL SYSTEM

DELIVERY

PREPARED

NW


DRAWING NO.



H 7. 1

GENERAL Scope

Scope of works include the unloading, safe keeping, assisting in the testing, installation and commissioning

Function

System to monitor and removal of stones from the transported Nuts by controlling the air flow rate in the Destoner Column.


The control shall be based on the following process variables : a. Number of Presses in operation b. Predetermined separation air velocity in the Destoner column.

The supply shall consist of : 1. PLC unit system. The PLC shall be linked to the Central control station via LAN networking. 2. Damper pneumatic actuator 3. Air flow meter. The air flow meter shall measure the air flow rate and compare it with the set value. It will sent a signal to the PLC which in turn automatically adjust the damper accordingly to the set value of the air flow rate. 4. Installation & Operating instructions, service manual and buffer tank drawing. 5. Testing, commissioning and training of operator.

Manuals


General


Page 1 of 1

NUT ELEVATOR


DATE:

13-May-00


OIL PALM MILL

PREPARED

NUT ELEVATOR

DELIVERY

NW



DRAWING NO.

ITEM No.

H 8.

QUANTITY / UNITS

1

GENERAL Scope

Scope of works include the manfacture, erection & installation Testing, commissioning, handing over and guarantee

Function:

To convey Nuts onto the NUT BIN


One ( 1 ) unit Nut Elevator as follows :


Conveyor chain c/w buckets 9,000 kg Nuts per hour As per drawing As per drawing

Construction Material: Casing: Sprocket Bucket: Chain rail: Chain: Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:

Mild steel with 6mm minimum thickness 12T, 100mm pitch, grey iron Mild steel Mild steel angle Steel c/w hardened steel flanged rollers, 100 mm pitch, 6800 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 30 rpm 1 1450 30 955 >


Motor:Power: Type:


APPROVED MAKES



Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold , EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

OTHER REQUIREMENTS 1. Miantenance door shall be provided at the bottom booth 2. Take-up bearing c/w tensioning devices to be provided at the bottom sprockets & shaft 3. Top booth cover to be bolted construction for ease of maintenance 4. Outlet chute to be provided Page 1 of 2

Nut Conveyor No.1


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NUT CONVEYOR No.1

DELIVERY

NW



DRAWING NO.


GENERAL Scope


Function:

To convey Nuts from the Nut Elevator to the Nut Silo.

SPECIFICATIONS Quantity Capacity: Type: Size: General Arrangement: Construction Details:

One ( 1 ) unit Nut Conveyor No. 1 as follows : 9,000 kg / hr of cracked micture Full flight screw 300 mm dia. As per drawing As per drawing


Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor


Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup




1450 56 375 >



2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent. Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN

OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate

Page 1 of 1

H 9. 1

PALM OIL STORAGE TANK


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

CPO STORAGE TANK DELIVERY


CPO STORAGE

DRAWING NO.


I 1. 2

GENERAL Scope

Scope of works include the Design, fabrication, delivery, Installation testing, commissioning and guarantee.

Function:

To store and heat palm oil prior to despatch

SPECIFICATIONS Quantity Capacity: Construction Details:-

Two ( 2 ) units Palm Oil Storage Tanks as follows : 2000 tons. As per drawing and in accordance with BS 2654

Construction Material:Tank Shell Tank Bottom Tank Roof Steam Coil: Roof trusses: Handrailing:

Mild steel Mild steel Mild steel 50mm dia. seamless API 5L Gr B Sch 40 Mild steel Black pipe Class B

Nozzles to be provided:Users Oil inlet Oil outlet Drain Vent Steam inlet Cond.outlet Oil recycle Sounding temp. gauge Flanges:

Size (mm)

Qty

100 150 100 150 50 50 80 150 1/2 " BSP

1 1 1 1 2 2 1 1 1

Protrusion (mm) 150 150 150 150 150 150 150 600 80


Material Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40

To BS 4504

Other Accessories:Spiral staircase c/w handrailing Mechanical level indicator c/w stainless steel float, steel guide wire for float Bottom manhole of 600mm diameter Top manhole of 600mm diameter Internal monkey ladder Interconnecting platform Painting:Internal External

crude palm oil 2 coats of MIO zinc chromate, followed by 2 coats of gloss finish

Testing:

Water testing to full level for a duration of at least 2 weeks. Water to be supplied by contractor

Calibration:

In accordance with local authority's requirements

Page 1 of 1

CPO DESPATCH PUMP


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

CPO DISPATCH PUMP DELIVERY

REVISION No. LOCATION CPO STORAGE

DRAWING NO.


GENERAL Scope

Scope of works include the purchase, delivery, installation testing, commissioning and gurantee

Function

To convey Crude Palm Oil from the Storage Tanks and loading into Oil Tanker.


Two ( 2 ) units Palm Oil Despatch Pumps as follows: Gear or screw positive displacement BS 4504 PN 10 flange


90 Crude Palm Oil 60 0.9 0.0798 120 500 6

CONSTRUCTION Casing Gear or screw Shaft Sealing Coupling Drive:

MT crude palm oil per hour. o

C

Ns/m2 kPa RPM (Max) m liquid

Cast Iron GG25 Cast Iron GG25 Carbon steel Mechanical seal Flexible Motor directly coupled with flexible coupling to gearbox and pump

Motor:Power: Type: APPROVED MAKES Pump: Motor: Gear reducer: Coupling: Bearing:

approx. 7.5kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415 V / 3-Ph / 50 Hz Specified or Equivalent Tuthill, Viking, IMO, Leistritz Crompton, Brook SUMITOMO, Renold, HANSEN Fenner (Fenaflex), Renold SKF, FAG, NTN


Page 1 of 1

I 2. 2

NUT CONVEYOR No.2


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NUT CONVEYOR No.2

DELIVERY

NW


KERNEL RECOVERY PLANT

DRAWING NO.


GENERAL Scope


Function:

To convey nuts from Destoner to Nut Buffer Silo


One ( 1 ) unit Nut Conveyor No.2 as follows :

Capacity: Material Type: Size: General Arrangement: Construction Details:

9,000 kg per hour Wet Nuts Full flight screw 300 mm dia. As per drawing As per drawing


Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:

Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling


1450 56 375 >



2.2 KW Vendor to advise TEFC 4-pole, S.C, IP 55, Class F Ins., 415V / 3-Ph / 50 Hz Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectoPower Fenner (Fenaflex), Renold FAG, SKF, NTN


Page 1 of 1

J 1. 1

NUT BUFFER HOPPER


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NUT BUFFER HOPPER

DELIVERY

NW


DRAWING NO.


ITEM No.

J 2.

QUANTITY / UNITS

1

GENERAL Scope


Function:

To receive nuts and act as buffer storage before feeding into the nut ripple mills or crackers.


One ( 1 ) unit Nut Buffer Hooper as follows :

Capacity: Basic Dimensions: Construction Details:Construction Material:-

12 m3 (comprising of 3 hoppers for nut discharge) As per drawing As per drawing Mild steel

Requirements

a. Steel supporting structure of mild steel angles and channels of size detail in the drawings. b. Discharge apperture fitted with flanged stop sluce & chute. c. A supporting frame shall be provide for mounting of a Vibro-feeder and magnetic metal trap to detail design.

Page 1 of 1

NUT FEEDER


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NUT FEEDER

DELIVERY

NW



DRAWING NO.

ITEM No.

J 3.

QUANTITY / UNITS

GENERAL Scope


Function:

To feed nuts by a vibrating tray from nut buffer hopper into the ripple mills.


Three ( 3 ) units Nut Feeder with Magnetic Trap as follows :

Type: Material to convey Capacity Each: Drive: Motor:-

Magnetic vibratory feeder Palm Nuts 3,000 kg per hour. Vibratory motor Power: Type:

approx. 0.33 Vendor to advice Electro-magnetic, 415V or 220V @ 50Hz

Magnetic Trap

One Magnetic Plate of 200 x 200 mm x 20 mm thick

MATERIAL DESCRIPTION Material Bulk Density: Average Nut Diameter: Condition Of Material:

Palm Nuts 700 25 loose

Temperature:

APPROVED MAKES

40

kg/m3 mm o

Eriez or equivalent

Page 1 of 1

C

3

RIPPLE MILL


DATE:

13-May-00


OIL PALM MILL

PREPARED

RIPPLE MILL

DELIVERY

NW



DRAWING NO.


J 4. 3

GENERAL Scope


Function:

Cracking of Palm Nuts

SPECIFICATIONS Three ( 3 ) Ripple Mill as follows : Unit Capacity

6,000 kg per hour

Material

Palm Nuts


a.

Each ripple mill shall be driven by a motor with adjustable variable speed vee rope drive.

b.

The ripple plates will be hard faced, heavy duty, and reversible to prolong the operational life between rebuilding of the cracking faces.

c.

Solid alloy steel rotating ripple bars will be fitted to the wear resistant rotor discs.

d.

The motor, vee rope drive and guard will be mounted on a rigid fabricated steel baseplate designed to allow the ripple mill to discharge into the cracked mixture screw conveyor mounted below.

Performance Guarantee:

Each ripple mill shall have cracking efficiency of not less than 97%.

Motor

approx. 5.25kw 4-pole, TEFC, Class F, IP 55

Power Supply

415V 3 phase 50Hz

Page 1 of 2

C.M CONVEYOR NO.1


DATE:

7-Aug-99


OIL PALM MILL

CM CONVEYOR No.1

DELIVERY

PREPARED

NW


DRAWING NO.


ITEM No.

J 5.

QUANTITY / UNITS

GENERAL Scope

Function: SPECIFICATIONS Quantity Material to convey Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:


Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee To convey cracked micture from RIPPLE MILLS to CRACKED MIXTURE ELEVATOR One ( 1 ) unit Cracked Mixture Conveyor as follows: Palm Nut Cracked Mixture 9,000 kg per hour Full flight screw 300 mm dia. As per drawing As per drawing Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56

rpm

Geared motor directly coupled to conveyor shaft by flexible coupling




Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN

1450 56 375 >



Page 1 of 1

1

C.M CONVEYOR NO.2


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

CM CONVEYOR No.2 DELIVERY



DRAWING NO.


GENERAL Scope


Function:

To convey cracked micture from Winnowing System to C.M Conveyor No.3


One ( 1 ) Cracked Mixture Conveyor No.2

Material to be conveyed Capacity: Type: Size: General Arrangement:

Palm Nuts cracked mixture 9,000 kg per hour. ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing


As per drawing


Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup




1450 56 375 >


Motor:Power: Type:


APPROVED MAKES



Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower

Coupling: Bearing:


OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated Page 1 of 2

J 6. 1

C.M CONVEYOR NO.2


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

CM CONVEYOR No.2 DELIVERY


DRAWING NO.



3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate

Page 2 of 2

J 6. 1

CRACKED MIXTURE ELEVATOR


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

CM ELEVATOR

DELIVERY

NW



DRAWING NO.

ITEM No.

J 7.

QUANTITY / UNITS

GENERAL Scope

Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee 12 months.

Function:

To convey cracked mixture from CM CONVEYOR to PRIMARY WINNOWING COLUMN

SPECIFICATIONS Quantity Type: Material to Convery Capacity:

One ( 1 ) Cracked Mixture Elevator as follows : Conveyor chain c/w buckets Palm Nut Cracked Mixture 9,000 kg per hour.

General Arrangement:

As per drawing


As per drawing

Construction Material: Casing: Sprocket

Mild steel with 6mm minimum thickness 12T, 100 mm pitch, grey iron

Bucket: Chain rail: Chain:

Mild steel Mild steel angle Steel c/w hardened steel flanged rollers, 100 mm pitch, 6800 kg breaking load

Drive: Shaft Speed: Transmission Sprocket Ratio:



1450 30 1194 >


Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:

3.75 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

OTHER REQUIREMENTS 1. Miantenance door shall be provided at the bottom booth 2. Take-up bearing c/w tensioning devices to be provided at the bottom sprockets & shaft 3. Top booth cover to be bolted construction for ease of maintenance Page 1 of 2

1



DATE:

7-Aug-99


OIL PALM MILL

CM ELEVATOR

DELIVERY

PREPARED

NW


DRAWING NO.



4. Outlet chute to be provided

Page 2 of 2

J 7. 1

VIBRATING TROUGH


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

VIBRATING TROUGH DELIVERY

REVISION No. LOCATION KERNEL RECOVERY PLANT

DRAWING NO.


GENERAL Scope


Function:

Separating of un-cracked nuts and feeder to Winnowing column


One ( 1 ) unit Vibrating Trough as follows :

Type: Material to convey Capacity Each: Drive: Motor:-

Magnetic vibratory feeder PK cracked mixture 9,000 kg per hour. Vibratory motor Power: Type:

approx. 0.33 Vendor to advice Electro-magnetic, 415V or 220V @ 50Hz

MATERIAL DESCRIPTION Material Bulk Density: Average Nut Diameter: Condition Of Material: Temperature:

Palm Nuts Cracked mixture 3 700 kg/m 10 mm loose kernel and broken shell o 40 C

APPROVED MAKES

Eriez or equivalent

Page 1 of 1

J 8. 1

PRIMARY WINNOWER SYSTEM


DATE:

7-Aug-99


OIL PALM MILL

PRIMARY WINNOWER

DELIVERY

PREPARED

NW



DRAWING NO.

ITEM No.

J 9.

QUANTITY / UNITS

GENERAL Scope

1

Scope of works include the manfacture, erection & installation Testing, commissioning, handing over and guarantee

Function:

To separate the cracked mixture from light particles using air separation method


One ( 1 ) Primary Winnowing System sa follows :

System consist of:

Adjustable damper, expension column, support, ducting, nut discharge chute, cyclone, airlock and fan

Material to process Separation Capacity:

Palm nut cracked mixture 9,000 kq per hour.

Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:

Rotary vane 2 As per drawing As per drawing Mild steel 300 mm 45 rpm Geared motor directly coupled to conveyor shaft by flexible coupling


1450 45 212 >


Power: Type:


Motor:-

Ducting General Arrangement: Construction Details: Construction Material: Basic dimensions: Diamater: Thickness: Cyclone 1 stage General Arrangement: Construction Details: Construction Material: Basic dimensions:

As per drawing As per drawing Mild steel 400 6

mm mm

As per drawing As per drawing Mild steel 1,350 mm dia.

Page 1 of 2



DATE:

7-Aug-99


OIL PALM MILL

PRIMARY WINNOWER

DELIVERY

PREPARED

NW



DRAWING NO.

ITEM No.

J 9.

QUANTITY / UNITS

1

Sheet 2. Airlock for Cyclone Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:



1450 45 467 >


Power: Type:


Motor:-

Fan Type: Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System: Belt guard: Type of Mounting: Baseframe: Motor:-

Centrifugal 24,000 m3/hr 375 mm wg Mild steel Carbon steel Carbon steel Cast steel Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by belt and pulley To be provided Floor Common baseframe to be provided

Power: Type:

approx. 30 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent.

APPROVED MAKES Motor: Fan: Coupling: Gear reducer: Bearing: Transmission Belt:

Crompton Parkinson, Brush Novenco, James Hawden, Chicago Renold, Fenner SUMITOMO, HANSEN, Renold, EPG ElectroPower. NTN, SKF, FAG Fenner

Page 2 of 2

WINNOWING COLUMN DAMPER CONTROL SYSTEM


DATE:

13-May-00


OIL PALM MILL

WINNOWING DAMPER CONTROL

PREPARED

DELIVERY

NW


DRAWING NO.


ITEM No.

J 10.

QUANTITY / UNITS

1

GENERAL Scope

Scope of works include the unloading, safe keeping, assisting in the testing, installation and commissioning.

Function

System to monitor and control of kernel losses in the cyclone by controlling the air flow rate in the Primary Winnowing Column.


One (1) Primary Winnowing Damper Control System as follows:The control shall be based on the following process variables : a. Number of Presses in operation b. Pre-determined separation air velocity in the Primary Winnowing column.

The supply shall consist of : 1. PLC unit system. The PLC shall be link to the Central control station via LAN networking 2. Damper pneumatic actuator 3. Air flow meter. The air flow meter shall measure the air flow rate and compare it with the set value. It will sent a signal to the PLC which in turn automatically adjust the damper accordingly to the set value of the air flow rate. 4. Installation & Operating instructions, service manual and buffer tank drawing. 5. Testing, commissioning and training of operator.

Manuals


General


Page 1 of 1

SECONDARY WINNOWER


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

SECONDARY WINNOWER DELIVERY


DRAWING NO.



GENERAL Scope

Scope of works include the Design, Fabrication, delivery installation, testing, commissioning and guarantee.

Function:


SPECIFICATIONS Quantity System consist of:

One ( 1 ) Secondary Winnowing system as follows : Adjustable damper, expension column, support, ducting, nut discharge chute, cyclone, airlock and fan

Material for Process Separation Capacity:

Palm Nut Cracked Mixture 9,000 kq per hour.

Separation Column General Arrangement: Construction Details: Construction Material: Column size:

As per drawing As per drawing Mild steel 600

Ducting General Arrangement: Construction Details: Construction Material: Basic dimensions: Diamater: Thickness: Cyclone General Arrangement: Construction Details: Construction Material: Cyclone diameter:

mm dia.

As per drawing As per drawing Mild steel 400 6

mm mm

As per drawing As per drawing Mild steel 1,350 mm

Page 1 of 2

J.11 1

SECONDARY WINNOWER


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

SECONDARY WINNOWER DELIVERY



DRAWING NO.


J.11 1

Sheet 2. Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:



1450 45 467 >


Motor:Power: Type: Fan Type: Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System: Belt guard: Type of Mounting: Baseframe: Motor:Power: Type:

APPROVED MAKES Motor: Fan: Coupling: Gear reducer: Bearing: Transmission Belt:

2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins.,415V/3-Ph/50 Hz

Centrifugal, 18,000 m3/hr 280 mm wg Mild steel Carbon steel Carbon steel Cast steel Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by belt and pulley To be provided Floor Common baseframe to be provided approx. 22kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

Crompton Parkinson, Brush Novenco, James Hawden, Chicago Renold, Fenner SUMITOMO, HANSEN, Renold, EPG ElectroPower NTN, SKF, FAG Fenner

Page 2 of 2

SECONDARY WINNOWER DAMPER CONTROL


DATE:

13-May-00


OIL PALM MILL

SECONDARY WINNOWER DAMPER CONTROL

PREPARED

DELIVERY

NW


DRAWING NO.


ITEM No.

J.12

QUANTITY / UNITS

1

GENERAL Scope

Scope of works include the design, manufacture, assembly, delivery testing, installation supervision, commissioning and guarantee.

Function

System to monitor and control of kernel losses in the cyclone by controlling the air flow rate in the Secondary Winnowing Damper Column.


One (1) Secondary Winnowing Damper Control System as follows:The control shall be based on the following process variables : a. Number of Presses in operation b. Predetermined separation air velocity in the Secondary Winnowing column.

The supply shall consist of :

1. PLC unit system. The PLC shall be link to the Central control station via LAN networking 2. Damper pneumatic actuator 3. Air flow meter. The air flow meter shall measure the air flow rate and compare it with the set value. It will sent a signal to the PLC which in turn automatically adjust the damper accordingly to the set value of the air flow rate. 4. Installation & Operating instructions, service manual and buffer tank drawing. 5. Testing, commissioning and training of operator.

Manuals


General


Page 1 of 1

C.M CONVEYOR NO.2


DATE:

13-May-00


OIL PALM MILL

CM CONVEYOR 3

DELIVERY

PREPARED

NW



DRAWING NO.

ITEM No.

J 13.

QUANTITY / UNITS

GENERAL Scope


Function:


SPECIFICATIONS Quantity Material to be conveyed Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:


One ( 1 ) Cracked Mixture Conveyor No.3 Palm Nuts cracked mixture 9,000 kg per hour. ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling

Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:-

Power: Type:

1450 56 512 >




Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN


Page 1 of 1

1

C.M CONVEYOR NO.2


DATE:

13-May-00


OIL PALM MILL

PREPARED

CM CONVEYOR 4

DELIVERY

NW



DRAWING NO.


GENERAL Scope


Function:




One ( 1 ) Cracked Mixture Conveyor No.3 Palm Nuts cracked mixture 9,000 kg per hour. ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing



1450 56 512 >


Motor:Power: Type:




Coupling: Bearing:



Page 1 of 1

J 14. 1

HYDROCYCLONE


DATE:

13-May-00


OIL PALM MILL

PREPARED

HYDROCYCLONE 3 STAGE

DELIVERY

NW



DRAWING NO.


GENERAL Scope


Function:

To separate kernel and shell from cracked mixture

SPECIFICATIONS Quantity Description:

Two ( 2 ) Hydroclone Kernel Recovery system as follows : The system consists of 1 shell cyclone c/w vortex finder, 2 kernel cyclone c/w vortex finder, 1 shell pump, 2 kernel pumps, dripping drum, water tank, intergral piping.

Type: Capacity: General Arrangement:

2-stage separation system 9,000 kg/hr cracked mixture As per drawing

Shell Pump:

Units Type: Make/model: Capacity: Discharge Head: Construction: Speed: Drive:

Kernel Pump:

Units. Type: Make/model: Capacity: Discharge Head: Construction: Speed: Drive:

Cyclone material:

One ( 1 ) Centrifugal, open impeller, vertical split casing Warman 4/3, Robuschi 95.34 m3/hr 11 m w.g Cast iron impeller, ni-hard casing liner < 1200 rpm TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz c/w to pump via belt and pulley Two ( 2 ) Centrifugal, open impeller, vertical split casing Warman (Aust) 6/4, Robuschi 136.2 m3/hr 11 m w.g Cast iron impeller, ni-hard casing liner < 1200 rpm TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz c/w to pump via belt and pulley mild steel with manganese cone liners

Dripping drum screen:

stainless steel mesh 40

APPROVED MAKES

Motor: Gear reducer: Transmission Belt: Transmission Chain: Bearing:

Crompton Parkinson SUMITOMO, HANSEN, RENOLD, EPG ElectroPower. Fenner (Fenaflex) Renold, Tsubaki NTN,SKF, FAG

Page 1 of 1

J 15. 2

WET SHELL TRANSPORT



PROJECT CODE

OIL PALM MILL

WET SHELL TRANSPORT SYSTEM

DELIVERY

PREPARED

NW


DRAWING NO.


GENERAL Scope

J.16 1


Function:

To transport wet shell from Hydrocyclone to SHELL BUNKER

SPECIFICATIONS Quantity System consist of: Transport Capacity:

One (1) Lot Wet Shell Transport system ducting, cyclone, airlock and fan 4,500 kg/hr of wet shell

Ducting General Arrangement: Construction Details: Construction Material: Diameter:

As per drawing As per drawing API 5L Gr B Sch 40 pipe 150 mm

Cyclone General Arrangement: Construction Details: Construction Material: Diameter:

As per drawing As per drawing Mild steel mm

Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:


Gear box: Input speed: 1450 Output speed: 45 Output torque: 467 Design Service Factor: >


Motor:Power: Type:

2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Page 1 of 2

WET SHELL TRANSPORT



PROJECT CODE

OIL PALM MILL

PREPARED

WET SHELL TRANSPORT SYSTEM


NW



J.16 1

Sheet 2. Fan Type: Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System: Belt guard: Type of Mounting: Baseframe: Motor:Power: Type: APPROVED MAKES Motor: Fan: Coupling: Gear reducer: Bearing: Transmission Belt:

High Pressure Blower 4,500 m3/hr 750 mm wg Mild steel Carbon steel Carbon steel Cast steel Vendor to advice (not more than 2900 rpm) Motor directly coupled to fan To be provided Floor Common baseframe to be provided Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

Crompton Parkinson, Brush Novenco, James Hawden, Chicago Renold, Fenner SUMITOMO, HANSEN, Renold NTN, SKF, FAG Fenner

Page 2 of 2

WET KERNEL TRANSPORT SYSTEM



PROJECT CODE

OIL PALM MILL

PREPARED

NW

WET KERNEL TRANSPORT SYSTEM DELIVERY


DRAWING NO.


GENERAL Scope


Function:

To convey Wet Kernel from the recovery station to feed the battery of kernel dryers



One ( 1 ) unit Wet Kernel Conveyor as follows : Wet Kernel 4,500 kg per hour ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing



1450 56 640 >





OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate Page 1 of 2

J. 17 1

SHELL BUNKER STRUCTURE



PROJECT CODE

OIL PALM MILL

PREPARED

NW

SHELL BUNKER & STRUCTURE DELIVERY


DRAWING NO.



GENERAL Scope


Function:

To store shell material from the various separation systems and Structure to support the shell bunker, cyclones & fans


General Arrangment:

One ( 1 ) unit Shell Bunker of 4 compartments and Structure as follows : As per drawing

Volumn Construction Details:

Construction Material: Structures: Plaform Handrail: Structure bolts & nuts:

As per drawing

Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe High tensile

OTHER REQUIREMENTS 1. Handrail shall be 900mm high with intermediete poles at 2000 c/c 2. 100mm high kick plate to be provided around the platform 3. Hoist beam shall be installed on building roof trusses as shown in the relevant drawings

Page 1 of 1

J 18. 1

WET KERNEL ELEVATOR


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

WET SHELL ELEVATOR DELIVERY


DRAWING NO.



GENERAL Scope


Function:

To convey wet kernel from Hydrocyclone to the Kernel Silo


One ( 1 ) Wet Kernel Elevator. Conveyor chain c/w buckets 4,500 kg/hr dry kernel As per drawing As per drawing

Construction Material: Casing: Sprocket Bucket: Chain rail: Chain: Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:

Mild steel with 6mm minimum thickness 12T, 101.6 mm pitch, grey iron Mild steel Mild steel angle Steel c/w hardened steel rollers, 101.6 mm pitch, 6800 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 30 rpm 1 1450 30 700 >



Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

OTHER REQUIREMENTS 1. Miantenance door shall be provided at the bottom booth 2. Take-up bearing c/w tensioning devices to be provided at the bottom sprockets & shaft 3. Top booth cover to be bolted construction for ease of maintenance 4. Outlet chute to be provided

Page 1 of 1

J 19. 1

WET KERNEL CONVEYOR NO.2


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

WET KERNEL CONVEYOR 2.

DELIVERY

NW



DRAWING NO.


GENERAL

Scope


Function:

from Wet Kernel Elevator to kernel silo.

SPECIFICATIONS Quantity Material to be Conveyed Capacity: Type: Size: General Arrangement: Construction Details:

One ( 1 ) unit Wet Kernel Conveyor as follows : Wet Kernels 9,000 kq per hour ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing





1450 56 640 >


Motor:Power: Type:





Page 1 of 1

J.20 1

KERNEL SILO


DATE:

13-May-00


OIL PALM MILL

KERNEL SILO & FAN

DELIVERY

PREPARED

NW



DRAWING NO.


GENERAL Scope


Function:

To store and dry the kernel to the required moisture level. Hot air is produced by the steam/air heater and blown into the silo by a fan through air ducting system

SPECIFICATIONS Quantity System:

Two ( 2 ) units Kernel Silos with Compartments as follows : Consist of silo, air duct, steam/air heater, fan, shaking grate

Silo Capacity each: Basic Dimensions:

m3 (nett)

70 Width Length Body Height

3,300 mm 3,300 mm 7,100 mm


As per drawing

Construction Material:

Mild steel

Air Duct Construction Details: Construction Material:

As per drawing Mild steel

Steam/Air Heater Type: Quantity: Air inlet Condition:

Finless plain tube 1 set for each duct brunch o 30 C Dry bulb 27,000 m3/h flow

Air outlet Condition: Steam condition:

70 3

o

C Dry bulb kg/cm2 @ 95% dryness

Construction: Fin Tube: Fin spacing Temperature control:

Aluminium Copper 2 mm (minimum) by thermostatic control valve with stainlees steel capillary wire

Fan Type: Capacity: Static pressure: Maximum fan speed Motor:

Centrifugal 27,000 m3/h 150 mm wg 1500 rpm Powerapprox. 11kw Vendor to advice Type TEFC, SC, 4-Pole, 415V/3Ph/50Hz, IP 55, Class F Ins. Page 1 of 2

J. 21 2

DRY KERNEL CONVEYOR


DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

DRY KERNEL CONVEYOR No.1 DELIVERY



DRAWING NO.


GENERAL Scope


Function:

To convey dry kernel from Kernel Silo to kernel Transport

SPECIFICATIONS Quantity Material to be Conveyed Capacity: Type: Size: General Arrangement: Construction Details:

One ( 1 ) unit Dry Kernel as follows : Dry Kernel 9,000 kg per hour ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing





1450 56 375 >


Motor:Power: Type:




Coupling: Bearing:


OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate

Page 1 of 1

J. 22 1



DATE:

13-May-00


OIL PALM MILL

PREPARED

NW

DRY KERNEL ELEVATOR DELIVERY


DRAWING NO.



GENERAL Scope


Function:

To convey Dry Kernel

SPECIFICATIONS Quantity Material to be Conveyed Type: Capacity: General Arrangement: Construction Details:

One (1) unit Dry Kernel Elevator Dry Kernel Conveyor chain c/w buckets 9,000 kq per hour ( for 90MT FFB / hr ) As per drawing As per drawing

Construction Material: Casing: Sprocket Bucket: Chain rail: Chain:

Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:

Mild steel with 6mm minimum thickness 12T, 101.6 mm pitch, grey iron Mild steel Mild steel angle Steel c/w hardened steel rollers, 101.6 mm pitch, 6800 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 30 rpm 1 1450 30 955 >



Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower. Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

OTHER REQUIREMENTS 1. Miantenance door shall be provided at the bottom booth 2. Take-up bearing c/w tensioning devices to be provided at the bottom sprockets & shaft 3. Top booth cover to be bolted construction for ease of maintenance 4. Outlet chute to be provided

Page 1 of 1

J. 23 1



DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

KERNEL WINNOWING DELIVERY


DRAWING NO.


GENERAL Scope


Function:


SPECIFICATIONS Quantity System consist of:

One ( 1 ) Primary Winnowing System as follows : Adjustable damper, expension column, support, ducting, nut discharge chute, cyclone, airlock and fan

Material to be separated Separation Capacity:

Palm Nuts Cracked Mixture 9,000 kg per hour.

Separation Column General Arrangement: Construction Details: Construction Material: Size:

As per drawing As per drawing Mild steel 600 mm dia.

Ducting General Arrangement: Construction Details: Construction Material: Basic dimensions:

As per drawing As per drawing Mild steel Diamater: Thickness:

Cyclone General Arrangement: Construction Details: Construction Material: Basic dimensions: Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:

400 mm 6 mm

As per drawing As per drawing Mild steel 1,350 mm dia. Rotary vane 2 As per drawing As per drawing Mild steel 300 mm 45 rpm Geared motor directly coupled to conveyor shaft by flexible coupling


1450 45 467 > Page 1 of 2


J. 24 1



DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

KERNEL WINNOWING DELIVERY


DRAWING NO.


J. 24 1

Sheet 2. Motor:-

Power: Type:


Fan Type: Flowrate: Static Pressure:

Centrifugal, self-cleaning 3 18,000 m /hr 375 mm wg

Construction Material: Casing: Impeller: Shaft: Pulley:

Mild steel Carbon steel Carbon steel Cast steel

Speed: Drive System: Belt guard: Type of Mounting: Baseframe: Motor:-

Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by belt and pulley To be provided Floor Common baseframe to be provided Power: Type:

approx. 22kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

APPROVED MAKES Motor: Fan:

Crompton Parkinson, Brush Novenco, James Hawden, Chicago

Coupling: Gear reducer: Bearing: Transmission Belt:

Renold, Fenner SUMITOMO, HANSEN, Renold, EPG ElectroPower. NTN, SKF, FAG Fenner

Page 2 of 2

DRY KERNEL TRANSPORT


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

DRY KERNEL TRANSPORT DELIVERY



DRAWING NO.


GENERAL Scope


Function:

To transport dry kernel from KERNEL SILO to the Kernel Bulk Silo

SPECIFICATIONS Quantity System consist of: Material to be conveyed Separation Capacity:

One ( 1 ) Dry Kernel Transporter as follows : Ducting, cyclone, airlock, fan and supporting fixtures Dry Kernel 9,000 kg per hour.

Ducting General Arrangement: Construction Details: Construction Material: Diameter:

As per drawing As per drawing API 5L seamless Sch 40 pipe 250 mm

Cyclone General Arrangement: Construction Details: Construction Material: Basic dimensions:

As per drawing As per drawing Mild steel As per drawing

Fan Type:

High Pressure Blower 8,000 m3/hr 450 mm wg

Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System: Belt guard: Type of Mounting:

Mild steel Carbon steel Carbon steel Cast iron Vendor to advice (not more than 2900 rpm) Motor directly coupled to fan To be provided Floor

Baseframe:

Common baseframe to be provided

Motor:Power: Type:

approx. 7.5kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz

APPROVED MAKES Motor:

Crompton Parkinson, Brook

Coupling: Bearing: Fan:

Fenner (Fenaflex), Renold NTN, FAG, SKF Novenco, James Howden, Phoenix

Page 1 of 2

J. 25 1

DRY KERNEL CONVEYOR


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

DRY KERNEL CONVEYOR No.2

DELIVERY


DRAWING NO.


GENERAL Scope


Function:

To convey dry kernel from Kernel Silo to kernel Transport

SPECIFICATIONS Quantity Material to be Conveyed Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:


One ( 1 ) unit Dry Kernel as follows : Dry Kernel 9,000 kg per hour ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling


1450 56 375 >



NW



OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate

Page 1 of 1

J.26 1

BULK KERNEL SILO


DATE:

7-Aug-99

PREPARED

NW


OIL PALM MILL

KERNEL BULK SILO

DELIVERY



DRAWING NO.


J.27 4

GENERAL Scope


Function:

Storage of dry kernel for bulk dispatch.

SPECIFICATIONS Quantity Type: Total Capacity: Main Dimensions:

Four ( 4 ) Kernel Bulk Silo as follows : Steel plate and structure fabricated 100 metric tonnes dry Palm Kernel width: length: height of top section: Bottom Hopper Height: Bottom Hopper Angle: Number of Hopper:

General Arrangement:

4 16 6.2 2 45 4

m m m m o

Silo consist of 4 compartments with 4 discharge hoppers. Each compartment having a width of 4 m x 4 m length. The silo is supported by 10 main legs that are sufficiently braced. The side of the silo is braced by mild steel sections to prevent bulging out. The internal partition plates are also stiffened by mild steel. The silo is covered at the top by mild steel plates with sufficient intermediate trusses. The cover plate is sloped to the side at 2.5o to prevent from stagnant water. A vent pipe, manway is to be provided at the cover plate. Internal ladder shall slo be provided. The discharge hopper shall be equipped with discharge chute complete with rack and pinion and chain operated door. A step ladder with handrial, provided from ground level to the silo top.

Construction Material:Outer Casing: Legs: Leg Bracing: Side and Hopper Bracing: Internal Partition: Internal Bracing: Roof Plate: Roof Trusses: Staircase Main Frame: Handrail: Holding down bolt: Staircase Step: Vent Pipe: Internal Ladder: Manway Size: Height of discharge chute: Discharge Opening:

Mild steel with 6 mm minimum thickness 300 mm dia. Sch 40 carbon steel pipe 80 mm dia. Sch 40 carbon steel pipe bolted to gusset plates 100 x 50 x 6 thk mild steel channel Mild steel with 6mm minimum thickness 100 x 50 x 6 thk mild steel channel Mild steel with 4.5 mm minimum thickness 75 x 75 x 6 mm mild steel angles 150 x 75 x 6 mm mild steel channel 40 mm dia. black pipe medium class M40 x 450mm long ms bolts 175 mm wide x 1000 mm long Galvanised steel grating 200 mm dia. pipe with U-Bend and mesh cover 50 x 6 mm mild steel flat for side frame and 20mm solid mild steel bars 450 x 450 mm 4.5 m from ground level 300 x 300 mm

Page 1 of 1

WATER-TUBE BOILER

SCOPE

To design, supply, deliver to site, installation, testing, commissioning and guarantee of one (1) unit bi-drum water-tube boiler.

SPECIFICATIONS The steam boiler shall be 20,000 kg/hr. water tube Bi-Drum type, designed specifically to burn palm fibre and shells. Steam Condition at Mains Superheat Temperature Approx. Feed Water Temp at MCR Boiler MCR

: : : :

Boiler Operating Range

:

Overload Capacity Range

:

Overall Efficiency Electrical Supply

: :

22 kg/cm2 gauge , 30 o C. 60o C 20,000 kg steam /hour @ operating pressure. 50% to 100% MCR 110% of MCR (short period) Not less than 75 % 415 V ± 6 %, 50 Hz, 3 Phase, 4 wire.

The supply of the steam boiler shall include but not be limited to the following: 1. 2. 3. 4. 5. 6. 7.

Supporting structure. Steam water drums with internal fittings. Headers and tubes. Mountings and fittings. Spring loaded safety valves for steam drum. Soot blower system. Automatic feed water regulation using the latest technology available in the market c/w high, high-high and low and low-low water alarm. The alarm shall not be resetable until the level is corrected. Indicating lights shall also be installed on boiler front and control panel to indicate the states of alarm. 8. Integral feed water piping from feed water pumps to boiler drum.. 9. Integral steam piping from boiler drum to main stop valve and any equipment within the scope of works. 10. All boiler drain piping. 11. Integral electrical system from boiler MCC to equipment. 12. Reflex and Bi-colour water level gauge glasses. 13. Manual and automatic blowdown valves. 14. Furnace grate.

15. Explosion doors. 16. Forced, Secondary (over fire) and Induced Draught fans, complete with automatic and manual draught control. All fan sizes, capacities static pressures and volumes are to be specified. 17. Fuel feeder fan complete with feeder spouts and adjustment to facilitate efficient fuel spreading across its whole grate surface. 18. Dust collecting system. 19. Chimney and flue gas ducting. 20. Mechanised fuel feeder of pendulum type with anti fire back flash features. 21. All ducts. 22. All refractories and common red bricks. 23. All galleries, ladders and railings. 24. All main, auxiliary and non-return valves. 25. Water sampling and cooling system. 26. All gauge and instrumentation complete with one (1) steam/water flowmeter, steam/water temperature meter, steam pressure meter, draught/temperature meter and smoke density meter for each boiler. 27. Blowdown chamber silencer complete with piping from the boiler. 28. Instrument and control panel complete with mimic diagram indicating state of operation inclusive of necessary field instrument wiring. All indicating lights shall use 24 VAC power supply. 29. Recommended spare parts and tools for maintenance. 30. Insulation complete for all heated surfaces. 31. Steam pressure and water flow recorders/meters of 250 mm circular type. 32. Operating manuals. 33. Chemicals for boiling outs. 34. Cleaning and painting. 35. One (1) electric driven and one (1) steam driven feed pump of proven performance. The pumps shall be sized at least 1.5 times the MCR of the boiler. 36. Computerised DATA LOGGING system for the operation of the boiler with option for future automation. 37. Detailed technical specifications and drawings. 38. Fixed mounted pollution monitoring instruments Boiler Design & Construction The essence of design shall be reliability and efficiency in order to give long continuous service with high economy and low maintenance cost. In complying with the requirement of the specifications, both with respect to arrangements and details, design is to conform to

the best current engineering practices. Each of the several parts of the plant is to be of the maker 's standard design provided that this design is in general accordance with these specifications. Particular attention shall be given to internal and external access in order to facilitate inspection, cleaning and maintenance. The design, dimensions, and materials of all parts are to be such that they will not suffer damage as a result of stress under the most severe service conditions. Material used in the construction of the boiler and ancillaries are to be of the highest quality and selected particularly to meet the duties expected of them. Steam generation tubes shall be of adequate sizes and tube ends shall be expanded onto their seating. All construction shall be to British Standards or equivalent acceptable to the Malaysian authorities, and in accordance with Lloyd 's safety regulations and local authorities regulations). All designs shall be submitted for approval by the local authorities with all necessary drawings and test certificates. All relevant information and documents shall be copied to the Engineer. Design Code : In accordance to BS 1113 and BS 5759 or approved equivalent standards. Manifolds For Side & Rear Water Walls Constructed from solid drawn hot finished seamless pipe to BS 3602 G410 and closed at each end with a flat plate of material to BS 1501 - 151 - Gr 430A. Inspections & Tests These shall be carried out and certified by Lloyd, Bureau Veritas or other approved authorities. Boiler Mountings & Fittings All mountings and fittings necessary for the safe and proper operation of the plant shall be provided. Each item to be complete with ancillary piping and any other required accessories.

Two water level gauges of Reflex and Bi-colour type located to give easy observation from the boiler floor level. Adequate illumination shall be provided. One remote water level indicator located at the instrument and control panel or at the boiler floor level with adequate illumination shall also be provided.

Safety valves of spring loaded type, for the steam drum, of adequate capacity shall be provided, complete with release piping, supports and silencers as necessary. Steam soot blowers shall be supplied in adequate numbers and situated such that proper cleaning of the heating surfaces is effected and the operating efficiency of the boiler is maintained at its maximum without manual cleaning. Automatic Feed Water regulation shall be provided to maintain automatically the working water level at all times and at varying load conditions. Isolating valves shall be provided on the outlet and inlet of the regulator and a by-pass valve is also provided for use when the regulator is out of commission. The regulator shall be individually connected to the steam and electrical Feed Water pumps. One electric and one steam driven Feed Water pumps of turbine type shall be provided. Capacity of each pump shall be at 150% MCR of boiler rating. Pressure gauges and relief valves shall be provided for each Feed Water line. Water level alarms with distinct audible alarm and coloured indicator lights to signal high and low water levels in the drum. The alarm shall be audible within a 38m distance from the boiler during normal factory operations. The furnace and grate shall be designed for the efficient combustion of oil palm fibre and shell which are the normal fuel utilised. Self de-ashing facilities shall be incorporated. Pin-hole grates are not acceptable. There shall be occasions necessary where firewood and dewatered empty oil palm bunches are used. Fuel normally used are of the following characteristics: Shell to fibre Moisture content in fibre

: up to 25% shell : up to 42% by weight

Moisture content in shell

: up to 22% by weight

Induced, forced and secondary draughts shall be provided with draught control arrangements operated automatically and hand controls at the boiler front. Drafts will be sufficient to ensure effective combustion at maximum continuous rating and meet environmental regulations on smoke density and emission levels. Insulation and refractories, of high quality shall be used. Instrumentation Instrumentation shall be provided for : • • • • • • • •

steam drum and superheater drum pressure gauge (150mm installed on drum). steam drum pressure gauge (250mm installed on boiler front). steam temperature gauge (150mm c/w pocket installed on drum) flue gas temperature gauge. furnace draughts steam flow, water flow and pressure recorders/meters and totaliser (installed on panel). steam, feed water and flue gas temperature recorders/meter (installed on panel) smoke density meter, recorder with alarm at Ringleman 2 scale (installed on panel)

All control instrument shall use 4-20mA signal and meant for hooking-up to Central Control Station (by Others). Platform, Ladders, Staircase All necessary operating floors, access galleries and platforms complete with handrails, stairways and ladders required for the safe and convenient operation and maintenance of the plant. Blowdown And Drains Blowdown outlets and water drainage outlets from drums, headers, etc., shall each be provided with two stop valves in series with special handles or keys. Automatic blow down valves with TDS based controllers shall also be provided.

Water Sampling Cooler

Water sampling shall incorporate a stainless steel cooling coil and associated equipment. The scope shall include the installation of cooling water piping from nearby water supply line.

Chimney Chimney height shall be designed for an efflux velocity of 8 m/sec and to comply with the Malaysian environmental regulations but shall not be less than 30m. Chimney shall be of self-standing type. Necessary sampling points shall be provided in compliance with local authority’s regulations. Ladder and landing platform shall be provided at the sampling points. Number plate measuring 450x450mm painted in black shall be provided at the top of the chimney. Copper strips conductor shall be provided throughout the length of the chimney complete with earthing rods and chambers. Calculation on chimney structural design, efflux and height shall be furnished. Multicyclone A multicyclone dust collecting system shall be designed for emission of particles of less than 0.4 gm/Nm3 and to comply with the Malaysian environmental regulations. Dust removal and disposal system shall be incorporated. A dust handling and disposal system shall incorporate to remove the dust. Maintenance Tools Special tools and apparatus shall be provided for the maintenance and repair of the boiler. One set of tube expanders and one set of mechanical tube cleaner shall be included.

Fuel Feeding System One complete set of automatic fuel feeding system shall be offered with the supply. The feeding system shall be pendulum type with anti fire flash features incorporated with it. The gearbox/geared motor used for the drive system shall have at least 1.5 factor of safety. The fuel feeding system supplied must be ensured of effective distribution of the palm fibre and shell over the fire grate. Detail design shall be furnished together with the tender. Cleaning & Painting After fabrication and before delivery to the Site, the boilers and ancillaries are to be well wire-brushed and cleaned, before given one coat of primer. After erection the whole plant including bare pipe surfaces and handrailings are to be wire-brushed and cleaned, after which all parts except surfaces intended to be lagged are to be given two coats of white colour and quality paint. All paintwork is to be finished in colour according to specifications. All hot surfaces shall be painted with one coat of primer and two coats of finishes of silicon-based heat resistant paint in accordance with manufacturer’s recommendation. Drawing & Specifications Sufficient drawings technical data and specifications shall be furnished together with the tender. Schedules of electrical loading, fan sizes, etc. shall also be provided. Submission of NDT done on welds and joints are necessary. Electrical Motor Control Center (MCC) of IP44 complete with MCCB, ammeter, voltmeter, starters, ventilation fan and internal light shall be provided. Cables to motors shall be of PVC/SWA/PVA copper type and run on G.I cable trays. All electrical works shall be in accordance with rule and regulation of local authorities, BS and IEC Standard. Fans All fans shall be tested and witnessed by the Engineer in workshop or at the site for capacity, pressure and mechanical balancing to ensure that these comply with the requirements specified. The test procedures shall conform to BS or equivalent

standards. Induced draught fan blades shall be of heat resistance material and the fan speed shall not be more than 750 rpm. ID fan shall be coupled with fluid coupling to motor. Fan Damper Controller. Induced draught fan damper shall be controlled by PID Controller through hydraulic type actuator. Forced draught fan damper shall be controlled by the same type of controller either through electrical or hydraulic actuator and the damper shall be located at the fan inlet. Tests on Completion The manufacturer shall carry out capacity and rating tests to ensure the specifications are complied, before taking over by the Owner. The boiler unit shall be steamed continuously to its maximum continuous rating for a minimum period of three (3) hours operating in conjunction with the turbo alternators. The capacity test on each boiler unit shall be carried out to achieve a 110% output rating during this period. Technical data, specifications and relevant literatures shall also be provided for technical evaluation. Approved Makes Motor Gearboxes Pump Fan

: : :

: Elektrim, Crompton, TEFC, 4-pole, Class F, IP 55 HANSEN, Renold, Benzlar-Sala SIHI, Worthington Airvenco, ABB-Flakt, Phoenix

Flanges DIN PN 40 for for pressure above 3 kg/cm2 DIN PN 16 for for pressure below 3 kg/cm2

FUEL CONVEYOR - Horizontal


DATE:

7-Aug-99


OIL PALM MILL

FUEL CONVEYOR

DELIVERY

PREPARED

NW


BOILER HOUSE

DRAWING NO.


K. 1 1

GENERAL Scope

Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee.

Function:

To convey Oli Palm Solid waste fuel to the boilers.

SPECIFICATIONS Quantity Type: Capacity: Dimension

One ( 1 ) unit Fuel Screw Conveyor. Full flight screw - 750 mm dia. 30,000 kg / hr of mixed fuel ( for 90 tons FFB per hour ) as per drawing

Construction Material: Housing Screw Frame: Wear Plate:

6 mm thick m.s. plate Mild steel Mild steel sections Mild steel of minimum 6mm thk

Conveying Section: Inclination: Conveyor Shaft Speed: Dimension: Drive System:

Bottom section of the conveyor Contractor to advise 35 rpm As per drawing Geared motor coupled conveyor shaft by transmission chain & spocket

Transmission Sprocket Ratio:

1.43


1450 50 >

rpm rpm 1,433 Nm (min) 1.5

Motor:Power: Type:


APPROVED MAKES


Motor: Gear reducer: Coupling: Transmission Chain:

Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki

Bearing:

NTN, SKF, FAG

OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Top of the conveyor shall be covered with ms plate. 5. Provision for maintenance platform and ladder to be provided. Page 1 of 2

FUEL CONVEYOR - Inclined


DATE:

7-Aug-99


OIL PALM MILL

FUEL CONVEYOR No. 2

DELIVERY

PREPARED

NW


BOILER HOUSE

DRAWING NO.

ITEM No.

K. 2

QUANTITY / UNITS

GENERAL Scope

1

Scope of works include the design, fabrication, delivery, erection installation, testing, commissioning and guarantee.

Function:

To convey shell and fibre from Fuel ( Screw ) Conveyor to the boiler fuel feeder.

SPECIFICATIONS Quantity Type: Capacity:

One ( 1 ) unit Inclined Fuel ( Scrapper ) Conveyor. 750mm width Tray - scrapper plate on twin roller chain & sprocket 30,000 kg of mixed fuel of Fibre & Shell. for 90 MT FFB per hour Operation

Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate: Conveying Section: Inclination: Conveyor Shaft Speed: Dimension: Drive: Transmission Sprocket Ratio: Variable Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:

Steel c/w hardened steel flanged rollers, 150 mm pitch, 15000 kg breaking load Mild steel Mild steel sections 493.2mm PCD, grey cast iron Mild steel of minimum 6mm thk 750 mm width - Top section of the conveyor 6 deg 35 rpm As per drawing Motor directly coupled to Cyclo speed reducer by HJ Adaptor 1.43 1450 50 >


Motor:Power: Type:

7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V / 3-Ph / 50 Hz

APPROVED MAKES



Crompton Parkinson SUMITOMO, Hansen, Renold, EPG ElectroPower Fenner (Fenaflex) Renold, Tsubaki Renold, Tsubaki, PC, ACE NTN

OTHER REQUIREMENTS:1. Vendor to furnish technical specifications, drawings and catalogues 2. Wear plate of 6mm minimum thickness to be provided for chain rails 3. Mild steel outlet chute to be provided at the end of the conveyor 4. Drive end shaft fitted with flange bearings

Page 1 of 2

FUEL CONVEYOR - Inclined


DATE:

7-Aug-99


OIL PALM MILL

FUEL CONVEYOR No. 2

DELIVERY

PREPARED

NW


BOILER HOUSE

DRAWING NO.


5. Non-drive end shaft to be fitted with chain tensioning devises c/w take-up bearings 6. Contractor to provide drawing and detail specifications.

Page 2 of 2

K. 2 1

FUEL FEED CONVEYOR


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

FUEL CONVEYOR No. 3 DELIVERY

REVISION No. LOCATION BOILER HOUSE

DRAWING NO.


GENERAL Scope

Scope of works include the design, fabrication, delivery testing, installation, commissioning and guarantee.

Function:

To convey Oil Palm solid waste fuel to the Boiler.


One ( 1 ) unit Fuel Feed Conveyor as follows : Drag chain c/w scrapper plate 30,000 kg/hr of mixed fuel

Construction Material: Chain:

Steel c/w hardened steel rollers, 100 mm pitch, 6800 kg breaking load

Drag Plate: Frame: Sprocket: Wear Plate: Conveying Section: Inclination: Conveyor Shaft Speed: Dimension: Drive System:

Mild steel Mild steel sections 250 mm PCD, grey cast iron Mild steel of minimum 6mm thk Bottom section of the conveyor Horizontal S-Type 35 rpm As per drawing Geared motor coupled conveyor shaft by tarnsmission chain & sprocket

Transmission Sprocket Ratio: Gear box: Input speed: Output speed: Output torque: Design Service Factor:

1.43

Motor

11 KW TEFC 4-pole, S.C, IP 55, Class F Ins.,415V/3-Ph/50 Hz

Power: Type:

1450 50 >


APPROVED MAKES



Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devices c/w take-up bearings 5. Top of the conveyor shall be covered with suitable size wire mesh

Page 1 of 1

K. 3 1

FUEL PLATFORM

SPECIFICATION SHEETS PROJECT NAME PROJECT CODE

DATE: OIL PALM MILL

DELIVERY

MACHINE NAME

FUEL AND BOILER OPERATING PLATFORM


13-May-00 NW 1

LOCATION DRAWING No.

BOILER STATION

Item No.

K3

Quantity

Lot

GENERAL Scope


Function:

To be used as boiler operating platform, fuel storage

SPECIFICATIONS General Arrangment: Construction Details: Construction Material: Structures: Plaform Handrail:

One lot Fuel and Boiler Operating Platform. As per drawing As per drawing Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe

OTHER REQUIREMENTS 1. Handrail shall be 900mm high with intermediete poles at 2000 c/c or otherwise shown in the drawings 2. 100mm high kick plate to be provided around the platform

Page 1 of 1

FUEL FEED CONVEYOR


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

FUEL CONVEYOR No. 4 DELIVERY


BOILER HOUSE

DRAWING NO.


GENERAL Scope


Function:

To convey shell and fibre from the inclined fuel conveyor to Boilers fuel feeder


One ( 1 ) unit Fuel Feed Conveyor as follows : Scrapper plate on twin roller chain & sprocket. 30,000 kg / hr of mixed fuel of fibre & shell for 90 MT FFB per hour operation.

Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate: Conveying Section: Conveyor Shaft Speed: Dimension: Drive System: Transmission Sprocket Ratio: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:

Steel c/w hardened steel rollers, 100 mm pitch, 15000 kg breaking load Mild steel Mild steel sections 250mm PCD, grey cast iron Mild steel of minimum 6mm thk Bottom section of the conveyor 35 As per drawing

rpm

Geared motor coupled conveyor shaft by tarnsmission chain & sprocket 1.43 1450 rpm 50 rpm 1,433 Nm (min) > 1.5 7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins.,415V/3-Ph/50 Hz Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devices c/w take-up bearings 5. Top of the conveyor shall be covered with suitable size wire mesh 6. Contractor shall provide drawing and detail specification. Page 1 of 2

K. 4 1

FUEL STORAGE PLATFORM


DATE:

7-Aug-99


OIL PALM MILL

FUEL PLATFORM

DELIVERY

PREPARED

NW


DRAWING NO.

BOILER HOUSE


GENERAL Scope


Function:

To be used as boiler fuel storage platform

SPECIFICATIONS Quantity General Arrangment:

One lot Fuel Storage Platform as follows : As per drawing

Construction Details: Construction Material: Structures: Plaform Handrail:

As per drawing Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe

OTHER REQUIREMENTS 1. Handrail shall be 40 mm black pipe 900mm high with intermediete poles at 2000 c/c or otherwise shown in the drawings 2. 100mm high kick plate to be provided around the platform 3. Provision for stairways, walkways and ladder to be provided. 4. Tenderer shall provide details and drawing in the offer.

Page 1 of 1

K. 5 1

EXCESS FUEL DISPOSAL CONVEYOR


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

EXCESS FUEL CONVEYOR DELIVERY


BOILER HOUSE

DRAWING NO.


GENERAL Scope


Function:

To convey excess fuel from the boiler fuel feeder conveyor for disposal


One ( 1 ) unit Excess Fuel Disposal Conveyor complete with top cover as follows :

Type: Capacity:

Full flight Screw - 750 mm dia. 30,000 kg Solid waste fuel per hour. for 90 MT FFB per hour operation.

Construction Material: Housing Screw Frame: Wear Plate: Top cover

6 mm thick ms plate Mild steel Mild steel sections Mild steel of minimum 6mm thk 6 mm thick ms plate

Conveying Section:

Bottom section of the conveyor

Conveyor Shaft Speed: Dimension: Drive System:

35 rpm As per drawing Geared motor coupled conveyor shaft by tarnsmission chain & sprocket 1.43

Transmission Sprocket Ratio: Gear box: Input speed: Output speed: Output torque: Design Service Factor:

1450 50 >


Motor:Power: Type:



Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower



OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devices c/w take-up bearings 5. Top of the conveyor shall be covered with suitable size wire mesh 6. Contractor shall provide drawing and detail specification. Page 1 of 1

K. 6 1

SUPPORTING STRUCTURE


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

STRUCTURE FOR K 6.

DELIVERY

NW


DRAWING NO.

BOILER HOUSE

ITEM No.

K. 7

QUANTITY / UNITS

1

GENERAL Scope


Function:

Steel Structure to support the excess fuel conveyor

SPECIFICATIONS Quantity General Arrangment:

One lot Supporting structure as follows: As per drawing

Construction Details: Construction Material: Structures: Walkway Plaform Handrail:

As per drawing Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe

OTHER REQUIREMENTS 1. Walkway of 800mm width and Handrail shall be 900mm high with intermediete poles at 2000 c/c or otherwise shown in the drawing 2. 100mm high kick plate to be provided around the platform

Page 1 of 1

FUEL RETURN ELEVATOR


DATE:

7-Aug-99


OIL PALM MILL

FUEL RETURN ELEVATOR

DELIVERY

PREPARED

NW


BOILER HOUSE

DRAWING NO.


K. 8 1

GENERAL Scope

Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee 12 months.

Function:

To convey solid waste fuel from the storage area back to the fuel feed conveyor

SPECIFICATIONS Quantity Type: Capacity: General Arrangement: Construction Details: Construction Material: Casing: Sprocket Bucket: Chain rail: Wear plate: Chain:

One (1) unit Fuel Return Conveyor Double conveyor chain c/w buckets 30,000 kg Solid waste fuel per hour. As per drawing As per drawing

Mild steel with 6mm minimum thickness 12T, 150mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 150mm pitch, 13600 kg breaking load

Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:


APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:

Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower. Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG

1450 25 2865 >




Page 1 of 1

WATER TUBE BOILER


DATE:

7-Aug-99


OIL PALM MILL

WATER TUBE BOILER

DELIVERY

PREPARED

NW


DRAWING NO.

BOILER HOUSE


GENERAL Scope


Steam Condition at Mains Superheat Temperature Approx. Feed Water Temp at MCR Boiler MCR Boiler Operating Range Overload Capacity Range Overall Efficiency Electrical Supply

K. 9 1

Scope of works include the assistance in the unloading, safe keeping, close co-operation between the contractors, outside the battery limits of the Boiler contract, such as connections of water & electricity supply, assisting in the HP testing and during commissioning.

One ( 1 ) unit Water Tube Boiler as follows : The steam boiler shall be 35,000 kg/hr. water tube type, designed specifically to burn palm oil solid waste of fibre, shell and empty bunches. 21 kg/cm2 gauge , 30 o C. 60o C 35,000 kg steam /hour @ operating pressure. 50% to 100% MCR 110% of MCR(short period) 74 % AT Max. 414 V ± 6 %, 50 Hz, 3 Phase, 4 wire. The supply of the steam boiler shall include but not be limited to the following: 1. Supporting structure. 2. Steam water drums with internal fittings. 3. Headers and tubes. 4. Mountings and fittings. 5. Spring loaded safety valves for steam drum. 6. Soot blower system. 7. Automatic feed water regulation using the latest technology available in the market c/w high, high-high and low and low-low water alarm. The alarm shall not be resetable until the level is corrected. Indicating lights shall also be installed on boiler front and control panel to indicate the states of alarm. 8. Integral feed water piping from feed water pumps to boiler drum.. 9. Integral steam piping from boiler drum to main stop valve and any equipment within the scope of works. 10. All boiler drain piping. 11. Integral electrical system from boiler MCC to equipment. 12. Reflex and Bi-colour water level gauge glasses. 13. Manual and automatic blowdown valves. 14. Furnace grate. 15. Explosion doors. 16. Forced, Secondary (over fire) and Induced Draught fans, complete with automatic and manual draught control. All fan sizes, capacities static pressures and volumes are to be specified. 17. Fuel feeder fan complete with feeder spouts and adjustment to facilitate efficient fuel spreading across its whole grate surface. 18. Dust collecting system. 19. Chimney and flue gas ducting. 20. Mechanised fuel feeder of pendulum type with anti fire back flash features. 21. All ducts. 22. All refractories and common red bricks. 23. All galleries, ladders and railings. 24. All main, auxiliary and non-return valves. 25. Water sampling and cooling system. 26. All gauge and instrumentation complete with one (1) steam/water flowmeter, steam/water temperature meter, steam pressure meter, draught/temperature meter and smoke density meter for each boiler.

Page 1 of 3

WATER TUBE BOILER


DATE:

7-Aug-99


OIL PALM MILL

WATER TUBE BOILER

DELIVERY

PREPARED

NW


DRAWING NO.

BOILER HOUSE

ITEM No.

K. 9

QUANTITY / UNITS

1

Sheet 2. 27. Blowdown chamber silencer complete with piping from the boiler. 28. Instrument and control panel complete with mimic diagram indicating state of operation inclusive of necessary field instrument wiring. All indicating lights shall use 24 VAC power supply. 29. Recommended spare parts and tools for maintenance. 30. Insulation complete for all heated surfaces. 31. Steam pressure and water flow recorders/meters of 250 mm circular type. 32. Operating manuals. 33. Chemicals for boiling outs. 34. Cleaning and painting. 35. One (1) electric driven and one (1) steam driven feed pump of proven performance. The pumps shall be sized at least 1.5 times the MCR of the boiler. 36. Computerised DATA LOGGING system for the operation of the boiler with option for future automation. 37. Detailed technical specifications and drawings. 38. Fixed mounted pollution monitoring instruments Fuel Material

There shall be occasions necessary where firewood and dewatered empty oil palm bunches are used. Fuel normally used are of the following characteristics: Shell to fibre : up to 25% shell Moisture content : up to in 42% fibre by weight Moisture content : up to in 22% shell by weight

Fans.

Induced, forced and secondary draughts shall be provided with draught control arrangements operated automatically and hand controls at the boiler front. Drafts will be sufficient to ensure effective combustion at maximum continuous rating and meet environmental regulations on smoke density and emission levels.

Insulation & Refractory

Insulation and refractories, of high quality shall be used.

Instrumentation

Instrumentation shall be provided for : steam drum and superheater drum pressure gauge (150mm installed on drum). steam drum pressure gauge (250mm installed on boiler front). steam temperature gauge (150mm c/w pocket installed on drum) flue gas temperature gauge. furnace draughts steam flow, water flow and pressure recorders/meters and totaliser (installed on panel). steam, feed water and flue gas temperature recorders/meter (installed on panel) smoke density meter, recorder with alarm at Ringleman 2 scale (installed on panel) All control instrument shall use 4-20mA signal and meant for hooking-up to Central Control Station (by Others).

Platform, Ladders, Staircase

All necessary operating floors, access galleries and platforms complete with handrails, stairways and ladders required for the safe and convenient operation and maintenance of the plant.

Blowdown And Drains

Blowdown outlets and water drainage outlets from drums, headers, etc., shall each be provided with two stop valves in series with special handles or keys. Automatic blow down valves with TDS based controllers shall also be provided.

Water Sampling Cooler

Water sampling shall incorporate a stainless steel cooling coil and associated equipment. The scope shall include the installation of cooling water piping from nearby water supply line.

Page 2 of 3

WATER TUBE BOILER


DATE:

7-Aug-99


OIL PALM MILL

WATER TUBE BOILER

DELIVERY

PREPARED

NW


DRAWING NO.

BOILER HOUSE

ITEM No.

K. 9

QUANTITY / UNITS

1

Sheet 3. Chimney

Chimney height shall be designed for an efflux velocity of 8 m/sec and to comply with the Malaysian environmental regulations but shall not be less than 30m. Chimney shall be of self-standing type. Necessary sampling points shall be provided in compliance with local authority’s regulations. Ladder and landing platform shall be provided at the sampling points. Copper strips conductor shall be provided throughout the length of the chimney complete with earthing rods and chambers. Calculation on chimney structural design, efflux and height shall be furnished.

Multicyclone

A multicyclone dust collecting system shall be designed for emission of particles of less than 0.4 gm/Nm3 and to comply with the Malaysian environmental regulations. Dust removal and disposal system shall be incorporated. A dust handling and disposal system shall incorporate to remove the dust.

Fuel Feeding System

One complete set of automatic fuel feeding system shall be offered with the supply. The feeding system shall be pendulum type with anti fire flash features incorporated with it. The gearbox/geared motor used for the drive system shall have at least 1.5 factor of safety. The fuel feeding system supplied must be ensured of effective distribution of the palm fibre and shell over the fire grate. Detail design shall be furnished together with the tender.

Drawing & Specifications

Sufficient drawings technical data and specifications shall be furnished together with the tender. Schedules of electrical loading, fan sizes, etc. shall also be provided. Submission of NDT done on welds and joints are necessary.

Electrical

Motor Control Center (MCC) of IP44 complete with MCCB, ammeter, voltmeter, starters, ventilation fan and internal light shall be provided. Cables to motors shall be of PVC/SWA/PVA copper type and run on G.I cable trays. All electrical works shall be in accordance with rule and regulation of local authorities, BS and IEC Standard.

Fans

All fans shall be tested and witnessed by the Engineer in workshop or at the site for capacity, pressure and mechanical balancing to ensure that these comply with the requirements specified. The test procedures shall conform to BS or equivalent standards. Induced draught fan blades shall be of heat resistance material and the fan speed shall not be more than 750 rpm. ID fan shall be coupled with fluid coupling to motor.

Fan Damper Controller.

Induced draught fan damper shall be controlled by PID Controller through hydraulic type actuator. Forced draught fan damper shall be controlled by the same type of controller either through electrical or hydraulic actuator and the damper shall be located at the fan inlet.

Page 3 of 3

ASH REMOVAL CONVEYOR


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

NW

ASH REMOVAL CONVEYOR DELIVERY


BOILER HOUSE

DRAWING NO.


GENERAL Scope

Scope of works include the design, fabrication, installation testing, commissioning, handing over and guarantee

Function:

The removal of Ash from the Boiler for disposal

SPECIFICATIONS Quantity Material to convey Capacity: Type: Size: General Arrangement: Construction Details:

One ( 1 ) unit Ash Removal Conveyor as follows: Boiler Ash 3,000 kg per hour Full flight screw 300 mm dia. As per drawing As per drawing



Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup


56

rpm

Geared motor directly coupled to conveyor shaft by flexible coupling



APPROVED MAKES




1450 56 375 >



Page 1 of 1

K. 11 1

GROUND FEED TANK


DATE:

7-Aug-99


OIL PALM MILL

PREPARED

GROUND FEED TANK

DELIVERY

NW

REVISION No.

LOCATION BOILER WATER FEED

DRAWING NO.

ITEM No. QUANTITY

L 1. 1

GENERAL Scope


Function:

To store and pre-heat soft water before feeding to DEAERATOR FEED TANK

SPECIFICATIONS Quantity Capacity: Construction Details:Construction Material:Tank Shell Tank Bottom Tank Roof Open Steam Coil: Insulation:

Nozzles to be provided:Uses water inlet overflow drain vent steam inlet temp. gauge temp.probe Flanges:

One ( 1 ) Ground Feed Tank as follows : m3 120 As per drawing and in accordance with BS 2654 Mild steel Mild steel Mild steel 50mm dia. seamless API 5L Gr B Sch 40 80mm thk Rockwool insulation c/w 0.7mm thk.aluminium sheet

Size (mm)

Qty

100 100 100 150 50 3/4 " BSP 3/4 " BSP

1 1 1 1 1 1 1

Protusion (mm) 150 150 150 150 150 80 80

Flange Material PN 10 PN 10 PN 10 PN 10 PN 16

Raised face slip-on to DIN 2526

Other Accessories:Mild steel monkey ladder c/w cage 2.3m from ground to the top Mechanical stainless steel float level indicator Bottom manhole of 600mm diameter Top manhole of 600mm diameter Internal monkey ladder

Page 1 of 1

GI 'C' BS 1387 GI 'C' BS 1387 GI 'C' BS 1387 GI 'C' BS 1387 seamless API 5L Gr B Sch 40

SOFTENER BOOSTER PUMP


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE OIL PALM MILL

PREPARED

NW

SOFTENER BOOSTER PUMP DELIVERY


DRAWING NO.

BOILER WATER FEED


GENERAL Scope

Scope of works include the design, manufacture, delivery installation, testing, commissioning and guarantee

Function:

To pump clarified water to the Softeners

SPECIFICATION Type Connection

Two ( 2 ) Softener Booster Pumps as follows : Centrifugal, End-suction Raised face flange to BS 4504 PN 10


60 water ambient 1 60 2900 3

m3/hr


CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling Drive: Motor:-

Cast Iron GG25 Cast Iron GG25 S.S AISI 304 Gland packing S.S AISI 304 Flexible Motor directly coupled with flexible coupling to the pump

Power: Type: APPROVED MAKES

5.5 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent.

Pump: Motor: Coupling: Bearing:

Robuschi, SIHI, Grundfos Crompton Parkinson, Brush Fenner (Fenaflex), Renold NTN, SKF, FAG


Page 1 of 1

L 2. 2

DEAERATOR FEED TANK


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

DEAERATOR FEED TANK

DELIVERY

PREPARED

NW


DRAWING NO.

BOILER WATER FEED


L 3. 1

GENERAL Scope

Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee

Function:

To store and heat soft water before feeding to Deaerator

SPECIFICATIONS Quantity Capacity: Construction Details:Construction Material:Tank Shell Tank Bottom Tank Roof Open Steam Coil: Supporting structure: Insulation:

One ( 1 ) Deaerator Feed Tank as follows : 45 m3 As per drawing Mild steel Mild steel Mild steel 50mm dia. seamless API 5L Gr B Sch 40 Mild steel 80mm thk Rockwool insulation c/w gauge 0.7mm aluminium sheet cladding

Nozzles to be provided:Users water inlet overflow drain vent steam inlet temperature gauge temperature probe Flanges:

Size (mm) Protrusion (mm) 100 150 100 150 100 150 150 150 50 150 3/4 " BSP Socket 3/4 " BSP Socket Slip-on raised face To BS 4504

Other Accessories:Mild steel monkey ladder Mechanical float level indicator Top manhole of 600mm diameter

Page 1 of 1

Flange PN 10 PN 10 PN 10 PN 10 PN 16

Material GI 'C' BS 1387 GI 'C' BS 1387 GI 'C' BS 1387 GI 'C' BS 1387 seamless API 5L

DEAERATOR FEED PUMP


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED

NW

DEAERATOR FEED PUMP DELIVERY


BOILER WATER TREATMENT

DRAWING NO.


GENERAL Scope

Scope of works include the design, manufacture, delivery installation, testing, commissioning and guarantee.

SPECIFICATION Quantity Type Connection

Two ( 2 ) Deaerator Pump as follows : Centrifugal, End-suction Raised face BS 4504 PN 16

OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Delivery Head Speed NPSH available

60 Water 90 1 0.00114 128 1450 3

CONSTRUCTION Casing Impeller Shaft Sealing Coupling Drive: Motor:-

m3/hr o

C

Ns/m2 KPa RPM (Max) m liquid

Cast Iron GG-C25 Cast Iron GG-C25 or bronze carbon steel Gland Packing Flexible Motor directly coupled with flexible coupling to the pump Power: Type:

APPROVED MAKES Pump: Motor: Coupling: Bearing:

18 kw - Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Robuschi, Warman, MTP Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, SKF, FAG


Page 1 of 1

L 4. 2

DUPLEX WATER SOFTENER


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED

NW

DUPLEX WATER SOFTENER DELIVERY


DRAWING NO.


ITEM No. QUANTITY

L 5. 1

GENERAL Scope

Scope of works include the Design, manufacture, delivery, installation testing, commissioning and guarantee.

Function

To condition the water before deaeration and feed to water tube boiler

SPECIFICATION

The water softener shall have the following specifications:-

Quantity Type

One (1) unit Duplex Water softener DUPLEX

Capacity

45 m3/hr of water flow.

Type of resin

Food grade

Piping System

Integral piping system shall be provided.

Inlet Water Quality

Colour <5 Hazen unit Turbidity <5 ppm to silica scale Iron content <0.3 ppm Fe Manganese <0.1 ppm as Mn pH 7-7.6 Aluminum < 0.2 ppm Total dissolve solid < 5 ppm

Control

Semi-auto using SOLO Valve.

Regeneration Period

Interval between each regeneration shall not be less than 96 hours. Capacity and quality during regeneration shall remain unaffected.

Accessories

Suitable pressure gauges shall be provided at inlet and outlet piping. A brine tank shall be provided Two (2) Chemical dosing pumps of piston type with SS 316 wetted part and chemical tank shall be provided.

Performance Test

Samples shall be taken at hourly intervals for inlet and outlet water and analysed for hardness. The results shall be statistically analysed by taking the mean average and standard deviation.


Total hardness of water ex-softener shall not exceed 1 ppm.CaCO3

Motor Flange:

415 V 3ph 50 Hz, 4-pole, TEFC, Class F, IP 55 ANSI 150# and above

Page 1 of 1

CHEMICAL DOSING SYSTEM


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED

NW

CHEMICAL DOSING PUMPS DELIVERY DRAWING NO.

REVISION No. LOCATION BOILER WATER TREATMENT

ITEM No.

L 6.

QUANTITY

GENERAL Scope


Function

The dosing of chemicals into boiler feed water

SPECIFICATIONS

Lot of Chemical Dosing system as follows :

System Consists of:

2 units Chemical dosing pumps 2 units Solution tanks Set interconnecting pipes and appurtenance

Chemical Dosing Pumps Quantity: Type: Construction: Capacity: Pressure: Accessories: Motor:

2 Diaphragm SS wetted part Rubber diaphragm 2000 l/day 6 bargs suction and discharge tubing, strainer, sinker, discharge tubing, valve set, main connection with check valve built in and lubricating oil. 0.3 kw 240V/1-Ph/50Hz

Solution Tank Quantity: Type: Construction: Capacity: Accessories:

2 Cylindrical HDPE 2000 litres electric mixers, covers and level switches.

Requirements.

Vendor to provide technical details, catalogues, drawing etc….

Page 1 of 1

2

VACUUM DEAERATOR


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED

NW

VACUUM DEAERATOR DELIVERY


DRAWING NO.


ITEM No.

L 7.

QUANTITY

GENERAL Scope


Function

To process deaerated water for the boiler.

SPECIFICATIONS Quantity Capacity

One ( 1 ) Vacuum Deaerator as follows : Not less than 45,000 kg/hr of water at 60

C

Construction

Constructed from mild steel and conforming to the latest B.S. or ASME Codes for pressure vessels and Factories and Machinery Regulation.

System Vacuum

Provided by a steam ejector located on top of the vessel. Maximum steam pressure available is 20 kg/cm2

Transfer of Deaerator Water

The deaerated water shall be withdrawn by a extraction pump and directed to the boiler feed pump The extraction pump shall have a mechanical seal and air-tight

Scope of Supply a. b. c. d. e. f. g.

Pressure vessel with spray nozzles, sight glasses, vacuum pressure gauge, level indicator, manhole etc. Inlet valves. Outlet valves before and after pump. Non-return valve after pump. By-pass line connecting inlet pipe to deaerator to outlet pipe of extraction pump. Steam ejector. Certification from the Factories & Machinery Department.

Tests on Completion

Samples shall be taken at hourly intervals for inlet and outlet water and analysed for oxygen content. The results shall be statistically analysed by taking the mean average and standard deviation.


Oxygen content of water ex-deaerator shall not exceed 0.03 ppm.

Motor

415 V 3ph 50 hz, 4-pole, TEFC, Class F, IP 55

Flange:

ANSI 150# and above.

Requirements.


Page 1 of 1

1

VACUUM DEAERATOR


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED

NW

VACUUM DEAERATOR DELIVERY


DRAWING NO.


ITEM No.

L 7.

QUANTITY

GENERAL Scope


Function

To process deaerated water for the boiler.

SPECIFICATIONS Quantity Capacity

One ( 1 ) Vacuum Deaerator as follows : Not less than 45,000 kg/hr of water at 60

C

Construction

Constructed from mild steel and conforming to the latest B.S. or ASME Codes for pressure vessels and Factories and Machinery Regulation.

System Vacuum

Provided by a steam ejector located on top of the vessel. Maximum steam pressure available is 20 kg/cm2

Transfer of Deaerator Water

The deaerated water shall be withdrawn by a extraction pump and directed to the boiler feed pump The extraction pump shall have a mechanical seal and air-tight

Scope of Supply a. b. c. d. e. f. g.

Pressure vessel with spray nozzles, sight glasses, vacuum pressure gauge, level indicator, manhole etc. Inlet valves. Outlet valves before and after pump. Non-return valve after pump. By-pass line connecting inlet pipe to deaerator to outlet pipe of extraction pump. Steam ejector. Certification from the Factories & Machinery Department.

Tests on Completion

Samples shall be taken at hourly intervals for inlet and outlet water and analysed for oxygen content. The results shall be statistically analysed by taking the mean average and standard deviation.


Oxygen content of water ex-deaerator shall not exceed 0.03 ppm.

Motor

415 V 3ph 50 hz, 4-pole, TEFC, Class F, IP 55

Flange:

ANSI 150# and above.

Requirements.


Page 1 of 1

1

DEAERATOR EXTRACTION PUMP


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

DEAERATOR EXTRACTION PUMP

DELIVERY

PREPARED

NW



DRAWING NO.

ITEM No. QUANTITY

GENERAL Scope

Scope of works include the design, manufacture, delivery installation, testing, commissioning and guarantee.

SPECIFICATION Two ( 2 ) Deaerator Extraction Pump as follows : Type Connection

Centrifugal, End-suction Raised face flange to BS 4504 PN 10


90 water ambient 1 60 2900 3

m3/hr



Cast Iron GG25 Cast Iron GG25 S.S AISI 304 Gland packing S.S AISI 304 Flexible Motor directly coupled with flexible coupling to the pump Power: Type:

11 kw - Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz


Page 1 of 1

L 8. 2

DIESEL SKID TANK


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED

NW

DIESEL SKID TANK DELIVERY


DRAWING NO.

ITEM No.

POWER HOUSE

QUANTITY

GENERAL Scope


1


Function: SPECIFICATIONS Quantity Capacity: Basic Dimensions:

M 1.

To receive and store diesel oil for diesel generator

One ( 1 ) Diesel Skid Tank as follows: 18,000 litres Dia 2,100 mm SHL 4,200 mm As per drawing

Construction Material: Tank Structural support

Mild steel Mild steel

Nozzles:Uses Diesel in drain Diesel out Vent Flanges: Level Indicator: Supporting Structures:

Size (mm) 100 50 50 100

Qty 1 1 1 1


Protrusion (mm) Material ## API 5L Gr B Sch 40 ## API 5L Gr B Sch 40 ## API 5L Gr B Sch 40 ## API 5L Gr B Sch 40

Raised face to BS 4504 Plastic tube with steel tube as guard c/w isolation cocks Mild steel c/w catwalk and platform as per drawing

Page 1 of 1

OVERHEAD DIESEL SKID TANK


DATE:

7-Aug-99


OIL PALM MILL

OVERHEAD DIESEL SKID TANK

DELIVERY

PREPARED

NW


POWER HOUSE

DRAWING NO.

ITEM No. QUANTITY

M 1. 1

GENERAL Scope


Function:

To receive and store diesel oil for diesel generator


One ( 1 ) Overhead Diesel Skid Tank as follows: 18,000 litres 2,100 mm 4,200 mm As per drawing



Dia SHL

Nozzles:Users Diesel in drain Diesel out Vent Flanges: Level Indicator: Supporting Structures:

Size (mm) 100 50 50 100

Qty 1 1 1 1


Protrusion (mm) Material 150 API 5L Gr B Sch 40 150 API 5L Gr B Sch 40 150 API 5L Gr B Sch 40 150 API 5L Gr B Sch 40


Page 1 of 1

DIESEL UNLOADING PUMP


DATE:

7-Aug-99


OIL PALM MILL

DIESEL UNLOADING PUMP

DELIVERY


NW 1

LOCATION

POWER HOUSE

DRAWING NO.

ITEM No. QUANTITY

GENERAL Scope

Scope of works include the manufacture, delivery, installation testing, commissioning and guarantee

Function:

To pump diesel to the overhead diesel skid tank and day tank

SPECIFICATION Quantity Type Connection

One ( 1 ) Diesel unloading pump as follows : Centrifugal Raised face flange to BS 4504 PN 10


6000 Diesel ambient 0.96 10 1500 3

lts per hour



Cast Iron GG25 Cast Iron GG25 S.S AISI 304 Mech. Seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling to the pump Power: Type:

approx. 1 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz


Page 1 of 1

M 2. 1

BACK PRESSURE RECEIVER


DATE:

7-Aug-99

MACHINE NAME


PREPARED

NW

BACK PRESSURE VESSEL DELIVERY

REVISION No.

1

LOCATION

POWER HOUSE

DRAWING NO.

ITEM No. QUANTITY

GENERAL Scope


Function:

To act as a buffer vessel for low pressure steam generated by turbine for process use.

SPECIFICATIONS Quantity Design & Construction Code: General Arrangement & Asembly: O.D: S.H.L: Plate thickness: Type of welds: Material Standard: Working Pressure: Working Temperature: Compliance with local regulation: Tolerance In term Of Straightness:

One ( 1 ) Back Pressure Receiver with components as follows : BS 5500 or ASME for un-fired pressure vessel as per drawings 1,230 mm 8,000 mm 15 mm (min) Double V-butt welds Carbon steel Grade 151 to BS 1501 Pt.1 kg/cm2 (dry saturated steam) 3.5 o 150 C Yes 3 mm (maximum deviation)

Nozzle:Uses Steam make-up Steam exhaust Steam to Steriliser Single Port Safety Valves Double Port Safety Valves Turbine exhaust Steam to BST and feed tank Steam to Process Steam to Clarification Pressure control Spare c/w blind flange Drain Steam condensate trap Temperature gauge Pressure gauge Pressure recorder Pressure controller

size (mm) 100 150 300 150 200 350 100 150 150 100 350 50 25 3/4" BSP 3/4" BSP 3/4" BSP 3/4" BSP

Protrusion (mm) 150 150 150 150 150 150 150 150 150 150 150 150 150 100 100 100 100

qty 1 1 1 1 1 1 2 1 1 1 2 2 2 1 1 1 1

Page 1 of 2

Flange PN 16 PN 16 PN 16 PN 16 PN 16 PN 16 PN 16 PN 16 PN 16 PN 16 PN 16 PN 16 PN 16

Material API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40 API 5L Gr B Sch 40

M 3. 1

BACK PRESSURE RECEIVER


DATE:

7-Aug-99

MACHINE NAME


PREPARED

NW

BACK PRESSURE VESSEL DELIVERY

REVISION No.

1

LOCATION

POWER HOUSE

DRAWING NO.

ITEM No. QUANTITY

M 3. 1

Sheet 2.

Scope of supply :

Flange: Saddles:

Insulation:

a. b.

1 Lot

c. d. e. f. g. h.

1 1 2 1 1 Lot

Back pressure Vessel as per specification above Installation only of BPR control sysytm, supplied by others as per item M 5 Safety Valve 150mm PN16 as per Item M 6. Safety Valve 200mm PN16 as per Item M 6 Steam condensate line and valves Temperature gauge 150mm dia. face Pressure gauge 150mm dia face Insulation and SS cladding

Raised face to BS 4504 To fit snugly into receiver body with no open gap, one saddle remains fixed and the other is allowed to slide on solid steel bar during expension 80mm rockwool Fibretex 450 with necessary attachement for holding the insulation material

Testing Type: Pressure: Code & Regualations:

Hydrostatic 1.5 x design pressure (to JKKP's requirement) BS 5500 or ASME for un-fired pressure vessel and local authorities

Page 2 of 2

BACK PRESSURE RECEIVER CONTROLLER


DATE:

7-Aug-99


OIL PALM MILL

BPR Controller

DELIVERY


NW 1

LOCATION DRAWING NO.

POWER HOUSE

ITEM No. QUANTITY

M 4. 1

GENERAL Scope

Scope of works include the Unloading, safe keeping, assist in the installation, testing, and commissioning

Function

Steam balance pressure control of the back pressure vessel


Working pressure Working temperature Design pressure

One ( 1 ) Back Pressure Receiver Controller. as follows: The vessel shall be designed to ASME or BS 5500.

3.3 kg/cm2 145 degree C 3.5 kg/cm2 An automatic make-up steam controller of proven make shall be provided. The controller shall cut off steam supply to the vessel when boiler pressure drops below a predetermined level and resupply steam when the predetermined level is reached again. The following data to be incoperated:Make : Capacity Pipe Size Sensivity range Material

Page 1 of 1

DIESEL DAY TANK


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED

NW

DIESEL DAY TANK DELIVERY

REVISION No.

1

LOCATION

POWER HOUSE

DRAWING NO.

ITEM No. QUANTITY

GENERAL Scope


Function:

To receive and store diesel oil for daily use of diesel generator


One ( 1 ) Diesel Day Tank as follows: 1,500 litres 1.2 x 1.2 x 1.2 m As per drawing



Nozzles:Uses Diesel in drain Diesel out Vent

Flanges: Level Indicator: Supporting Structures:

Size (mm) 50 50 50 100

Qty 1 1 1 1


Protrusion (mm) Material 150 API 5L Gr B Sch 40 150 API 5L Gr B Sch 40 150 API 5L Gr B Sch 40 150 API 5L Gr B Sch 40


Page 1 of 1

M 5. 1

AIR COMPRESSOR


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

PREPARED

NW

AIR COMPRESSOR DELIVERY

REVISION No.

1

LOCATION

POWER HOUSE

DRAWING NO.

ITEM No. QUANTITY

GENERAL Scope

M 6. 1


Function:

To provide compressed air for instrumentation

SPECIFICATIONS Quantity Compressor Spects:

One ( 1 ) Air Compressor as follows :

Type: Capacity: Working Pressure: Design Pressure:

Non-oil free rotary screw/tooth & air- cooled 50 litres/sec (FAD) 7 barg Vendor to advise

Brand Name Free Air Delivery Temp.: Type Of Control

Broomwade, Atlas Copco or approved equivalent Vendor to advise Electronic or electro-mechanical pressure switch for low oil air pressure switch for high bleed-off Automatic Type 75 dB(A) max.

Drain: Noise Level: Motor Power: Type: Starter Board Air Receiver:

Vendor to avice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz BS 5486, IP 54 protection, c/w isolator and ampere meters, heavy duty type contactor to BS 775 Built-in

Page 1 of 1

DIESEL DRIVE - 150 KW ALTERNATOR


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

OIL PALM MILL

DIESEL DRIVEN ALTERNATOR 150 KW

DELIVERY

PREPARED

REVISION No.

NW

1

LOCATION

DRAWING NO.

POWER HOUSE

ITEM No. QUANTITY

GENERAL Scope

Function: SPECIFICATIONS Quantity

M 8. 1

Scope of works include the unloading at site, safe keeping installation, assist in testing and commissioning. Generation of Electricity

Cooling system

One ( 1 ) Diesel drive 150kw Alternator as follows : Each diesel-alternator shall be of manufacturer standard design and in accordance with the following Air-cooled

Starting system

Electrical, remote controlled.

Electricity Supply

0.8 P.F. / 415 Volt / 3 phase - 4 wire / 50 Hz

Engine

4 stroke - vertical inline or Vee form. Engine speed shall be 1500 RPM controlled by a NEMA Class `D' direct acting oil relay, PSG Woodward governor or equivalent, complete with local and remote control. The remote control unit is to be incorporated into the Main Switchboard (by others) incorporating voltage Parallel operation with a similar unit and turbo- alternators having similar governors and alternator characteristics shall be made possible. The engine shall be complete with lubricating oil pump, lubricating oil filters, fuel oil filters, lubricating oil pressure, air inlet filter, thermometers for cooling water inlet outlet and exhaust manifold. The unit shall be provided with emergency trips to automatically shut down the engine in the event of overspeed, low lubricating oil pressure and high temperature.

Alternator

Instrument

A set of 24 V batteries shall be provided for the starting system. Drip proof, screen protected, revolving field, Class F insulation, of brushless self regulating type. An Automatic Voltage Regulator (AVR) unit shall be provided. Provision shall be made for manual control in event of failure of the AVR. An instrument and control panel shall be provided and mounted on the engine. It shall have the following features: Tachometer - mechanical or electrical type Lubricating oil pressure Temperature Start/stop Speed adjustment Battery charger Sufficient drawings technical catalogues and specifications shall be submitted by the supplier.

Page 1 of 1

DIESEL DRIVE - 350 KW ALTERNATOR


DATE:

7-Aug-99

MACHINE NAME


DIESEL DRIVEN ALTERNATOR 350KW

DELIVERY


NW 1

LOCATION

DRAWING NO.

POWER HOUSE

ITEM No. QUANTITY

GENERAL Scope


Function:

Generation of Electricity


Cooling system

Two ( 2 ) Diesel drive 350kw Alternator as follows : Each diesel-alternator shall be of manufacturer standard design and in accordance with the following Air-cooled

Starting system

Electrical, remote controlled.

Electricity Supply

0.8 P.F. / 415 Volt / 3 phase - 4 wire / 50 Hz

Engine

4 stroke - vertical inline or Vee form. Engine speed shall be 1500 RPM controlled by a NEMA Class `D' direct acting oil relay, PSG Woodward governor or equivalent, complete with local and remote control. The remote control unit is to be incorporated into the Main Switchboard (by others) incorporating voltage Parallel operation with a similar unit and turbo- alternators having similar governors and alternator characteristics shall be made possible. The engine shall be complete with lubricating oil pump, lubricating oil filters, fuel oil filters, lubricating oil pressure, air inlet filter, thermometers for cooling water inlet outlet and exhaust manifold. The unit shall be provided with emergency trips to automatically shut down the engine in the event of overspeed, low lubricating oil pressure and high temperature. A set of 24 V batteries shall be provided for the starting system.

Alternator

Drip proof, screen protected, revolving field, Class F insulation, of brushless self regulating type. An Automatic Voltage Regulator (AVR) unit shall be provided. Provision shall be made for manual control in event of failure of the AVR.

Instrument

An instrument and control panel shall be provided and mounted on the engine. It shall have the following features: Tachometer - mechanical or electrical type Lubricating oil pressure Temperature Start/stop Speed adjustment Battery charger Sufficient drawings technical catalogues and specifications shall be submitted by the supplier.

Page 1 of 1

M 9. 1

STEAM TURBINE DRIVE - 1200 KW ALTERNATOR


DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE

TURBINE DRIVEN ALTERNATOR 1200KW

OIL PALM MILL

DELIVERY


NW 1

LOCATION

POWER HOUSE

DRAWING NO.

ITEM No. QUANTITY

M 10. 1

GENERAL Scope

Scope of works include the unloading at site, safe keeping, mounting on foundation installation, assist in testing and commissioning.

Function:

Generation of Electricity


One ( 1 ) Steam Turbine drive 1200kw Alternator as follows :

Specifications………….

The turbine shall be manufacture’s standard design, of single stage, impul impulse turbine, non condensing unit designed for operation at the following operations:a)

Pressure on Inlet Steam is 19.35 kg/cm2 (275 psig)

b)

Temperature of Inlet Steam is at saturated pressure

c)

Pressure of exhaust steam is 3.16 kg/cm sq. 45 psig dry saturated

d)

Steam consumption shall not exceed 23 kgs/kwh at maximum load.

e)

The maximum turbine speed shall be 11,000 R.P.M. and the speed is to be controlled by NEMA Class ‘D’ direct acting oil relay governor complete with local and remote control. The remote control shall be operated by a suitable rated D.C. electric motor mounted onto the governor with its control unit incorporated into the Main Switchboard.

f)

The casing must fully conform to ASME Section VI for allowable stress level or equivalent.

g)

Turbine speed shall be reduced to alternator synchronous speed by means of reduction gears. Gearbox lubrication shall be provided by the turbine lube oil system.

h)

A flexible coupling preferably with ring torsion device shall be provided between the turbo-gear and alternator.

I)

Minimum of two nozzle control hand valves to reduce steam consumption at partial load.

j)

Turbine shaft shall be accurately machined from high quality heat treated steel and shall be designed and constructed so that injurious distortions will not occur with changes in load on the unit.

Page 1 of 4



DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE


OIL PALM MILL

DELIVERY

PREPARED

NW

REVISION No.

1

LOCATION

POWER HOUSE

DRAWING NO.

ITEM No.

M 10.

QUANTITY

1

Sheet 2.

Specifications………

k)

Turbine wheel shall be of alloy steel and have a shaped profile. The completed rotor assembly shall be in dynamic balance so that it will run smoothly and without undue vibration. The nozzle block shall be designed to produce efficient expansion of the steam. The materials used shall be selected for their strength and for their corrosion and erosion resistant qualities. They shall have the form and the dimensions which are essential to efficiency and strength.

L)

A safety valve on the turbine casing and turbine exhaust line must be provided.

m)

A suitable oil pump shall be mounted on or driven from the turbine shaft and shall deliver oil, from the reservoir supplied with the unit at sufficient pressure for hydraulic operation of the control mechanism and for bearing lubrication.

n)

A motor driven turbo auxilliary oil pump shall be furnished for use when starting the unit and in emergencies. Pressure regulation, with manual reset, shall be provided for automatic operation of the pump. The pressure lubricating system shall be complete with pressure gauges, filters, oil coolers, relief valves, dial thermometers and necessary piping and controls. The lubricating oil reservoir shall be incorporated in the turbo-alternator base.

o)

Suitable steam strainer, located upstream of the throttle valve and its seat, shall be provided. The strainer screen shall be readily removable.

p)

The unit shall be equipped for manual control of the steam flow into the turbine when starting.

q)

The flow of steam into the turbine shall be controlled by the speed governor controlled valve. The valve shall be double-seated and designed to minimize throttling losses. The valve shall be actuated by means of a suitable relay-controlled hydraulic mechanism. The valve, valve stam and valve seat shall be made of corrosion and erosion-resistant materials suitable . for the service.

r)

The unit bearing shells shall be horizontally split and lined with high grade babbit. They shall be arranged for pressure lubrication and operated without injurious temperature rise or undue bearing wear. The bearing shells shall be readily removable without removing the rotor. Means shall be provided to prevent leakage of oil or oil vapours from the bearing housings. The turbine shall be equipped with a thrust bearing to maintain the correct axial relation between rotating and stationary parts. Efficient and rugged seals shall be provided where the turbine shaft passes through the casing. Shaft seals shall be replaceable.

Page 2 of 4



DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE


OIL PALM MILL

DELIVERY

PREPARED

NW

REVISION No.

1

LOCATION

POWER HOUSE

DRAWING NO.

ITEM No.

M 10.

QUANTITY

1

Sheet 3. Specification ……….

s)

The turbine parts enclosing high temperature steam shall be covered with heat insulating material, and wherever practicable, this material shall be protected by a removable sheet metal jacket.

t)

The unit shall be provided with emergency trips to automatically shut down the turbine in the event of overspeed or low lubricating oil pressure. 1. Pressure gauges for inlet steam, steam chest, exhaust steam and lubricating oil. 2. Temperature gauge for inlet for inlet steam, steam chest, exhaust steam, lubricating oil and cooling water. 3. Tachometer.

u)

The alternators shall be of drip proof, screen protected, revolving field, salient pole type with damper windings, Class E insulation or better to BS 2757 or equivalent, of the brushless self-regulating type, with in line exciter and automatic voltage constant within +1% at all loads and power factors between 0.8 lagging and unity, continuously site rated to comply with engine net horse-power at 0.8 P.F. according to BS 2613. The full load output voltage shall be 240/440 volts 3 phase 4 wire 50 Hz winding shall be in star connection with neutral solidly earthed. Electric heaters shall be provided in the alternator stator for prevention of condensation. Supply to the heater shall be supplied from the Main Switchboard and arranged so that the heater is switch ‘OFF’ when the alternator is ‘NO’.

v)

The alternator and exciter shall be manufactured and tested in accordance with BS 2613 but derated to suit local conditions with winding insulated with Class ‘E’ or better insulation to BS 2757, specially impregnated for tropical duty and fitted with ball and/or roller bearings. The Alternator shall be of make Stamford, Markon or approved equivalent.

w)

The Automatic Voltage Regulator shall be capable of providing a voltage regulation of not less than +1% at all loads and power factors between 0 lagging and unity. The response time of the unit shall be 0.5 second when full load is applied and 1 second when full load is shed.

x)

The alternator shall be provided with synchronising droopkit to cater for parallel running to achieve satisfactory parallel running of all generating sets, suitable quandrature current compensation circuits for all the alternators shall be provided to ensure proper load sharing.

y)

The alternator shall be capable of withstanding 10% overload for one (1) hour in twelve (12) hours.

z)

The alternator shall be capable of withstanding induction motor staring charge loads of up 250% of the alternator rating for 10 seconds or less.

Page 3 of 4



DATE:

7-Aug-99

MACHINE NAME

PROJECT CODE


OIL PALM MILL

DELIVERY

PREPARED

NW

REVISION No.

1

LOCATION

POWER HOUSE

DRAWING NO.

ITEM No.

M 10.

QUANTITY

1

Sheet 4.

Tests on Completion

Tests on each generating set shall comprise starting, stopping, running and load tests and shall be carried out upon the installation as a complete unit including the electrical control gear. The supplier shall provide certified records in triplicate of all readings and curves showing the results obtained from these tests. (a) (b) (c) (d) (e)

Full load 75% load 50% load 25% load 110% load

: : : : :

(4) four hours (1) one hour (1) one hour (1) one hour (1) one hour

During each of these periods, steam consumption trials shall be carried out and the actual figures obtained recorded in the test results. Performance curve (for open exhaust and 3.16 lg/cm2 (45 psig) back pressure) and graphs of specific steam consumption in kgs. per KW hour shall be prepared. Readings shall be taken and recorded at half-hour intervals throughout the tests of exhaust temperatures, cooling water temperatures, lubricating oil and engine speed, inlet steam pressure and temperature, exhaust steam pressure and temperature. Governor trials shall be carried out immediately after the load trials in accordance with BS 649.

After Sales Service

Contractor to provide 2 free service for the turbine for the first operational year.

Page 4 of 4

MECHANICAL & ELECTRICAL DRAWINGS

01. General Machinery Layout

1

GENERAL MACHINERY LAYOUT

02. FFB Loading Ramp.

2

FFB LOADING RAMP WITH CONVERYOR SYSTEM – SIDE VIEW

03. FFB Conveyor Arrangement

3

FFB CONVEYOR ARRANGEMENT

04. FFB Cage

4

FFB CAGE ( cap: 7500 kg )

05. Cage transfer Carriage

5

CAGE TRANSFER CARRIAGE

06. Sterilizer Mobile Rail Piece

6

STERILIZER MOBILE RAIL PIECE

07. Sterilizer Vessel

7

STERILIZER VESSEL ( with double door, 2800mm dia. X 7 Cages of 7.5 mt FFB each. )

8

08. Sterilizer Section with details

STERILIZER – SECTION WITH DETAILS

9

09. Cage Tippler Station

CAGE LOADING

CAGE TIPPLER STATION.

10. cage Tipple Details

10

TIPPLER DETAILS. ( for 7mt FFB cage )

11. Sterilizing and Threshing Station

11

STERILIZING AND THRESHING STATION

12. Thresher Feed Conveyor “S” Type Scraper Bar.

THRESHER FEED CONVEYOR – “S “ TYPE SCRAPER BAR ( 1500 mm wide )

12

13. Typical Scraper Bar Conveyor

13

SCRAPER BAR CONVEYOR – TYPICAL ARRANGEMENT ( 1500 mm wide )

14. Threshing Station

14

FRUIT ELEVATOR

TOP FRUIT CONVEYOR

EMPTY BUNCH CONVEYOR

THRESHING STATION

15. Threshing Station – Section with details

15

FFB feed conveyor

THRESHING DRUM

THRESHING STATION ( for 45mt FFB per hour process )

16. Screw Conveyor

16

A SCREW CONVEYOR – TYPICAL ARRANGEMENT ( 600 mm dia. )

17. Fruit Elevator

17

FRUIT ELEVATOR – BUCKET TYPE ( 600 mm wide Bucket )

18. Extraction Station

18

HO WATER TANK

TWIN SCREWPRESS PLATFORM

VIBRATING SCREEN PLATFORM

CRUDE OIL EXTRACTION STATION

19. Cake Breaker Conveyor

19

CAKE BREAKER CONVEYOR WITH SUPPORTS.

20. Deparicarper Station

20

SHELL & FIBRE BUNKERS

DEPARICARPER WINNOWING COLUMN

DEPARICARPER STATION ( Fibre & Nuts Separation )

21. Clarification Station

21


22. Clarification Station - Elevation

22

CLARIFICATION STATION - ELEVATION

23. Static Clarifier Tank

23

STATIC CLARIFIER TANK DETAILS ( cap : 120 m³ )

24. Pure OIL Tank

24

PURE OIL TANK DETAILS ( cap: 30m³ )

25. Sludge Tank

25

SLUDGE TANK DETAILS ( cap : 30 m³ )

26. Sludge Settling Tank

26

SKIMMER DETAILS

SLUDGE SETTLING TANK ( cap: 20m³ )

27. Sludge Oil Recovery Tank

27

SLUDGE OIL RECOVERY TANK DETAILS ( cap: 150 m³ )

28

28. CPO Storage Tank

CRUDE PALM OIL STORAGE TANK ( cap: 2000 mt )

29. Nut Grading & Cracking Plant

29

NUT GRADING, CRACKING & WINNOWING PLANT

30. Kernel Recovery Plant

30

Wet Kernel Transport & Cyclone assembly

CM Double Winnowing system Kernel Drying Silo

Heater & Fan

HYDRO CLAYBATH

KERNEL RECOVERY PLANT.

31. Hydro claybath Kernel Separator

31

HYDRO- CLAYBATH KERNEL RECOVERY SEPARATOR

32. Kernel Dryers & Bunkers

32

KERNEL TRANSPORTER

KERNEL DRYERS

KERNEL STORAGE BUNKERS

KERNEL DRYERS & STORAGE BUNKERS

33.. Kernel Silo Details

33

KERNEL DRYER SILO DETAILS ( cap : 70 m³ )

34. Dry Kernel Distribution Conveyor

34

DRY KERNEL DISTRIBUTING CONVEYOR

35. Back Pressure Vessel

35

BACK PRESSURE RECEIVER VESSEL DETAILS ( 1200mm dia ID x 8000 mm length )

37

37. Sterilizer system

PID STERILIZER STATION

38. Compressed Air

38

PID COMPRESSED AIR

39. PID Press Station

39

PID PRESS STATION

40. PID Clarification Station

40

PID CLARIFICATION STATION

41. PID Sterilization Condensate

41

PID STERILIZER CONDENSATE – OIL RECOVERY SYSTEM

42. PID Sludge oil recovery system

42

PID SLUDGE OIL RECOVERY SYSTEM

43. PID Kernel Plant

43

PID KERNEL RECOVERY PLANT

44. PID Power House

44

PID POWER HOUSE

45. PID Boiler house

45

PID BOILER HOUSE

45. PID Boiler house

45

PID BOILER HOUSE

WELCOME TO PREDICTIVE MAINTENANCE Sometime in the '90's, the maintenance service company as we knew it died. The people who carried out good maintenance practices such as PM ( Predictive Maintenance ) got laid off. We lost the manager, maintenance engineers and support people who made the systems work. The old paradigms and strategies don't apply in the new corporate order. We must ask fundamental structural questions about what types of tasks maintenance personnel should do and who should do maintenance tasks. The first question concerns the mission of maintenance. What is the mission of maintenance? There used to be as many answers to this question as there were companies. When a company even had a mission statement, it ranged from ensuring quick reaction times fixing breakdowns to serving the customer. Some companies are intent on reducing downtime, and others focus on cost control or quality. A few focus on safety or environmental security. All these missions are useful and important. And all ignore the deep issue: the organization has changed and something very simple transcends these missions or values. The old mission statements and the new culture collide. The old mission statement contradicts the new core corporate philosophy of being a el an, mean, fast, in-your-face competitor. The old vision of maintenance is as obsolete as a relay rack. Here is the new vision: The mission of the maintenance department is to provide excellent support for customers by reducing and eventually eliminating the need for maintenance services. That calls for re-engineering traditional roles. On one side, maintenance must merge with machine, equipment and plant design to integrate maintainability improvements into design. The accumulated knowledge and lessons of maintenance will be immediately merged into the design profession. Designers and maintainers will have a revolving door. On the other side, routine maintenance activity should be merged into operations. The PM (predictive maintenance) model shows that operators can handle the task and that the whole maintenance effort will benefit from operator involvement. What happened to our organization ? What is the best structure to produce palm oil products, to generate productivity or to provide education? Increasingly the answer is not a traditional structure. The optimum structure is increasingly a matrix, a network, a wheel or something people never thought of before.

Page 2. In some notable cases (such as IT Industry), the best organization is virtual. It is assembled ad hoc with independent contractors who are experts in their fields and dissolved when the need changes or ends. The lean and mean virtual corporation depends far less on bricks and mortar than the old

one did. The creed of the new organization is that everyone must add value to the product. Everyone is expendable, out sourceable. Think of the current corporate hero, who is no longer a lone product-development genius but now a tough cost-cutter (who just engineered a 1,000-person right-sizing). Imagine how she would react when you tell her you need additional people to carry out PM and other sound maintenance practices. Breakdowns are not okay! Traditionally, maintenance people have believed that breakdowns are okay. After all, that's what we're paid for. The same attitude supports designs that demand constant investment in PM and routine maintenance. This acceptance of the status quo is unacceptable. Breakdowns should be viewed as failures of the maintenance system. Any equipment that needs periodic attention to avoid breakdowns is likewise a failure of design engineering. Where do PM and predictive maintenance fit in the new structure? Organizations spend millions of dollars on PM (preventive maintenance, which includes all predictive technologies, such as infrared inspection and vibration analysis). Do we scrap the hard-won improvements in uptime and reliability gained through the judicious use of PM? The fatal flaw of PM is that it requires a constant investment of labor and materials to maintain the uptime. PM itself never improves the underlying engineering situation. No improvement will ever flow from a traditional PM orientation, because it never addresses the flaws in the design, use or operation of the equipment. What's more, when your company downsizes and your PM crew is laid off and not replaced, reliability and uptime will return to their old frequency. PM does, for a price, increase the life of equipment and decreases the size and scope of failures. The new organization has a place for PM. View it as a station or resting place on the way to maintenance elimination. When you don't have the time, resources or technology to figure out the underlying problem, use a PM approach to reduce your exposure to breakdowns. Also continue PM, along with other methods, where the implications of breakdown are deadly or terribly expensive. Virtually everyone involved in maintenance improves a system at one time or another. Yet until now most people haven't viewed it as their mission! Page 3.

Here's an example of the new approach I'm talking about.

A manufacturer had excessive problems with air cylinders:

1. His calculations showed he was getting only 1 year between rebuilds in his adverse environment. A seal kit cost $30 plus labor and downtime. 2. He instituted a PM system with weekly cleaning and inspections. The PM approach worked, and increased to 2 years. The problem was that he needed people to make all the checks and cleaning. 3. At a local trade show, he saw a new type of seal kit that promised a long life in adverse environments. It cost $85. His tests revealed that the new seal lasted more than 5 years without a PM program! As the new seals were phased in, his maintenance requirement dropped, reliability increased, and the production line was well served by the reduction and eventual elimination of maintenance services. Every maintenance improvement reduces the need for maintenance labor and increases the service level to the maintenance user. The same asset can be successfully maintained by a smaller and smaller crew. Maintenance departments that take this approach will be doing their part to ensure that their

organization survives and thrives.

Noel Wambeck 30th June 1992

OIL PALM MIL MAINTENANCE MANUAL

1

OIL PALM MILL MAINTENANCE MANUAL June 1999 By Noel Wambeck.

STORE AND PARTS MAINTENANCE. General requirements for spare parts store are: q Perfect cleanliness q Perfect order q Routine checking for corrosion. q Routine cleaning and re-treatment.

Sometimes you will require delivery of spare parts for immediate use but frequently order spare parts which are kept in the store for long periods before use. You have the right to receive spare parts which are :

• • • • •

The correct spare parts as specified in your order. In perfect condition. Properly treated and packed for long storage. Properly labeled. Packed in clean, efficient and attractive way.

On receipt of the spare parts, inspect for : 1. 2. 3. 4. 5.

Order supplied as specified Mechanical damage. Water contamination Rust and corrosion Unprotected surfaces.

Damaged or incorrect supply of spare parts may warrant their rejection as unfit for service.


2

1. Order supplied as specified. Each item received shall be checked for correctness against the specified order for quantity, quality, model numbers etc…..

2. Mechanical damage. Report the mechanical damage immediately to the supplier, fabricator, manufacturer or insurance agent for items ordered directly oversea.

3. Water contamination. Immediately remove and discard all wet paper, cardboard, shavings or other wet packing material. Dry the spare parts and provide temporary protection by brushing on dewatering oil or spraying on WD40 dewatering oil. This work should not be delayed and the affected spare parts should not be left wet overnight. It is not advisable to wipe water off such items as roller bearing and gears. It is better to use one or two applications of dewatering oil. The inside treated wrapper of ball bearing should be if possible, dried and reused or replaced by new grease coated paper.

4. Rust and corrosion. Because of insufficient protection and poor packing corrosion will be found to be in progress on many items in every shipment of spare part received. In some cases the corrosion may be slight and in other cases heavy. If not treated properly the corrosion will continue. Temporary protection may be necessary on arrival of the spare parts but complete cleaning and proper protection are absolutely essential to ensure that the corrosion does not continue whilst the spare parts are in stock. Frequently corrosion will be encountered and it is then necessary to remove and arrest the corrosion. In such case each part must be treated according to the nature of the part and the extent of the corrosion. Care must be taken not to spoil the finish or to reduce the size of the part. Abrasives should be avoided. Where possible “JENOLITE” should be used to convert and soften the rust. Rubbing and polishing pads should be used in conjunction with the Jenolite treatment. After the removal of the corrosion the part should be cleaned with mineral turpentine.


3

Where appropriate, zinc chromate primer paint should be applied as a protective. Such treatment is suitable for non working surfaces of shafts which can be easily cleaned before the installation or replacement of the item for use. It has the advantage of a lasting protection under difficult conditions and of being dry and clean to handle. For most other spare parts with rust and corrosion, it is necessary to treat them with deawatering oil within one minute of cleaning them with clean turpentine. The parts should then be drained for from one to eight hours before being treated with one or two coats of Ensis 260. The full process using the special cleaning table are as follows: 1. Wash in first turpentine tray, clean and wash again until all dirt and corrosion is removed ( discard and renew turpentine when necessary.) 2. When part is clean of dirt and corrosion wash in second tray of perfectly clean turpentine. 3. Drain for not more than one minute. 4. Treat in third tray with dewatering oil Ensis 252 5. Drain for one to eight hours. 6. Treat in fourth tray with Ensis 260. Allow to dry for at least 24 hours between each coat. Use only clean material. Use quality clean paint brushes with dewatering oil and Ensis coat oils, never use cotton waste or cloth. For unprotected surfaces : Where such surfaces are not corroded they should be cleaned and treated as for rust and corrosion but without the corrosion removal treatment. Repacking and sealing : Except for large items parts should, after the protective treatment, be sealed in pvc bages suitable for storage. Such works should be carried out on a dry day when everything is warm and when protective coating oils has sufficient time to harden. Every precaution must be taken to ensure that moisture is not sealed in with the spare part. Store shelves should have a cover of pvc sheet to prevent parts from contacting the wood or steel surface of the shelves. Periodic cleaning : Frequent checks must be made to ensure that no deterioration takes place whilst the spare parts are in stock.


4

Retreatment : May be necessary of any spare part which is kept in stock for more than a few months. Ball and roller bearings : May be kept in the store for long periods. They demand a very high standard of protection and even local light staining may be rejected as unfit for service. To meet these stringent requirements meticulous attention must be paid to every aspect of cleaning, protection and packaging. When bearings are received they should be immediately checked for water contamination. If the water has not contaminated the inside wrapping and there is no evidence of staining the damaged packing material should be discarded and the bearing kept under observation for a few days. If no deterioration is apparent and carefull inspection shows that the original protective oil and inside wrapping is in order, repacking is all that is necessary. If there is evidence of staining, whether associated with water contamination or not, the bearing should be immediately cleaned and retreated. Efforts should be made to remove the staining by careful polishing. Bearings that have been cleaned and repacked must be inspected frequently. The periodic inspection of all bearings in stock is necessary.

An example of a spare part Bin card : Good oil palm mill Sdn Bhd.

SPARE PARTS BIN CARD

Example of Bin Card No.

: FRW1.01SP 001 (Weighbridge load cell )

Spare Part Name of manufactured Model / Serial No Location of machine

: Load cell : Avery : : FFB Reception

Local agent Tel : Fax: Parts in stock / Location

: Avery Malaysia Sdn Bhd Email: Contact : : Mill store – Rack 1 / Shelf 3/ Bin 2

Details of movement

Ref No.

In

Out

7 Jun99 Date received 9 Jun99 Work order

GR005 WO201

2 0

0 1

Balance

Value RM.

2 1

660.00 330.00

MACHINERY AND EQUIPMENT LIST.


5

In order to be able to check each piece of machinery and equipment a listing showing each machine and piece of equipment must be made. This listing will be of importance for the rest of the mills operating life span and must be careful and accurately prepared. Usually it will be possible to have the original Master List of Machinery as a guide, but the listing should at least include items as per the following example: 1. Identification Numbers. Establish positive identification of each machine, piece of equipment and by each station or section of the mill and process. Preferrably in the form of a data base on the computer Example : paint or attach code numbers, if these do not already exist, to each; Fruit Reception

-

Weighbridge – 1 Weighbridge – 2 Loading Ramp 1 Cage Transfer Unit 1

= = = =

FRW1.01 FRW1.02 LR1.01 CTU1.01

Listing must be as complete as possible, listing all items in and around the mill that will require some form of maintenance sooner or later, including the buildings, offices, workshops, stores, etc. Add details for each item recorded. Good oil palm mill Sdn Bhd.

MACHINERY & EQUIPMENT LIST

Example Name Type Year manufactured Operational manual Location

: : : : : :

Local agent Tel : Fax: Parts in stock / Location

: Avery Malaysia Sdn Bhd

2.

FRW1.01 (Weighbridge) Avery Load cell 1999 yes FFB Reception

: Mill store – Rack 1 / Shelf 3/ Bin 2

Maintenance Work Orders.


6

Prepare maintenance work orders (job cards) for each item listed, using where possible and available the manufacturers recommendations for maintenance as described in the manuals.

Good oil palm mill Sdn Bhd.

MAINTENANCE WORK ORDER (Job Card)

Work order No :

Date :

Received by :

Attended by :

Machine / Equipment System / Plant Work request :

Time : Start : Completed :

………..FRW1.01 - Weighbridge. ……………..

Manhours:

…………………………………………………….. …………………………………………………….. …………………………………………………….. …………………………………………………….. ……………………………………………………..

Cost of works :

……………………………………………………..

Comments / Notes :

……………………………………………………..

Material / Parts used:

Maintenance checklist : Daily

: q Clean all work surfaces, q Check zero balance, check printer device q Check sump for water and pump

weekly q Clean all moving parts q Check Lubrication oil / grease pivots etc. q Check electrical cables, connections, contactors, Timers, switch gear etc. monthly q Full inspection, issue a full report, enter in history data base for any repairs, parts replaced etc. q Inspect building, roofs, lighting etc. half yearly q Inspect fire prevention / fighting units, safety requirements if so required. yearly q (follow manufacturers recommendation)


7

For more complicated machinery the work orders / job cards need to be multiple and / or in particular sections, i.e.:

Good oil palm mill Sdn Bhd.

MAINTENANCE WORK ORDER (Job Card)

Example as above for work order information with the following additions for electrical à q wiring q motor q switch gear for mechanical à q q q q q q q q

foundation mountings gearbox coupling Belting or Chains Bearings etc., etc. Check for noise, vibrations, overheating, overloading of motors & geardrives etc Check for steam, oil and other liquid leakage in pipe lines. q Check all Instruments and gauges q Check all Amp, kw and hour meters q Check all safety guards on moving machinery

This will form the basis for the “maintenance schedule” which is all important for mill engineers to plan their work load, their maintenance staff requirements, their factory through put (i.e. when machines will be out for maintenance) etc. and can be set out as a basic maintenance (activity) schedule, it must include all machinery and equipment, spaced out over the full working year.

MANNESMANN REXROTH SDN. BHD.

MAINTENANCE OF HYDRAULIC SYSTEMS

CONTENTS.... PAGE

1. Introduction To Maintenance ........................................... 2. Routine Maintenance ......................................................… 3. Filter Maintenance .......................................................…….. 4. Oil Maintenance .............................................................….. 5. General Recommendations For Maintenance ............……… 6. General Trouble Shooting Of Systems ............................…… 7. Maintenance Of Hose Assemblies .....................………….

1.

1 2- 3 3- 5 5- 6 6- 7 7-12 12-17

INTRODUCTION TO MAINTENANCE

1.1.1 Keeping Records To derive the maximum benefit from both routine and unplanned maintenance, it is essential to keep an accurate history of repairs, additions and alterations to the equipment. Observations by operating or maintenance personnel should also be recorded. 1.1.2

Mandatory to any records system is that each note, observation or comment is dated. If the machine record is analysed regularly, certain trends will become evident and the utilization time of the equipment can be planned to include anticipated service and adjustments. External factors peculiar to each installation exert considerable influence on the type of maintenance operations which will be necessary as well as the frequency with which they would be performed.

1.1.3 Records should include, but not be limited to :- A description of any signs of trouble with the equipment. - A description of preliminary investigation and findings. - An explanation of corrective action taken, replacement parts required and duration of down time.

1

MANNESMANN REXROTH SDN BHD

1.2

General Maintenance General maintenance should include examination for signs of problems developing. such as: q q q q q

Excessive noise and vibration - Shocks Discoloured oil Overheating Oil level low Oil leaks

1.2.2

All reports of potential trouble should be recorded, investigated and corrective action taken immediately.

1.3

General Service

1.3.1 Should it be necessary to call for Rexroth Hydraulics service assistance, save time and

money by preparing for the visit:-

1.3.2

q

Thoroughly clean the machine.

q

Have piping diagrams, spare parts information and special tools available to assists our service representative.

Should any part of the system or system components supplied by Rexroth Hydraulics Pty Ltd. be dismantled during warranty period without the written permission and authority of Rexroth Hydraulics Pty Ltd., warranty on the affected item/ shall be voided.

2

ROUNTINE MAINTENANCE….

2.1

Weekly

2.1.1

Check the system’s performance and general condition. Check that the oil level in the reservoir is correct on the sight glass. (Cylinders should be fully retracted when doing this). Check the oil colour as compared to a sample of new oil.

2

MANNESMANN REXROTH SDN BHD

2.1.3

Check reservoir cover, solenoids and pipe connections for leaks and tighten as required.

2.1.4

Check the indicator on filters and replace elements if required. When replacing elements, inspect for tell-tales signs of impending failure eg. metal particles.

2.1.5

Inspect relief valve locks, checking for unauthorized tampering.

2.1.6

Check accumulator precharge (where fitted).

2.2

Annually And/Or Every 20000 Hours Running Time

2.2.1

Check all mounting bolts for tightness. Remove coupling guards from pump/rnotor and check flexible couplings for wear.

2.2.2

Check filler-breather element for cleaniness and replace.

2.2.3

Have a sample of oil in the reservoir checked by a specialized laboratory for size and type of particle contamination. Drain the reservoir if recommended and refill with fresh oil of correct type.

20000 Hours Running Time

Drain the reservoir and remove inspection covers. Thoroughly clean the reservoir interior, filter screen or suction strainer when fitted.

3.

FILTER MAINTENANCE……. General

3.1.1

When the system is installed, it will have been cleaned to Rexroth Hydraulics Pty Ltd standards prior to commissioning. The tolerance of the most sensitive component in the system determines the maximum acceptable particle size of contaminant in the fluid. In any case this is not to be larger than 25 micron. Suitable filtration has been installed to maintain the size and level of contamination in the hydraulic fluid, but the ingress of contamination is relentless, and close attention to filter maintenance is critical. Potential sources of system contamination are discussed below.

3


3.2

Enviromental Contamination Entry Points

3.2.1

Air Breather A poor quality breather allows large airborne particles to be drawn into the system. There have been instances where filter elements have not been changed for years and the element has been found in pieces, giving free access for contaminants through the air intake.

3.2.2

Cylinder Seats

3.2.2

Wiper seals cannot be 100% effective in removing very fine contamination. Dr E. C.Finch of the Oklahama State University has shown that cylinder piston rod seals naturally ingress about one particle over 10 rnicron for each square centirnetre of swept rod area. Wear of seals or wipers can increase this considerably, and in a severe case, 20,000 particles over 10 micron could ingress for large size pistons.

3.2.3

Generated Contamination Contamination is created internally by the day to day operation of hydraulic system. If initial level of contamination is not within acceptable limits, wear will greatly accelerate the build up of generated contamination. Generated contaminants are the product of :1. Component wear due to cavitation and mechanical action. 2. Corrosion on internal surfaces exposed to atmosphere. 3. System fluid breakdown. 4. Bedding in of some components (eg. gear pumps).

3.3

Element Replacement

3.3.1

Filter element replacement is recommended according to the following, and must be carried out before filters reach a bypass condition.

3.3.2

Initial Start Up After initial start up of the new system or after a major overhaul, the filter elements should be replaced after approximately 10 hours of operation and then again after 100 operating hours. More frequent changes are required if filter indicators prove this to be necessary.

4


3.3.3

Subsequent Running After the first three months replace all elements, thereafter at six months intervals (500 operating hours), or more frequently if the filter indicators prove this to be necessary.

3.3.4

Filter Inspection When replacing elements, inspect for tell-tale signs of impending unit failure, such as metal particles.

3.3.5

Filter Indicators Filter indicators will only indicate filter condition while fluid is flowing through the filter.

4. 4.1

OIL MAINTENANCE……. Oil is refined and blended under relatively clean conditions, but it is usually contaminated during transit of storage by one of the following:1. Filling lines contribute metal and rubber particles. 2. Storage drums add flakes of metal or scale. 3. Rusting due to water contamination in metal storage tanks.

4.2

Samples of new oil tested show average counts of 30,000 to 50,000 particles above 5 micron per 100ral with a relatively low silt level, the principle contaminants being metal, silicon and fibres. The use of a filtration unit to transfer oil from the storage tank can remove much of this contamination before the oil reaches the hydraulic reservoir.

4.3

Survey Of Micron Ratings For Various Brands Of Hydraulic Mineral Oils As Supplied In Sealed 200 Litre Drums. Castrol Mobil Caltex Shell N.B.

Normally filtered to 80 micron, but can be filtered to 1O micron on request. Normally filtered to 10 micron (nominal). Normally filtered, but cannot supply information as to particle size. Normally filtered to 40 micron. The Lower Limit Visible To The Naked Eye Is 40 Micron (0. 002 “). 5


4.4

All hydraulic oils have a definite, useful life span. When the fluid has deteriorated to near the danger point, it should be discarded.

4.5

One major cause of short oil life is operation at too high a temperature. This speeds up the oxidation process, which forms acids and sludge in the oil causing rapid wear an corrosion to moving parts in the system.

4.6

Make a visual inspection of your oil weekly. Compare the colour and body with an unused sample of the same oil. A slight darkening is usually not serious, but a deep dark colour or a noticable thickening may indicate a serious deterioration.

4.7

On large volume systems, consult your oil company representative about having a sample tested. On small volume systems, it is cheaper to discard the used oil if there is any doubt as to its purity of cleanliness. .

GENERAL RECOMMENDATIONS FOR MAINTENANCE ….. 5.1

Trouble shoot and clean the unit before disassembly or removal of a component. Perform appropriate tests of the system before attempting repair.

5.2

Clean all assemblies and components prior to removal. Take all precautions necessary to prevent dirt entering the system.

5.3

Before any attempt is made to remove any hydraulic component, make sure that all hydraulic pressure is relieved and the prime mover cannot be started. If the hydraulic system is used for lift devices, these should be secured or in the rest position before disconnecting equipment. Ensure all accumulators are discharged of pressurized hydraulic fluid.

5.4

Label parts and protect precision machined surfaces. Don't mix parts.

5.5

Inspect all parts during disassembly for wear and damage.

5.6

If the system fluid is to be drained and reused, make sure that drain containers are clean and covered when not in use. Return the fluid to reservoir through a filter.

5.7

Clean all metal parts using a suitable solvent prior to re-assembley, and either blow dry with compressed air, or set aside on a clean and lint-ftee cloth to drain until completely dry. Lubricate with clean system fluid during assembly.

6


5.8

Replace all seals, gaskets and o'rings with new items of correct size.

5.9

Apply all repair procedures in a 'commonsense' manner. It is often hard to realise the forces involved in a hydraulic system, or just how quickly these forces will react to the inadvertent disconnection of a hose or the mistaken movement of a control lever.

5.10

If the need should arise to change a valve during service when oil is at high temperature, the unit MUST NOT be switched on as usual, but should be jogged to allow the oil to bring the valve to temperature gradually, thus preventing thermal shock and the possible resulting failure of a new assembly.

5.11

If any pipework is discounted, care must be taken to seal the pipe ends to prevent the ingress of foreign matter. Ensure complete sealing at pipe connections during reassembly avoid leakage of oil, or as in the case of suction lines, leakage of air in.

6.

GENERAL TROUBLE SHOOTING OF SYSTEM…..

6.1

Trouble shooting in hydraulics is a step procedure requiring a logical mind with a sound knowledge of underlying hydraulic principles. If, for example, there is no pressure in the system, either the pump is not producing the required flow, or there is an open circuit downstream of the pump. Start by checking the pump, then the relief valve and then the cylinders, merely following the components as they have been piped up. To fault find easily, one should be familiar with the generating characteristics of the different components used in the system, as well as the hydraulic circuit itself and circuit symbols.

6.2

The following tables may be used as a general guide to spotting problems in a system, but many other unexpected and uncalculated problems can crop up. Even in a simple system it may be necessary to call in a skilled and trained hydraulic technician.

7


6.3

Table I - Noisy Pump

Cause...What To Do... Oil Aeration

Cavitation ( The formalion of vacuum in a pump when it does not get enough oil )

Be sure that the oil reservoir is filled to normal level and that the oil intake is below the surface of the oil. Check pump seals, piping connections and all other points where air might leak into the system. If oil level is low, return line to reservoir may be exposed above the oil level. Check that the suction isolating valve (if fitted) is open. Check for clogged or restricted intake line or plugged air vents in the reservoir. Check strainers in the intake line. The oil viscosity may be too high, check recommendations.

Loose, worn stuck pump parts

Parts may be stuck by metallic chips, bits of lint etc. Products of oil deterioration such as gums, sludges, varnishes and laquer may be a cause of sticking. Return equipment to manufacturer for overhaul.

Inlet filter or strainer dirty

Filters and strainers must be kept clean enough to permit adequate flow adequate flow. Be sure that original filter has not been replaced by one of smaller capacity. Use oil of quality high enough to prevent rapid sludge formation.

Pump running too fast

Determine recommended speed. Check pulley and gear sizes. Make sure that no one has installed a replacement motor with other than recommended speed.

Pump out of line with drive motor

Check alignment. Misalignment may be caused by temperature distortion.

8


6.4

Table 2 - Leakage Around Pump

Cause .. . What To Do Worn shaft seal

6.5

Check shaft seat and other sealed connections for leakage. Replace/ tighten as required.

Table 3 - Pump Not Pumping Cause .. . What To Do Pump shaft turning in wrong direction

Shut down immediately. Some types of pump can turn in either direction without causing damage; others are designed to run in one direction only. Check belts, pulleys, gears, motor connections. Reversed leads on 3 -phase motors are a common cause of wrong rotation.

Intake clogged

Check line from reservoir to pump. Be sure that filters and strainers are not clogged. Check that suction isolating valve (where fitted) is open.

Low oil level

Intake line must be below oil level; If the oil supply is low, less oil will be available to carry away just as much heat. This will cause a rise in oil temperature, especially in machines without oil coolers. Be sure oil is up to recommended level in the reservoir.

,4ir leak in intake

If any air at all is going through the pump, it will be quite noisy, if this condition is allowed to continue, erosion damage to pump will result.

Pump shaft speed too low

Some pumps will deliver oil in a low speed range; others must be operated at recommended speed to give appreciable flow. First determine the manufacturer's recommended speed, then check the speed of the pump, preferably with a tachometer.

Unloading valve (when filled) not operating

High setting on unloading valve. If so, reset of if solenoid unloading type, solenoid control valve may be faulty, ie. spool is jammed by dirt or solenoid is burnt out. Pressure switch may not be operating.

Oil viscosity too high

Check oil recommendation. If uncertain of the viscosity of the oil in the system, it may be worthwhile to drain the system and refill with oil of the correct viscosity. 9


6.5

Table 3 - Pump Not Pumping (Con't ...)

Cause.. What To Do .. Relief valve setting low

6.6

Check setting of relief valve and compare with specifications. The setting may be too low because the load has increased. Discuss with manufacturer before adjusting to a setting other than specified on drawing.

Table 4 - Overheating Of System. Cause-.. What To Do .. Internal leakage too high

Check for wear and loose packings. Oil viscosity may be too low, check recommendations. Under unusual working conditions the temperature may increase enough to reduce viscosity of recommended oil too much. Check with manufacturer if this problem arises. Return equipment to manufacturer if there are signs of excessive wear.

Incorrectly sized Check manufacturer's recommendations. installation piping

Oil Cooler

On any system equipped with an oil cooler, high temperatures may be expected. If temperatures normally high, they will go even higher if oil cooler passages are clogged. In the case of water cooled heat exchangers, check for adequate flow of coolant or any presence of scaling. In the case of air-blast coolers, check fins for cleanliness.

10


6.7

Table 5 - Insufficient Pressure To Operate System. Cause-....What To Do Relief valve setting too low

If the relief valve setting is too low, oil may flow from the pump through the relief valve and back to the reservoir, across the open circuit without reaching point of use. To check relief setting, block the discharge line beyond the relief valve and check line pressure with a pressure gauge. The system may-overheat if this happens.

6.8

Relief valve

Look for dirt or sludge in the valve. If the valve is dirty, disassemble and clean. A stuck valve may be an indication that the system contains dirty or deteriorated oil.

Broken, worn or stuck pump parts

Install pressure gauge and block system just beyond the relief valve If no appreciable pressure is developed and relief valve is OK, Look for mechanical trouble in the pump. Contact manufacturer for replacement pump.

Table 6 - Erratic Action.

Cause..... What To Do Valves, pistons etc stuck- or binding

First check suspected part for mechanical deficiencies such as misalignment of a shaft, worn bearings etc. Then look for signs of dirt, oil sludge, varnishes and laquers caused by oil deterioration. Mechanical defficiencies can be rectified by replacing worn parts, but keep in mind that these deficiencies may be caused by the use of incorrect oil.

Sluggishness when a machine is first started

Sluggishness is often caused by oil that is too thick at starting temperatures. If this can be tolerated for a short period of time, the oil may thin out enough to give satisfactory operation once operating temperature is reached. If the oil does not thin out, or if the surrounding temperature remains relatively low, it may be necessary to switch to an oil with lower viscosity. Under severe conditions immersion heaters may be used to preheat the oil. If speed is too low, look for trouble in the drive motor.

11


oil viscosity too high

Mechanical trouble (broken shaft or loose coupling, etc)

6.9

If oil viscosity us too high, some types of pumps cannot pick up prime. Drain the system and fill with oil of the correct viscosity. Mechanical trouble is accomplished by noise the source of which can be easily located.

Table 7 - System Operates Slower Than Normal. Check The Following For Possible Causes:1.

Check the main system relief for partial unloading due to possible malfunction or setting too high.

2.

Check if internal leakage within the pump is excessive.

3.

Check if leakage within motor is excessive, ie. either port to port or crankcase leakage.

4.

Check that control valves are functioning correctly.

5.

Check condition of suction filters.

7.

MAINTENANCE OF HOSE ASSEMBLIES ….

7.1

There are a number of ways a high pressure hose can fail. The experienced service technician has probably seen most of them, but thought no more of it. As each of these visible symptoms of hose failure is the result of a specific cause, the service technician is remiss if he fits a replacement hose without looking deeper into the problem.

7.2

Every failure should be evaluated, even if the conclusion is that the hose lasted as long as could be reasonably expected. A few minutes spent on inspection and analysts of the failure can often save a lot of money in repair bills as well as preventing equipment downtime at an inopportune moment.

12


7.3

The symptoms of hydraulic hose failure as outlined fall into one of five categories: 1. 2. 3. 4. 5.

7.4

Improper application of the hose. Improper installation External damage Faulty equipment Faulty hose -

Analysis Of Failures.

7.4.1 The Hose Inner Liner Is Very Hard And Has Cracked.

Heat has leached the plasticisers, which give the hose its flexibility, out of the inner lining. Aerated oil cause oxidation in the inner liner. This reaction will make it harden. Any combination of oxygen and heat will greatly accelerate this hardening process. Cavitation in the inner lining has the same effect. 7.4.2 The Hose Has Cracked Both Externally And Internally, But The Elastometric Materials Are Soft And Flexible At Room Temperature.

The probable reason for this was intense cold while the hose was flexed. Most standard hoses are rated at 40'F, military hoses are rated at - 60'F, while teflon hose is rated at - 1 00' F. 7.4.3

The Hose Had Burst, And Examination Of The Wire Reinforcement After Stripping Back The Outer Cover Reveals Random Broken Wires Over The Entire Length Of Hose.

This indicates a high frequency pressure impulse condition. S.A.E. impulse test requirements for a double braid reinforcement are 20 million cycles at 133 % of recommended working pressure. The S.A.E. impulse test requirement for a four spiral wrapped reinforcement hose are 400,000 cycles at 133% working pressure and at a temperature of 200'F.

13


7.4.4

The Hose Has Burst But There Us No Indication Of Multiple Broken Wires Or The Hose May Have Burst In More Than One Place. Pressure exceeded the minimum burst strength of the hose. Either a stronger hose is needed or the hydraulic system has a malfunction which is causing unusually high pressure conditions.

7.4.5

The Hose Has Burst, And Examination Indicates That The Wire Braid Is Rusted And The Outer Cover Has Been Cut, Abreeded Or Deteriorated. The only function of the outer cover is to protect the reinforcement. Elements that could destroy or remove the outer cover include - abrasion, cutting, battery acid, steam cleaners and chemical cleaning solutions, etc. Heat and extreme cold must also be considered. Once the cover protection is gone, the reinforcement is susceptible to attack from moisture or other corrosive agents.

7.4.6

The Hose Has Burst On An Outside Bend And Appears To Be Ellipticle In The Bent Section. In The Case Of A Pump Suction Line, The Pump Is Noisy And Very Hot. The Delivery Line On The Pump Is Hard And Brittle. The bend radius of the hose is less than the minimum specified. Check the minimum bend radius for that particular hose and make sure that the application is within specifications. It is permissible to reduce the minimum bend radius only when the pressure is below that specified. In the case of the pump suppply line partial collapse of the hose causes the pump to cavitate, creating both noise and heat. This condition is serious and will often result in a catastrophic pump failure.

7.4.7

The Hose Has Flattened Out In One Or Two Areas, Appears To Be Kinked And Has Burst. It Also Appears To Be Twisted. Torquing of hose or reinforcement layers has weakened the hose allowing it to burst through the enlarged gaps between the braided plaits of wire strands. There should never be a twisting force on any hydraulic hose.

14


7.4.8

The Hose Inner Liner Has Broken Loose From The Reinforcement And Filed Up At The End Of The Hose. In Some Cases It May Protrude From The End Of The Hose Fitting. High vacuum, or wrong hose for vacuum service. No vacuum is recommended for double wire braid, four and six spiral wire hose unless some sort of internal support coil is used. Even though a hose is rated for vacuum service, if it is kinked, flattened out or bent too sharply, this' type of failure may occur.

7.4.9

The Hose Has Burst About 150 To 200 mm From The End Fitting, The Wire Braid Is Rusted. There Are No Cuts Or Abrasions On The Outer Cover. Improper assembly of the hose end fitting allowed moisture to enter around the edge of the outer shell. Moisture wicked through the reinforcement and heat generated by the system drove it out around the fitting area, generally from 15 0 mm to 200 mm away. Trapped between the inner and outer cover, it caused severe rusting of the wire reinforcement.

7.4. 10 Blisters In The Outer Cover Of The Hose. Oil Will Be Found In Them. A minute pin hole in the inner lining allowed the high pressure oil to seep between it and the outer cover. Eventually it formed a blister where the cover adhesion was the weakest. Insufficient lubrication of the hose and a screw fitting can cause this because the dry inner liner will adhere to the rotating nipple and tear enough to allow seepage. Faulty hose can also cause this condition. 7.4.11 Fitting Blow Of The End Of The Hose. 1.

The wrong fitting had been installed on the hose. Check specification with regard over or under crippling.

2.

On a crimped fitting, and incorrect machine setting may have been used resulting in over or under crimping.

3.

The outer socket of a screw-together fitting for multiple wire braid hose may be worn beyond its tolerance. These sockets should be discarded after being re-used about six times. The swaging dies used for a swaged hose assembly may be wom beyond tolerance, or the fitting may have been applied to the hose incorrectly.

4. 5.

The hose may have been installed without leaving enough slack to compensate for the possible 4% shortening that occurs when pressure is applied. This will impose a great force on the fitting.

6.

The hose may be out of tolerance. Refer to S.A.E. specifications.

15


7. .4.12

The Inner Liner Of The Hose Is Badly I)eteriorated With Evidence of Extreme Swelling. In Some Cases The Inner Liner May Be Parttially Washed Out. This inner liner was not compatible with the fluid being carried. Even if compatible, the addition of heat causes inner lining deterioration. Make sure that operating temperatures, both internal and external do not exceed recommendations.

7.3.13

The Hose Has Burst. The Cover Is Badly Deteriorated And The Surface Of The Rubber Is Grazed. This was simply old age. Crazed appearance was the effect of weathering over a period of time. It is usual for hose manufacturers to brand their hoses to show the date of manufacture. This should be checked to confirm your findings.

7.4.14

Hose Is Leaking At The Fitting Because Of A Crack In The Tube Adjacent To The Braze On A Split Flango Head. Because the crack is adjacent to the braze and not in the braze, this was a stress failure. It was brought on by a hose trying to shorten under pressure and with insufficient slack to do so. Cure is by lengthening the hose assembly or changing the routing to relieve stresses on the fitting.

7.4.15

A Spiral Reinforcement Hose Has Burst And Literally Split Open With The Wire Exploded Out And Badly Entangled. The hose was too short to accomodate the change of length that occurs when it is pressureised.

7.4.16

The Hose Has Badly Flattened Out In The Burst Area. The Inner Lining Is Very Hard Downstream Of The Burst, But Appears Normal Upstream Of The Burst. The hose was kinked by bending it too sharply or by squashing it so that a major restriction was created. Because of the restriction, pressure decreased to the level where cavitaion occurs. This condition causes heat and rapid oxidation to take place, hardening the inner liner of the hose downstream of the restriction.

7.4.17

The Hose Did Not Burst, But Leaks Profusely. A Bisection Of The Hose Revealed That The Inner Liner Has Been Gauged Through To The Wire Braid For A Short Distance (50 mm Or So). Erosion of the inner-liner has taken place. A high velocity needle like stream emitted from an orifice and impinging at a single point on the hose inner liner will hydraulically remove a section of it. Be sure that the hose is not bent close to a part that is orfficed. ffigh velocities and suspended particles in the fluid can cause considerable erosion in bent sections. of the hose assembly. 16


7.4.18

The Hose Fitting Has Pulled Out Of The Hose And The Hose Has Stretched. This May Not Be A High Pressure Appllication. Insufficient support of the hose. It is necessary to support long lengths of hose, especially if they are vertical. The weight of the hose in addition to the weight of fluid it carries is imposed on the hose end fittings. The hose should be supported at points along its length to prevent this from occurring. *****************************************************

17

Digester – Use and Maintenance

EFFECTIVE USE OF THE DIGESTER The degree of digestion depends mainly on the level in the digester as most of the digestion takes place at the bottom of the digester due to the higher pressure. A small reduction in the level of fruit in the digester results in a proportionately larger reduction in digestion. For optimum results in digestion an automatic control level device to ensure that the digester is kept full should be incorporated in the process design. The mesh in the digester should be maintained at 95°C. The digester should be installed with equipment such as the temperature control valve for steam injection to maintain the temperature at 95°C. The addition of steam to mesh immediately before it enters the press is advantageous. Raising the temperature at this stage reduces the viscosity of the oil and moisture that assists extraction. Allowing the temperature to rise to 100°C interferes with the proper digestion of the fruit. The sides of the digester should be insulated along the entire length of the digester, if this is done, direct steam injection will be reduced to the minimum. The addition of water in any form before pressing should be avoided as this interferes with good digestion and carries off fibre and dirt to the clarification station. Bottom digester drainage or drainage from the side of the feed chute should not be permitted. This practice causes fibre and dirt ( NOS) to be carried to the clarification section and of course reduces the percentage of fibre in the cake in the press. One of the reasons for the excellent performance of the screwpress with modern TENERA material is the higher percentage of fibre which is present. The spare parts list and drawings for the digester are enclosed in the appendices.

1


2

DIGESTER OPERATING INSTRUCTIONS AND SPARE PARTS. The digester is an intrinsic part of the continuous twin screwpress. It is matched in every respect to the screwpress and it is supplied as a complete extraction unit. This extraction unit is unsurpassed in oil extracting efficiency and in continuous trouble free operation. For some years manufacturers produced a very efficient spur gear drive that displaced the less efficient and more cumbersome combinations with belt drives. More recently they have incorporated a special gear reducer drive which further increases the reliability of the drive and reduces the long term maintenance cost for only a very small increase in power consumption.

1.

TYPES OF DIGESTERS

Manufacture digesters ranging from 600 litres to 3,500 litres and exceptionally to 5500 litres, incorporating then a fruit reserve. The digesters commonly used, matching the twin screwpress, are the 2,800, 3,200 and 3,500 litres models. The digesters are supplied either with wear rings in front of the arms or more frequently with complete liners. The standard digesters are supplied either with a steam injection device or less often with a steam jacket. (3 bars.g or 42—45 psi). The digesters can be fitted with a stainless steel liner and a stainless steel bottom instead of mild steel parts. Other optionals for the digesters are • temperature regulator • hydro-f low coupling slip ring motors • rotobindicator (level indicator) • hour counters • various types of control panels: • for digester alone • combined for press & digester


2.

3

NORMAL OPERATION

The digester is supplied fitted with four sets of digesting arms and one set of expeller arms. In practice it is usually only necessary to use three sets of digesting arms, It is normal to remove the top set and keep them in stock as spares. Over digestion is undesirable and completely unnecessary for the proper use of the extraction unit. In this respect it is worthwhile to note that the immediate result of over digestion is: a) b) c) d)

to increase the iron contamination of the palm oil, to increase the clarification loss, to increase the upkeep cost, to increase the power consumption.

Where satisfactory results can be obtained by the use of only three sets of digester arms this should be done. For normal operation the digester should be kept completely full at all times. The digester temperature should be kept at 95° C. Some customers find it advantageous to work at temperatures of between 950 C and 100°C. The steam valve to the digester steam jacket should be kept fully opened during the operation of the digester and the temperature of the fruit in the digester should be adjusted by controlling the steam to the live steam jets. There are two valves connecting the bottom of the digester for bottom oil drainage. Both valves should be checked from time to time to ensure that they are not blocked. In general it can be said that bottom digester oil drainage tends to directly increase clarification difficulties and at the same time introduce the bad effects of over digestion. When there is excessive oil visible at the digester chute window a limited amount of bottom drainage is desirable. Such drainage should not be so great that no surplus oil is seen at the window. In this respect is should be borne in mind that excessive bottom drainage is sometimes the result of operation at too low a temperature. Low temperature operation impedes the proper passage of the oil through the screwpress cage and strainer. The digester should never be left full overnight.


3.

4

BEFORE STARTING

It is important to check the following points before starting the digester: • The oil level should reach the half way mark of the oil level sight glass of the worm gear casing. Approximately 9 galls (41 litres) of Macoma 7S lubricating oil is required. This should be poured in through the top filling hole. • During the filling operation the oil drainage plug should be removed and a sample oil taken to check for dirt or water within the casing. • After ensuring that the fuses are removed the motor coupling should be rotated by hand to ensure that the mechanical system is free from obstruction. • The motor should be switched on and off briefly to check that the rotation of the digester arms is anti-clockwise when viewed from the top.

4.

WHEN FIRST STARTING

It is good practice for the first one week of operation not to fill the digester beyond the half way level. When starting a new extraction unit care should be taken not to leave the digester partly filled over night or during prolonged stoppages. The digester temperature should be maintained between 90°° C and 95°° C.

5.

MAINTENANCE

5.1 ELECTRIC MOTORS AND STARTERS The recommendations are given separately according to the make of the motor.

5.2 V-BELT DRIVE Keep the belts and pulleys free of oil and dirt. Ensure proper tension of the belts and avoid excessive slipping. Ensure proper alignment and parallel running of the two pulleys.


5

5.3 SPUR GEAR DRIVE The spur gear drive can give many years of trouble free service but it is absolutely essential to employ a high standard of fitting when replacing spare parts. Particular attention must be paid to the second middle shaft. A very high standard of fitting is required to ensure a perfect fit of the shaft and key. Should the running of the gear become noisy it will be because this key is slack. Continuous running under this condition will of course damage all the gears.

5.4 WORM DRIVE It is recommended that the oil be changed 12 days alter the first week of operation. The second oil change should be made after a further 400 hours of operation. Subsequent oil changes should be carried out every 3,000 hours. Absolute clean lines is essential and it is important to prevent any foreign matter from entering into the interior of the gear.

6.

DISMANTLING INSTRUCTIONS

It is recommended that the gear reduction drive unit should not be dismantled unless it is necessary for the replacement of a worn part. The digester arms and ejector arms can of course be readily removed without disturbing the rest of the digester. The tightness of the bolts holding the digester arms and the expeller arms should be checked at regular intervals. The main digester shaft will give many years of trouble free service. It should not be removed unless necessary. When it is necessary to remove the shaft the digester arms should first be removed and then the top split coupling should be opened, It will then be a simple matter to lift the shaft out of the digester through the opening opposite the fruit entry opening.

6


7.

LUBRICATION DATA

a) gear

BP

SHELL

Qty (litres) Intervals

ENERGOL GA 425 EP

MACOMA 75 1

35

Yearly

b) hydro-flow ENERGOI. HL 40

TELLUS T15

10

Yearly

c) lubricators

ALVANIA 3

—

Weekly

ENERGAEASE LS 3

SIDE AND TOP VIEWS OF A TYPICAL DIGESTER.


LIST OF SPARE PARTS FOR UDW TYPE DIGESTERS WITH CAPACITY FROM 2800, 3200 AND 3500 LITRES.

Part No

Qty

Spare part

28 32/1 35

1

Cylindric container

28/2

1

Temperature gauge

28 32/3 35

1

Cover and insulation

28 32/4 35

1

Steam piping

28/5

3

valves

28/6

1

Flanged T-piece

28/7

1

Steam trap

28/8

1

Pressure gauge with three-way-valve

28/9

1

Safety valve

28 32/10 35

1

Main shaft with nut

28/11

1

Pivot

28/12

1

Sleeve

28/13

1

Oil seal 60/80 x 10

28/14

1

Cover

7


28/15

1

Intermediate pipe

28/16

3

Intermediate pipe

28/17

4

Intermediate bipartite digesting arms

28/18

1

Base digesting arm

28/19

1

Base plate with seals

28/20

1

Bottom wearing ,Pate

28/21

1

Discharge cock 4

28/22

1

Discharge cock 2

28/23

1

Wear jacket

28/24

I

Wear jacket

28/25

1

Chute

28/26

1

Flat iron frame

28/27

1

Cover

28/28

1

Sight glass (Control opening)

28/29

1

Gasket 535/380 x 2

28/30

1

Gasket4lo/310x I

28/31

I

Gasket3lo/210x3

28/32

1

Shaft with fixing pins

28/33

1

Pinion

28/34

1

Rack valve

28/35

2

Flanged bearing with oil seal

28/36

2

Check ring

28/37

1

Chain wheel

8


28/38

1

Chain

28/39

1

Steam piping

28/40

1

Valve ½ “

28/41

4

Injectors

28/47

1

Split coupling (standard version)

28/48

1

Air vent

28/56

1

Hydro-flow coupling one side nave (standard version)

28/60

1

Coupling (special version) hydro-flow coupling;

28/61

1

double side nave (special version)

 October 1990 Noel Wambeck

9

TWIN SCREW PRESS

1

TWIN SCREW PRESS

2

When ordering spare parts please always state the following basic information in all your communication to facilitate a speedy delivery of your order. Order number ……………………………….. Date of order ………………………………… Press serial number ………………………….. Year of manufacture ………………………… BASIC SPECIFICATIONS : Item

P15 Twin Screwpress for the extraction of Crude Palm oil.

Electric motor

37 kw foot mounted TEFC 760 rpm 1 min. 3 phase AC 415 volts 50 Hz

Worm screw

305mm dia. X 1200 mm L. Feed section pitch 270 mm Extraction section pitch 190 root 100 mm dia shaft.

Hydraulic unit

BBC motor type HEUC 90S6 1.1 kw 910 rpm 1 min. 230 / 415 volts 50 Hz.

Capacity

14 - 16 tons FFB per hour. 32 - 40 amps loads

Screw speed

10.6 rpm = 200 mm dia pulley 12 rpm = 170 mm dia pulley

Oil Loss

Oil loss in fiber of less than 7% Oil 1 NOS ( on dry basis)

Broken nuts

Less than 7% on sample or 12% broken nuts to total nuts.

TWIN SCREW PRESS

3

INSTALLATION The press is supplied complete and mounted on a steel frame. There is no particular problem in installing the Usine de Wecker screw press. Consideration must be given to the local site conditions ease of maintenance and the proper location of the feeding and discharge points. Care should be taken not to put undue strain on the press body by distortion of the base plate as the result of bolting down to an uneven surface.

BEFORE STARTING It is important to check the following points when first starting the screw press. 1. The oil level should reach the middle of the oil. Level sight glass of the worm gear casing. The oil should be poured in through the top inspection cover hole. (Care being taken not to drop the cover screws or other objects into the gear case).

2. The oil level in the forward spur of the spur gear casing should reach the middle of the spur gear casing oil level sight. Total oil quantity for the gear housing: Approx. 90 litres (Approx. 20 gal.) Recommended oils: see page 25 3. The cover removed for the filling should be checked for tightness after replacement. Any excess oil may be drained through the drain cocks. There is one cock for each of the two cases. The two case spaces are connected. - Oil change and cleaning of The main gear box, in which the spur gear pair and the worm gear set have connected oil chambers. - After completion of the running - in period (that is to say after approx. 250 to 500 operating hours) the oil must be changed for the first time. - The oil should be drained immediately after stopping the drive while the oil is still warm. - The case should be thoroughly flushed with light flushing oil. Do not use petroleum, kerosene etc. - Subsequently oil changes should be carried out after 2000 to 4000 operating hours depending on the load on the gear set -but the time intervals should not exceed 18 months.

4. The grease lubricators at each end of the worm drive shaft ( 1002 ) should be checked.

TWIN SCREW PRESS

4

5. The grease lubricators on the hydraulically controlled cone shaft ( 1170 & 1171) should be checked.

6. The hydraulic system should be checked to ensure that it is perfectly clean and free from dirt and water. A similar cheek should be made of the containers and equipment used for filling the hydraulic oil. Approx. 30 lit. (6,9 gal.) of SHELL TELLUS 100 (or similar) hydraulic oil is required.

7. A visual check should be made to ensure that all bolts are secure and that the press is free from obstructions.

8. After ensuring that the fuses are removed the press screws should be rotated by hand by rotating the driving pulley.

TWIN SCREW PRESS

5

POWER AND CONTROL UNIT Operating Instructions.

A. Starting. 1. First check the oil level in the tank. The quantity of hydraulic oil required is about 30 litres. Viscosity of oil: ISO VG 100. (e.g. SHELL TELLUS 100 ) A combined oil temperature and oil level indicator is fitted to the tank.

2. After starting the press, the hydraulic pump is put into operation through a manual switch. Make sure the pump rotates in the same direction as the arrow.

3. The lever of the four-way valve should be set to "backwards" position. The cones will then move backwards . 4. As soon as the press cake is coming out of the press, set the lever to "forwards" position, and leave it so all the time.

B. Running 5. The necessary hydraulic pressure is adjusted by turning the control knob of the relief valve. The optimum working pressure has to be determined empirically (through oil/fibre loss and kernel breakage tests), according to local conditions. Maximum allowable pressure: 130 bar.

6. The hydraulic pump must run continuously, and should never be stopped for any reason.

7. Check the oil temperature from time to time. Maximum allowable temperature: 90° C.

8. In case of emergency (e.g. hydraulic pump failure) ' set the lever To "neutral" position (middle position). 1n that case, the cones are in locked position.

TWIN SCREW PRESS

6

C. Stopping 9. Stop the press.

10. Set the lever to "Backwards" position

11. Stop the hydraulic pump,.

D. Oil change The oil should be replaced for the first time after 1000 operating hours at the latest, followed by further oil changes about 2000 operating hours. The used oil should be emptied completely and residues carefully removed.

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7

THE OPERATION, ATTENDANCE AND MAINTENANCE OF HYDRAULIC PUMPS AND HYDRAULIC MOTORS. 1. General Good working of pumps and motors is guaranteed in case instructions, listed data and agreements are strictly observed. Avoid penetration of dirt and foreign matters of any kind. Hydraulic fluids to comply with recommendations No. SE 30. The following hints are based on CETOP recommendations (RP 12 H and RP 13H).

2. Mounting 2.1.

Flushing: Before mounting, residues of corrosion preventatives and dirt of any kind will have to be removed by flushing with the hydraulic fluid to be used.

2.2

Mounting: Tension-free mounting of unit, pipes and driving units imperative. Special data (torque of screws e.g.) are to be observed. Couplings and gears to be handled with care.

2.3

Waste oil pipe: Shaft seals of normal motors relieved by nuts. In case pressure inlet and motor outlet is more than 2 bar waste oil pipe is necessary. Pipe must be sufficiently large and should end in tank below fluid level so that unit remains filled. Siphon-effect in tank must be avoided.

2.4

Pump suction line: Must be laid with care. Under pressure including losses in filters or valves must not be surpassed. Shut-off valves must be protected against in-advertant closing. Air must not penetrate. Screwings to be sealed carefully.

3. First taking into operation 3.1.

Straightening nut: Please check above all straightening out of coupling, eliminate transport and mounting mistakes.

3.2

Electrical supply : Please check unit values.

3.3.

Direction of rotation: pumps and motors must operate in the given direction. Reversing will have to be effected in our works. Checking of direction with separated coupling or by switching drive on and off. Pump must be filled but not charged. When checking direction of motor, control device must be operated.

TWIN SCREW PRESS

8

3.4.

Filling: Normally, when taking into operation, filling of pumps not necessary. Avoid dry operation.

3.5

Start: Pumps and motors to run at first without charge. Shut-off valves will have to be opened. Valves in pressure line must be in neutral position resp. relief valves set at lowest pressure. Motor must repeatedly be switched on and off as long as good functioning is obvious. Charge can be increased gradually up to the rated value.

3.6.

Loading: When taking into operation assure that suction line is kept sufficiently below the fluid level, and that with the unit filled and the cylinders extended.

3.7.

Pressure limitation: Pump must be secured by a pressure relief valve installed near the discharge connection. With hvdromotors, secondary protection of motor circuit may be necessary. When taking into operation relief valves must be set at the lowest value. Then adjust to the mas. value and assure good functioning.

3.8.

Temperature: After having reached the operating values, the tempera-lure of the unit, especially that of the bearings and shaft seals, has to be checked. Bearing temperatures, observed at the surface, may exceed the oil temperature by 10 °C.

4 . Maintenance 4.1.

Frequency : Generally, hydro-gear pumps and motors need no attendance .,When attending the hydraulic unit the following points should, however, be checked.

4.2.

Straightening out: check coupling, screws and connection

4.3

Performance: The volumetric efficiency indicates the state of the pump. Deviations from the original stroke times and spreads should be observed. Deviations >10% necessitate close examination.

4.4

Filtering: Filter ( esp. suction filters) are necessary, for the protection of pump and motor. Please check according to quantity of dirt.

TWIN SCREW PRESS

9

OPERATION OF THE SCREW PRESS After having made the checks under the heading of the BEFORE STARTING instructions proceed as follows: 1. Ensure that the electrical system is in order and the trips and overloads are in working order. The overloads should initially be set to trip at well below full load. Regular checks should be made to ensure that the trips work properly and that the overloads are correctly set. Attention to this simple detail can avoid expensive interruptions of production. 2. Regular checks should be made to ensure that the slipping clutch slips in the event of an overload. (see special attached instructions for the setting of the clutch). Do riot rely on only the clutch or only the electrical overloads they should both be kept in perfect working order. The time required for this is small. 3. Ensure that the digester is not left full overnight. Start the digester arms when the digester is empty and start filling with hot fruit. The digester steam jacket should always be on steam. Live steam should be added to bring the temperature of the mash to between 95oC and 100oC. Excessive bottom drainage of the digester should not be necessary (in most cases it is undesirable). 4.

When the digester is over half full it is in order to start the screw press. To do this start the press motor and open fully the digester feed chute. The hydraulically controlled cones should be manually controlled until the press cake is of a satisfactory condition. Automatic control should be achieved within a few minutes. The object of the initial manual control is to prevent the passage of any oily cake into the cake breaker heater conveyor or the jamming of over-dried cake in the press.

5. The operator should close the cones to start the pressing process and then open them to allow full cake flow. The cones should then be slowly closed to obtain the required balance of dry fibre without too high a broken nut content. (Broken nuts in themselves are not important when the nut recovery system has a facility for their recovery but crushed kernels are always to be avoided). 6. It is necessary to have a supply of hot water ( say 95°C ) at the water feed pipe (1157) The water passes over the outside of the cage carrying with it the crude oil. The supply of water should be In the order of' 1,800 litres or 400 gal. per hour for a throughput of 10 ton ffb per hour The correct adjustment will be made to correspond with the proper operation of the clarification plant. 7.

Where it is provided, the auxiliary steam feed pipe to the top of the inlet end of the press screws should be adjusted so as to provide maximum heating without excessive emission of steam from the discharge openings of the press. Different fruit conditions will result in different motor loads for given cone pressures.

TWIN SCREW PRESS

10

MAINTENANCE

GENERAL The following instructions are a general guide. Clearly the adopted system of maintenance must suit the, individual requirements of' the palm oil factory as a whole. The attention given to the screw press and digester match that given to other important equipment in the factory. It, is certainly not the intention of' an impossible or expensive maintenance programme. On the contrary it is our aim to provide machines which are adequate for the conditions which prevail in oil palm mills. Our experience is that the standard of operation and upkeep is generally good and we only include the following routine instructions in the hopethat they may be of assistance where the engineer wishes to have something at hand to pass on to his workshop. There are no major pitfalls and we do not expect trouble. If however trouble is encountered or if there is any special problem the Usine de Wecker service is available and anxious to its assistance. It would not be out of place here to also add that our programme of improvement and development requires that we always listen and he ready to learn.

ELECTRIC MOTOR STARTERS When correctly installed and used the modern electric motor is a reliable piece of equipment with a life of many years. The trend toward pushbutton and automatic control has introduced complications into control gear and burn out of a motor is more likely to occur due to a fault in the control gear than to one in the motor itself. It is important that the control gear be properly installed and maintained. This entails periodical internal inspection so that any developing defects can be found and rectify in time to avoid failure. The motor starter should be fitted in a clean dry accessible position, where it is free from vibration which might result in undue wear of its moving parts and premature tripping. if required the starter can be operated by a remote pushbutton switch. The coil operated starter has the advantage that an emergency pushbutton switch, connected in series with the coil can be of a type which be locked out, thus preventing the motor being restarted until the button has been reset. Control gear should be keptclean externally; this applies particularly to ventilating openings.

TWIN SCREW PRESS

11

SAFETY PRECAUTIONS Protection against fire and electric shocks depends on the casings of the control gear being well earthed. Conduits should be kepttightly connected to all such gear, as should metallic cable sheathings and earthing conductors, to maintain the connections at low resistance. Before opening the control gear and touching any contacts the gear should be isolated from the supply. When a circuit is isolated b.\, removing the circuit fuses they should be held b.y the man in charge of the operations. An additional safeguard is to replace the fuses ~-,dummy unloaded fuses. A warning notice should be posted on the switch. The circuit should be tested by means of a lamp or other service to ensure that the circuit is dead. The testing device should itself be tested on a live supply before and after Testing for effectiveness.

INSULATION AND CONTACTS The insulation of the control Scar must be kept clean in order to avoid tracking and short circuiting. Any carbon or metal deposit on the insulation should be carefully removed. The contacts of the motor starters meet special attention since defective contacts may be subject to cumulative burning, resulting in burn out of' a motor windings due to open circuiting of one phase. Adequate pressure must be maintained on contacts, otherwise they may become welded -together so that -stop buttons and protective devices may be unable to release the gear in an emergency . Silver and silver faced contacts may blacken in service but normally should not be cleaned as silver oxide is good electrical conductor. They should be replaced when worn to about two thirds of their original thickness. Burnt or pitted copper contacts may be dressed with fine file, but care should be taken not to alter the profile of the contact. Badly worn or burnt contacts should be replaced.

UNDER VOLTAGE RELEASES The importance of the under-voltage release is not always fully- appreciated. Its primary function is to protect personnel against unexpected restarting of a motor when the supply is resumed after an interruption.

TWIN SCREW PRESS

12

It should trip the starter if the voltage falls below about 85 per cent of normal. This release is also the means whereby the motor is stopped by the pushbutton switch or by the overload released under faulty conditions. The operation of this important device is tested each time an electrical stop switch is pressed to stop the motor. Faults which may prevent the under-voltage release from tripping the starter are wear, faulty adjustment, weak or broken springs rough contact, an accumulation of dust or other foreign matter on the working parts, or the pressure of oil or matter on the poles of the electromagnet.

TWIN SCREW PRESS

13

OVERLOAD PROTECTION A very high proportion of breakdown can be averted by periodical inspection. There are however accident that happen which are difficult to anticipate. It is most desirable therefore that the overload releases be set at value which will protect the motor and call attention to such faults by tripping the starter. The connections of directly heated bi-metal strips and the heating elements of indirectly heated strips should be kept tight. Heating at a faulty connection may be transmitted to the bi-metal strip and cause premature tripping.

FUSES Fuse contacts should be kept clean and have adequate pressure. It is important that the same size of fuse be used in each phase of a set protecting the three phase motors.

RECOMMENDED CHECK LIST. a) Regular inspection at a maximum interval of once a week b) Checking of operation of overloads and trips once a week c) Checking of screws and nuts for tightness once a month d) Megger testing once a month e) Cleaning as necessary.

CONNECTIONS AND CONTACTORS Connections should be checked to ensure that they are clean and tight. Screwed or bolted connections that are subjected to vibration should be secured with spring washers or loch nuts. A faulty connection may overheat.

Discoloured connections should he investigated

Foreign matter on the pole faces of the electromagnetic contactors may result in chatter or cause the contactor to stick closed even when the coil is de-energised. These parts should be kept scrupulously clean.

TWIN SCREW PRESS

14

ELECTRIC MOTORS Once a week clean the outside of' the motors to ensure proper cooling. Once a month check screws arid nuts for tightness (both electrical & holding down bolts) Where grease points are provided do not grease more than at the interval required by the lubrication or name plate Intervals of 5,000, 7,000 and 8,000 hours are common. Where grease points are not provided the renewal and of the grease should be accompanied by a complete inspection and cleaning of the motor.

V-BELT DRIVE Keep the belts and pulleys free of oil and dirt. Ensure proper tension of the belts and avoid excessive slipping. Ensure proper alignment and parallel running of the two pulleys.

SLIPPING CLUTCH It is important to ensure that lubricating oil or other oils do not come into contact with any of the clutch parts. Lubrication is not required.

WORM DRIVE One shot of grease per day is recommended for the two end bearings of the driving worm. The regular checking of the

oil level and changing of the lubricating oil is necessary.

During the first week of running and after any major overhaul or repair the worm wheel should be inspected for wear. At the first sign of wear, reference should be made to the following instructions for the setting of the worm drive.

WORMGEAR MOUNTING INSTRUCTION'S In order to obtain the gears performance from a pair of wormgears, it is essential, when mounting them in their box, that they should be adjusted correctly and our experience is that any difficulties encountered with the wormgears can usually be traces to an initially incorrect adjustment. We give below some notes on assembly which apply generally to all wormgear mounting and which will be of particular use to users of our screw presses and digesters on those occasions when it may be necessary to take a box apart to replace a worn part.

TWIN SCREW PRESS

15

DISMANTLING THE WORM DRIVE.

Remove the worm drive a

Remove the pulley belts.

b

Remove the pulley circlip.

c

Using a pulling tool withdraw the pulley.

d. With the utmost care remove pad by part the bearing set and housing at the end of the worm (part 1002) opposite to the pulley, end. e. Now remove complete the bearing housing at the pulley, end rotating with care the worm wheel (part 1003). f. Remove the end cover door part 1013, g. Remove the adjusting nut part 1011- by means of the special spanner. Before unscrewing the slotted adjusting nut its securing screw has to be loosened otherwise the thread could lie damaged. h

Using a pulling tool withdraw the worm wheel spider part 1004.

To dismantle the spur gear box proceed as follows: a. Remove the screws and cage set as described and remove 14 bolts holding part 1145 to the gear casing part No.1001 ( withdraw part 1145) b

Remove the worm drive as described

c

Remove the locknut and lock washer part No. 1020 + 1019.

d

Remove the cover plate part 1010 with oil seals.

e

Withdraw with care bearings No. 1021

f

Withdraw the two shaft sets complete from the press end.

g. If necessary the bearing part No. 1024 would be withdrawn from the screw end or driving end of the shafts. h

The other bearings and spur gears etc, would be withdrawn from the worm drive end.

Particular attention should be paid to the instructions relating to ball and roller bearings. To reassemble process in the reverse order.

TWIN SCREW PRESS

16

WORMWHEEL ALIGNMENT In lining up a pair of wormgears there is only one variable adjustment which is to be made by the fitter, that is, the sideways positioning of the wormgear in relation to the centre line of the worm. No other adjustment is necessary or desirable. Provision should he made for the sideways adjustment during assembly of the wheel for the following reasons :

1. If' no provisions were made for adjustment, correct positioning of the wheel would be dependent on accurate machining to length of all parts which affect the position of the wheel, such as spacing washers, end caps, bearings, worm wheel boss and some of the gearbox dimensions. Since the accurate positioning of the wheel would depend on so many parts being machined to fine limits (which in any case might result in an appreciable error when the algebraic sum of the individual errors was computed) it is better to allow more generous tolerances for machining, and to make one adjustable part, such as a spacing washer or shims, for the final adjustment on assembly. 2. In all worm gear assemblies, no matter how rigid they may be, a certain amount of deflection takes place in the gear case, bearings and which results in a misalignment of the worm wheel relative to the worm. The amount of deflection is difficult to predict, and it is, therefore, sometimes desirable to alter the position of the wheel, after a run under load and observation of the tooth marking, the object being to position it such that it is correctly lined up when in the loaded position.

TWIN SCREW PRESS

17

ALLOWANCE FOR DEFLECTION AND OIL ENTRY GAP Wormgears are produced in such a manner as to allow for deflection and to give an entry gap for the lubrication on the entering sides of the wheel teeth. This is done by producing the gears with a leaving side contact. This is the sort of contact on the driving faces of the wheel teeth that should be aimed at when the gears are assembled and turned by hand to give a marking on the teeth from aworm which has had its threads smeared with a marking paint. This contact obviously leaves an empty gap for the oil, and moreover when the wheel deflects under load, the contact tends to become more central, whilst still leaving some entry gap. A driving face contact as shown in Figure 5 , is the worst possible condition under which a pair of wormgears can be run, since there is no entry for the oil, and moreover, any deflection will aggravate the trouble further. A gear mounted in this manner may cause a temperature rise in the oil as much as 20 per cent higher than the gear shown in Figure 4. The remedy is to move the wheel (by means of the adjustment provided in the design) a few thousandths of an inch to the left, until, by trial and correctly mount (error, a contact similar to that shown in Figure 4 is obtained. Movement of The wheel to the left will cause the contact to move to the right.

METHODOF ADJUSTMENT The wormwheel should first be mounted approximately~centra1 with the worm, and after coating the worm threads with a Prussian Blue or similar compound, the gears should be turned by hand to produce a tooth marking on the wheel. If the marking is not as desired, the wheel should be adjusted side wavs until a correct marking is obtained, by trial and error.

TWIN SCREW PRESS

18

SPUR GEARBOX The regular checking & changing of the oil is necessary. Inspection of the spur gears through the special covers is possible whilst the machine is running but more detailed inspection is recommended from time to time when the machine is stopped and with the covers removed. The rate of wear of the spur gears is very slow and there will be ample warning before they need to be replaced. The best indication of the condition of the bearings will be given by any change in the sound when the machine is running under normal load. The best protection for the bearing will be the proper attention to the cleanliness of the lubricating oil.

BALL AND ROLLER Such bearings are best left undisturbed. They give their best service when run under clean conditions. When it is necessary to remove them and refit them the following notes should be complied with: a) Never use unnecessary force b) Always use proper pulling tools c) Never transmit force from one ring to the other ring through the ball or taper race when removing or refitting a bearing d) Never refit a damaged or partly worn bearing e) Ensure perfect cleanliness f) Clean with mineral turpentine, never with diesel, petrol or kerosene, but do not leave the bearing dry or uncovered. Protect from corrosion with a light clean and protected from dirt & dust in a plastic bag.

TWIN SCREW PRESS

19

OIL EXTRACTION PRESS CAGE CYLINDER AND TWIN SCREWS The rugged working end of the press is subject to Wear and tear. The extent of the wear will depend upon the condition of the fruit. Regular upkeep is necessary to maintain the proper clearances which make possible the superior performance associated with the Twin screw press. For the instructions for the removal of the screws and cage please refer to the section headed “Dismantling Instructions". It is good pratice to have a spare cage and set of screws. It is recommended that the two sets be interchanged every 600 hours. Few users find it necessary to make more frequent changes but some prefer to extend the change to every 1,000 hours. A set of screws and a cage with proper upkeep will last for between 4,000 to 6,000 hours (that is to say for 40,000 ton FFB to 60,000 ton FFB ) The cage and screws are designed and manufactured to withstand operating conditions so as not to distort or and cause expensive damage to the rest of the special attention has been paid to the type of steel and its heat treatment.

UPKEEP OF CAGE Only the replacement of the worn out cage, liners (part number 1155 / 1156 ) necessary. The press cage supporting body ( part n b r 1153 and the clamping( Pa r t number 1154 ) bars are not subjected to wear and tear.

Figure 6. – Press Cage.

TWIN SCREW PRESS

20

UPKEEP OF SCREWS During the first few rebuilding operations of new screws it is only necessary to build up the first turn or flight of the screws ( part nbr.1142 and 1143 ) They should be built up by welding to their original thickness of approximately 30 mm . When the other flights have been worn by 6 mm to 10 mm they should be built up by welding on both sides. Attention must also he paid to ensure that the screw shaft does not wear thin. It should be built up in good time to its original dia. Of approx. 100 mm. Before machining to the outside' diameter of 305 mm the welds should be ground smooth. This: will reduce the nut breakage and promote an even wear.

OIL EXTRACTION PRESS CAGE CYLINDER AND TWIN SCREW The rugged working end of the press is subject to wear and tear. The extent of the wear will depend upon, the condition of the fruit. Regular upkeep is necessary to maintain the proper clearances which make possible the superior performance associated with the Usine de Wecker press. For the instructions for the removal of the screws and cage please refer to the section headed Dismantling Instructions"

It is good pratice to have a spare cage and set of screws. It is recommended that the two sets be interchanged every 600 hours. Few users find it necessary to make more frequent changes but some prefer to extend the chance to every 1,000 hours. A set of screws and a cage with proper upkeep will last for between 4,000 to 6,000 hours (that is to say for 40,000 ton FFB to 60,000 ion FFB) The cage and are designed and manufactured withstand operating conditions so as not to distort or breakup and cause expensive damage to the rest of the press Special attention has been paid to the type of steel and its heat treatment

TWIN SCREW P RESS

21

EFFECTIVE USE OF THE SCREWPRESS The screwpress in one link in the chain of essential processing tool in extraction of crude Palm Oil and should be considered in proper perspective with the other processing units. The press is a tool which permits control of the relationship between the percentage of oil loss on dry fibre and the percentage of oil loss on dry sludge as shown in the graph below.

OIL ON DRY RESIDUE % 12%

OIL ON DRY SLUDGE

OIL ON TOTAL RESIDUE

12%

11

11

10

10

9

9

8

8

7

7

6

6

OIL ON DRY FIBRE

5

5

RESIDUE AS FIBRE

25%

50%

75%

RESIDUE AS SLUDGE

75%

50%

25%

CONE PRESSURE

Relationship between the pressure and performance characteristic.

It must be noted that with an increase press pressure the oil on dry fibre is reduced but the oil on dry sludge is increased, resulting from the increased dry residue in sludge. Before optimum conditions are attained, increase in the press pressure results in recovering more oil from the fibre than is lost with the sludge. Than on the other hand an decrease of press pressure will result in less oil being saved from the fibre but at the expense of lost of oil with the sludge. Operating a very low pressure, it is possible to achieve practically no loss of oil in the clarification section and little or no trace of broken nuts but at the cost of 25% of oil on dry fibre. At the other extreme with an excessive operating press pressure, all the oil and dry material would pass to the clarification section including a high count of broken nuts.

TWIN SCREW P RESS

22

There is a relationship between nut breakage and the percentage of fibre passing to the clarification section. Nut breakage should be properly measured by the presence of broken shells as with Tenera material the variation in shell thickness can at times be heuristic, as some of the kernels have little or no shells surrounding them. The appearance in the press cake of smashed kernels normally indicates that the press pressure requires immediate adjustment or that the worm-screws are in need of rebuilding. The optimum conditions for operation of the twin screwpress will depend upon conditions of the fruit when it enters the screwpress to achieve effective use of the press. To establish the proper condition, accurate and true records of press expelled material samples is essential. The twin screwpress is designed for operation under difficult conditions and the mill engineer must decide on a program to suit his local requirements.

TWIN SCREW P RESS

23

PI5 TWIN SCREWPRESS - SPARE PARTS LIST.

Part No.

Qty. Description

Drawing No.

1001 1002 1003 1006 1007 1008 1009 1010 1011

1 1 1 1 1 1 2 1 1

470.340704.0000 413.340708.0200 413.340705.0300 413.340716.0400 413.340717.0200 413.340718.0200 302.340720.0300 435.340731.0200

1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035 1036 1037 1038 1039 1040

1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 4 1 1 1 2 1 1 2 2 1 1 2 2 1

Gearbox easing Drive worm Rim of worm wheel Spacer Tooth wheel Tooth wheel Supporting ring Cover Adjusting Nut complete with screw & ring Supporting ring Cover Joint Cover Joint Shim ring Disk spring Lock, washer Nut Self aligning roller bearing Self aligning roller thrust bearing Self aligning roller thrust bearing Self aligning roller hearing Oil gauge Discharge cock Oil seal Worm wheel nave Sight glass Sigh t glass ( 6 holes ) Sight glass ( 3 holes) Seal .for sight glass 1029 Seal ( 6 holes ) Seal (3 holes ) Air filter Cover Cover Supporting ring Bearing box Ring

302.340714.0300 699.340701.1100 401.340715.0400 435.340731.0200

699.340701.1100

73900 340700. 2000 699.340701. 1100 pos.16

739000.340700.0000

312.340709.0300

TWIN SCREW P RESS

24

Part.No

Qtv

Description

1041 1042 1043 1044 1045 1046 1047 1048 1049 1081 1082 1083 1084 1085 1086 1087 1088 1089 1090 1091 1092 1093 1094 1096

1 1 2 2 2 2 2 1 1 1 1 1 8 6 1 1 1 1 1 1 1 1 1 1

Ring Parallel key Felt ring 0 - Ring Roller bearing Self' aligning roller bearing Felt ring Cover Seal Traverse Nut ring - RH thread Nut ring - LH thread Felt ring Grease nipples Cy1inder Cover Piston rod Piston ring Piston ring Piston ring Ring Ring 0 - Ring Gasket

1103 1116 1117 1118 1119 1127 1131 1132 1133 1134 1135 1136 1137 1142 1143 1144 1145 1146

1 6 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1

Connecting plate Screw with accessories Oil seal 0 - Ring Turcon Glyd ring Guide bushing Right hand shaft with key Left hand shaft with key Cylinder Piston ring Cover Piston packing 0 -Ring Right hand worm screw Left hand worm screw Wearing plate Press body Inlet strainer

24 Aug.1979

Drawing No.

435.340728.0200

302.3407,76.300 302.340777.300 739.341881. 100 4 71.340 784. 200

401.340774.400 401.340 M. 400 682.347,78.200

341.342742.0300

412.340216.0100 412.340208. 0100 417.3444 /71. 200

MULTI - HYDROCYCLONE SYSTEM

Use of the Multi – Hydrocyclone system. Complements of Erik Tornroth of Westfalia Separator (M) Sdn Bhd for the Palm Oil Process Synopsis handbook / Oct 1999.

( The process of the removal of sand in crude oil before oil clarification process. ) A hydrocyclone is a cyclone used for liquid/solid separation. For practical reason, in the following write up, the short term cyclone will be used to describe a hydrocyclone. A cyclone utilizes fluid pressure energy to create rotational fluid motion. It is converting pressure energy to kinetic energy. As energy is non-destructable, it follows that a pressure drop or loss over the cyclone is necessary in order for the same to operate satisfactorily. Vice versa it can be stated that, although an inlet pressure may be detectable, this is not a guarantee that the suspension flowing through the cyclone will be rotating. A pressure drop over the cyclone is needed to release energy to force the suspension to rotate. The higher the pressure drop the higher the centrifugal force. It follows that the pressure after the cyclone must be lower than the pressure ahead of the cyclone. Normally it is recommended to install the cyclone in such a way that zero counter pressure on the vortex stream is achieved. This is to reduce possible chokages caused by settling of suspended matters. Zero counter pressure also allow the cyclone system to operate at lower inlet pressure than otherwise would be needed. This is generally good for the system. It is of importance that this fact is well understood. Placing the cyclone at the ground level and connecting the vortex outlet to a header pipe of considerable height creates a high counter pressure and usually not a good solution. The feed to the cyclone, Fig. 1 and 2, is introduced tangentially into the cylindrical portion . A rotational motion is created by which the solid particles are thrown outwards towards the walls. Simultaneously there is an inward radial motion arising from the location on the central axis of the outlet for the bulk of the liquid; the smaller part of the liquid, together with those solid particles which have reached the walls, discharges through the apex of the cone which forms the other part of the main body of the cyclone. Fig. 1

Fig. 2 – Feed to the cyclone

MULTI – HYDROCYCLONE SYSTEM

2

A cyclone may be installed at any angle or position which is desired, since its operation depends upon the rotational forces and not upon gravity. The efficiency with which particles of different sizes are recovered by a cyclone, typically follows a curve such as that given in Fig. 3. It is thus more convenient to express the efficiency of a cyclone in terms of one point on this curve, d50, which is the particle size for which the efficiency is 50 per cent.

Fig.3 The following equation generally applies.

d50 = 2.1 [ D c 3 η / Q (ρ ρ s -ρ ρ l )] 0.5 where ρ s and ρ l are the densities of the solid and liquid respectively in g/cm3 , η = the viscosity of the liquid in centipoises , Q is the feed rate in Imp. g.p.m., and Dc is the diameter of the cyclone in inches. This equation is typical although variations occur in the numerical constants and in the power to which Dc is raised; in some instances, Q is also raised to a power varying from 1.06-1.20. Similarly a typical equation relating throughput to pressure drop will be as follows:

P =12 Q2 / D c4 Different process and operating variables will affect performance. A change in feed flow rate, Q, will alter both the d50 cut off point and the pressure drop; thus, d50 is proportional to Q - 0.5, and P is proportional to Q2. In the same way it is possible to predict the effect that an increase in pressure drop has upon the cut off point, i.e.

d50 ∝ P- 0.25 This latter relationship conforms fairly closely with practical performance, whereas the former two are less precise though still of major value. It would be expected that a change in the difference in density between the liquid and solid would affect the cut off point according to the relationship


d50 ∝ ( ρ s - ρ l )- 0.5

3

The above equations are unfortunately less successful in predicting the effect of changes in viscosity. Thus, although the above equation shows

d50 ∝ η 0.5 and hence predicts a progressive decrease in separating efficiency as the viscosity rises, it does not predict the observed fact that a continued increase in viscosity ultimately results in a fundamental change in flow pattern and a consequent virtual cessation in separation. The general effect of increasing viscosity is to decrease the pressure drop at constant throughput, or to give a higher throughput at constant pressure drop. Viscosity has another important influence; a change in viscosity will alter the proportions into which the feed is split between the underflow and overflow, thereby affecting the separating efficiency. Altering the throughput (e.g. by varying the pressure drop ) will also affect the split and again the efficiency. The relation between the throughput, Q in gpm, and the split, S, may be expressed empirically in the following equation

S = 5 ( D u / D o ) x Qy where Du and Do are the underflow and overflow outlet diameters. The constants x and y vary according to the size of the cyclone; for small cyclones, x = 1.75 and y = - 0. 75, while for larger diameters x ranges up to 4.4 and y down to -0.44. The rotation of the fluid creates a low pressure axial core, which is generally filled with air, gas, or vaporized liquid as in Fig. 3. The diameter of this core which is generally constant over its length, increases with rotational velocity and therefore with throughput up to a maximum, typical diameters being 0.06 - 0.33 of the cyclone diameter. The existence of a core indicates stable operating conditions, and demands for any given cyclone a minimum throughput and also a minimum pressure drop which typically is about 0.3 bar. The main mass of liquid in a cyclone rotates as a free vortex, thus the product of the tangential velocity V and the radius R is a constant, so that as R decreases towards the centre of the vortex, V increases toward infinity. In practice, however, at very small values of R the liquid behaves as in a centrifuge and rotates as a solid body with constant angular velocity, i.e. VR -1 is constant. Arising from this, there is a zone where the tangential velocity is at a maximum, which for example in a 3 inch cyclone was shown to be at R = 0.2 inch ; and generally is at about Dc / 8. While open discharge of the underflow is normal; frequently the outlet is connected directly to a closed sump or 'grit box' which is full of liquid. This practice, which is, for example, widely used in the paper industry, enables very small quantities of grit to be separated from large flows, the grit being allowed to accumulate and discharged at intervals. Because of a natural recirculation of liquid from the 'grit box' back up into the cyclone, the cyclone is no longer able to separate quite such fine particles; although this represents a reduction in separating efficiency, at the same time the cut point is sharpened. The separating efficiency of any given cyclone is somewhat difficult to specify , because it embraces two distinct quantities. One of these is the minimum size of particle which is eliminated from the overflow, which is the 'cut point'; the other is the 'yield' of solids in the underflow expressed as a percentage of the amount present in the feed.


4

No absolute value exists for the 'cut point' because in practice the efficiency with which a cyclone can separate particles increases steadily as the particle size increases.

The shape of this curve will vary according to the design, so that an efficiency versus particle size curve is needed for every cyclone. It is customary to characterize a cyclone by one point on this curve, d50, which is the particle size for which the efficiency is 50 per cent; occasionally, the 95 per cent point, d95, is also used. In practice, confusion can arise from the fact that there are distinctly different ways in which cyclones are used. Thus the aim may be to perform a thickening operation; a cyclone can often achieve this very successfully, but it must be borne in mind that it is basically a classifier. Even as a classifier, however, two extremes can be distinguished, one being degritting, where the object is to eliminate from the overflow all material above a certain size; on the other hand, it may be desired to minimize the quantity of fines which go into the underflow, that is a 'de-sliming' operation. The length of the vortex finder must be decided with all eye on both aspects, since increasing it gives more chance for coarse particles following the short circuit lines to be separated and removed with the underflow; at the same time, however, the outlet point for the main bulk of the fines is thereby brought closer to the underflow outlet, so that there is an increase in the passage of fines into the underflow. The length is about

Dc / 2.5 - Dc / 3. The flow pattern of a cyclone is complex. Fig. 4 shows the typical spiral pattern, with movement initially downwards and then upwards. Between these two spiral paths a region exists where there is no vertical velocity either upwards or downwards. The mantle, as it is termed, has been shown to have a diameter of about Dc / 2.3 , where Dc is the diameter of the cyclone.

Fig. 4


5

Cyclones are characterized by the diameter of the cylindrical portion, which typically ranges from 10 mm to 750 mm. The throughput of a cyclone is proportional to the square of the diameter.

The minimum particle which can be separated is proportional to the square root of the cyclone diameter, so that to handle fine particles, small diameters are required. A 600 mm cyclone may be able to handle 330 m3/h, but it cannot separate particles smaller than about 50 micron. By comparison, a 10 mm cyclone can separate down to about 5 micron but can handle only 220 l/h. In practice this conflict is resolved by using several small cyclones in parallel. The ratio of the length of cylinder to length of cone is surprisingly unimportant. Normal practice is to make the cylindrical length from 2/3 to 2 times the diameter. It is the overall length that matters most, since both separating efficiency and throughput increase with length. Wider angle cones have the advantage of giving an increased separating efficiency at a given throughput, though to achieve this a higher pressure drop is incurred; Bradley therefore recommends that they should only be used either where the saving in headroom merits this extra running cost, or where their lower tendency to block with solids is of significance. The most critical factors in determining the performance of a cyclone are the diameters of the inlet port and the two outlet ports; the inlet and overflow between them determine the size of separation and the pressure drop, while the diameter of the underflow determines what proportion of the flow discharges through it and hence also what underflow solids concentration is achieved. In sizing the inlet port Di, the demands for maximum separating efficiency and minimum pressure drop conflict. Thus D i should be made about 1/6 or 1/7 of the cyclone diameter. Experiment has shown that an improved efficiency is achieved with a rectangular rather than a circular inlet (length to breadth ratio being 2: 1). The diameter of the overflow Do and of the vortex finder which is generally integral with it, can be largely decided from consideration of the flow pattern. Thus, on the one hand it should be larger than the zone of maximum tangential velocity, so that any material following the short circuit path still has to pass through a zone of increasing velocities as it flows along the bottom edge of the vortex finder; this will give the best chance for separation to occur in spite of the short path. On the other hand, the vortex finder should have a smaller diameter than the mantle, since otherwise the normal patterns of inward radial flow collapse. Putting these two together, the overflow diameter should lie between a maximum of D c / 2.3 and a minimum of Dc / 8. In practice, a value of about Dc / 7 is commonly preferred, so that Do > Di . The diameter of the underflow, De, is the least critical, and is in fact usually fitted with a valve which can be throttled to give the desired running conditions. Generally, De = about Dc /10 to Dc / 5, while the valve will reduce the ratio by a further factor of 2, which permits operation with the normal typical underflow equal to roughly 10 per cent of the feed volume. A danger of large particles is that they may be held trapped against the conical wall and become a centre for serious local abrasion. Abrasion is a major factor that must be taken into account in both the detailed design and the materials of construction of cyclones.

As stated earlier, the minimum pressure loss to give stable operation is about 0.3 bar.


6

In practice, values are typically 2.5 -3 bar while it is rarely economic to exceed 5 bar .

This pressure loss constitutes the only running cost, and corresponds to a power consumption in the range 40 - 400 kW/m3 of feed / h , for pressure losses of 0.3 -3 bar. These kW figures compare very favourably with 750 -2200 for disc centrifuges, and 1500 for scroll discharge centrifuges. The rotation also results in very high 'g' values, typically 2,500 in a 400 mm cyclone, 10,000 in a 75 mm cyclone, and 70,000 in a 10 mm. unit.

It should be stressed, however, that these are maximum figures occurring at one point only. The fluid is subjected to intensive shear forces which can easily result in emulsification when two liquid phases are present, The fact, in the region of maximum acceleration, the shear rate is also maximum. Even where the hazard of emulsification can be avoided, the cyclone suffers from the disadvantage that one unit cannot give complete separation of both phases; it Is necessary to accept that either the overflow or the underflow will be two-phased. The emulsification problem may generally be avoided by operating at lower throughputs than would be normal with a solid/liquid system, and accepting that this will result in a proportionally lower separating efficiency. In practical terms, Bradley states that the optimum conditions correspond to a pressure drop of about 1.5 bar which is about half the normal level. The other limitation may be avoided, when it matters, by use of two cyclones in series, the second one being fed with the mixture discharged from one of the outlets on the first one. Although at first sight it would appear that suitable sizing would always permit the choice of which discharge stream should be clear, the flow pattern within a cyclone makes it essential for a substantial part of the feed volume to discharge through the overflow; in practice, this means that a clear overflow cannot be obtained from a mixture containing only a small proportion of light phase. An important process variable is the viscosity of the liquids. The separating efficiency decreases with increasing viscosity, until effective separation cease in the region of 10-30 centistokes.

*

*

*

*

*

Complements of Erik Tornroth of Westfalia Separator (M) Sdn Bhd for the Palm Oil Process Synopsis handbook / Oct 1999.


Westfalia Separator (M) Sdn. Bhd.

Technical Description TDCPO-4l0/Ed.3

Automatic Triplex Multi-Cyclone Desanding System Westfalia Type ADP- 100 -3

Consisting of three (3) cyclones type PZ1 00/15, made completely of material high abrasion resistant ceramic for a combined flow rate of not less than 45,000 I/h. at an inlet pressure of approximately 3.0 bar. The cyclones will be made completely of material high abrasion resistant ceramic with rubber connection hoses and the operating separation efficiency based on water-sand-suspension amounts to 10-40 micron. The cyclones will, together with a sand collecting container, solenoid valves, pressure gauges, Acoustic alarm system and automatic discharge timing unit c/w air-controlled automatic valves, be fitted into a common frame made of angle steel, “Ready for operation”. Skid Mounted Module with items included as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set

Cyclones of Complete High Abrasion Resistant Ceramic Pneumatic Actuated S/Steel Ball Valves Diaphragm Pressure Gauges cM Siphon Tunes Flanged Connection and Flexible Hoses for Feed Flanged Connection and Flexible Hoses for Discharge Butterfly Feed Valves Union Coupling Connection for Cyclones Sand Outlets Flexible Hoses for Cyclones Sand Outlets Pneumatic Air Regulator Pneumatic Air Lubrication Control Panel c/w Auto Discharge Timer Controlled System Pneumatic Actuated Butterfly Sand Discharge Valve Pneumatic Pressure Sensor Switch Pneumatic Actuated Air Vent Valve Pneumatic Actuated Flush Water Valve Large Sand Receiver Tank Acoustic Alarm System Slip-on Flanges for Inlet Piping Slip-on Flanges for Outlet Piping


2

Hydrocydones have long been established as compact separators of dense solid particles from Liquids. Hence their use upstream of high-speed centrifuges helps to eliminate harmful abrasives in order to prolong the life of bowl components. Hydrocyclones can be operated in both automatic and manual modes. Experiences have proven that automating a hydrocyclone is a far more practical solution in the long term to control the wear of expensive centrifugal bowl components. The higher initial setup cost is well justified by having a reliable operation with guaranteed sand removal and savings on product losses. Figure 2 shows a schematic of a typical automated hydrocyclone. The feed enters the hydrocyclone (3) through valve (1). The required feed pressure is determined from the pressure gauge (2). Control cabinet (4) serves to control the operating programme. After a pre-selected interval, the isolating valve (5) is shut off by a simultaneous opening of valves (6) and (7). After the erosive particles are flushed, the sand collector (9) is refilled with water and the isolating valve (5) Opens to begin a new cycle of operation. The ‘Time’ parameter of all automatic control is adjustable to enable compatibility with local operating conditions.


THE WESTFALIA MULTI-HYDROCYCLONE DESANDING SYSTEM.

Fully Assembled in a Module Design and Ready for Operation A comparation of the two stage desanding cyclone system with the same diameter and different diameter cyclones.

Complements of Erik Tornroth of Westfalia Separator (M) Sdn Bhd for the Palm Oil Process Synopsis handbook / Oct 1999.

DECANTER USE AND MAINTENANCE. The use of the Decanter in the oil clarification station for the removal of solid matter, reduces the load on the static clarification settling tank or the sludge centrifuge separator by about 50 to 75%. The objective of incorporating the Decanter into the clarification station of the oil palm mill is to remove as much solid matter or NOS as possible and thus resulting in :

q q q q q q q

The removal of solids with bound proteins and other impurities such as metal filings. Better separation and recovery of crude oil. Reduce load to the clarification process and ease of operation. Reduced wear on other machinery and equipment in the process. Reduced loading of the effluent treatment process Production of value added by product by drying of the solid sludge and sold as Fertilizer. Economical gains in the overall process.

Function: The Decanter is a horizontal solid bowl centrifuge featuring continuous solids discharge by means of a scroll. The bowl rotates at the speed selected to suit the particular separating job. Through a stationary feed tube located in the centre of rotation, the crude oil mixture ( ex-press extraction ) is fed into the rotating bowl. The solids are thrown onto the bowl wall, while the oil and water of lower density form concentric layers in the bowl. The scroll rotates in the same direction as the bowl, but at a slightly lower or higher speed (depending on the application) than that of the bowl. The solids are scrolled to the conical end of the bowl, and removed from there by gravity into the fixed solids housing and dropped down to a solids conveyor system. The liquids, of different specific gravities, separate during the residence time in the liquid zone, (cylindrical part of the bowl) and are dispatched without any subsequent intermixing via two different outlet systems. The adjustable impeller makes fast and accurate setting possible during operation and optimal quality of the discharged palm oil. An electric motor connected to a fluid coupling runs both the bowl and the scroll at the required speed. For loading the decanter, the feed is controlled automatically by overload switches on the switch panel.

A SCHEMATIC DIAGRAM OF A DECANTER.

DECANTER USE AND MAINTENANCE

Page 2.

How it works :

Installation: The typical process line arrangement and use of the 2 or 3 phase Decanter are shown in the schematics below:

1.

A 2-Phase Decanter installation in an oil palm mill oil clarification process line schematic flow diagram.

DECANTER USE AND MAINTENANCE

2.

Page 3.

A 3-Phase Decanter installation in an oil palm mill oil clarification process line schematic flow diagram.

A CLAIRIFICATION PROCESS LINE WITH USE OF A 3 PHASE DECANTER WITHOUT A STATIC SETTLING TANK SCHEMATIC FLOW.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Digester Screw Press Sand trap tank Vibrating screen Crude oil tank with heat exchange coils Pump for crude oil 3 Phase Decanter Solids Screw conveyor Trailer or Dryer Heavy phase tank Pump Crude Oil buffer tank Oil Purifier Pump Vacuum dryer Buffer tank for light phase

CENTRIFUGE PURIFIER USE AND MAINTENANCE. Function. To remove impurities and some moisture from the clarified crude palm oil before the vacuum dry process.

Working Principles In liquid-solid, liquid-liquid separation centrifugal force is employed to replace the weaker force of gravity, resulting in more rapid separation of the phases.

When the bowl rotates about its vertical axis, liquids and solids are now acted by a centrifugal force, whereby the liquid layer assumes the equilibrium position shown in the next figure, with an almost vertical inner surface.

The solid particles settle horizontally outward and are tightly pressed against the vertical howl wall.

In a disk centrifuge as illustrated in the figure, feed is admitted to the centre or the bowl near its floor and rises through a stack of sheet metal disks that are actually truncated cones spaced apart. The assembly of disk carries

several holes of a certain diameter, which constitutes channels

through which the liquid rises.

The purpose of the disks is primarily to reduce the sedimentation-distance, since a solid particle only travels a short distance before it reaches the underside of one of the disks.

Once the solid is removed from the liquid, the chance of its re-entrainment in the effluent is small. It continues to move outward, because of the centrifugal force and al so the Ii qui d flow, until it is deposited on the wall of the bowl. The water, being heavier, flows towards the vertical shaft centre.

Page 2.

Crude Oil Purification. The bowl is used for purification when treating oil-water mixtures containing impurities. For this purposes the rising channels are open. Sometimes a blind disc (un-perforated and without spacers) is placed on top of the disc set.

The bowl is adjuster to the difference in densities between the oil and water by inserting a proper gravity ring.

Fill the purifier with water to build up a water seal in this bowl.

Then feed crude oil through the distributor into the bowl, where it displaces part of the seal water until hydraulic equilibrium is reached.

The feed crude oil, through the holes in the distributor, enters the space in between disc, where actual separation takes place.

Oil being lighter moves upward along the upper side of the discs and is thrown out of the outlet.

The water and solid particles being heavier moves outward along the underside of the separating discs, to be thrown out of the water outlet.

The solid impurities are deposited in the sludge accumulating area, and is later discharged periodically.

Page 3.

Installation Correct installation of the machine is important to ensure its optimal performance. Listed below are some salient points to note for the installation of the purifier :

1. The distance between bolts as well as other dimensions are given in the attached schematic. Ensure that there is sufficient room for hinging up the hood as well as the installing and the removal of the motor and pump.

2. The foundation must be level and rigid, so as to minimize vibration and noise. To avoid damage to the bearings, ensure that the foundation has no direct contact with foundations of other units (e.g. diesel engine, pump, etc.)

3. Vibration dampers should be mounted between the foundation and the machine base plate. Lock nuts applied after the foundation bolts checked if they are well fastened.

4. Arrange pipes, pumps and other apparatus so that they are accessible for inspection.

5. Fit the pipes and hoses so that the inlet and outlet connections of the machine are not subject to strain. All attachments should be made to allow variations in length so as to prevent transmission of strains and vibrations. AVOID SHARP CURVES.

6. Flush out each section of piping after mounting. The whole pipe system should be flushed to remove metallic ashes arid other impurities so that they do not get into the machine, pump or other apparatus.

7. The machine operates with an oil pre-heater, a water tank, hot water feeder lines as well as an electric motor.

Page 4. 8. Typically the oil is pre-heated in a heating tank before it is pumped into the feed of the purifier by the oil inlet pump.

9. The water tank with a capacity of about 35 litres is installed at 2 to 3 metres above the control valve. This height is critical as the water pressure must be maintained at a constant level for normal operation. It is essential that this water be reasonably clean, free from rust, clay arid other impurities so as not to choke up water passage or give rise to problem with the bowl and the sliding bowl 10. The hot water feeder line operates at a pressure of 2 kg / sq.cm. 11. A typical piping connections and layout for the purifier installation is shown below:

Fig.1 DETAILS OF PIPING AND CONNECTIONS.

Page 5.

Fig. 2

TYPICAL INSTALLATION LAYOUT FOR THE PURIFIER.

Page 6.

OPERATIONAL SAFETY AND MAINTENANCE. The Separator is a HIGH SPEED centrifuge that works reliably, provided that it is operated and looked after in accordance with the operating instructions of the manufacturer. The amount of solids in the feed liquid should be kept as constant as possible. Corrosive liquids and liquids containing abrasive solids, particularly when being processed at high temperature, may attack the bowl material after some time, resulting in impaired safety. All bowl components must be checked regularly.

Preparation before starting 1)

Set up the bowl as purifier or clarifier according to separation requirement.

2)

Release brakes.

3)

Check if the bowl rotates freely by turning it by hand

4)

Check the foundation bolts of the motor and separator as well as the hand-nut of the hood for security.

5)

Verify that the oil level in gear box lies between the required limits.

6)

See that there is water in the operating water tank

7)

Check the motor for correct direction of rotation.

8)

See that the process oil is heated up to the required temperature.

Starting and Running 1)

After all the above is verified, start the motor. Wait until the bowl has reached its rated speed required. A speed of 72 — 75 rpm as measured from the speed indicator means that the full speed of the bowl has been attained. This start-up takes about 6 minutes.

Page 7. 2) At the completion of starting, turn the control valve to “Seal” position. When water is seen flowing out from the indicator pipe, the bowl is wel1 sealed, then turn the control valve to “Make Up” position.

3)

If the separator is set up as a purifier, fill the bowl with water until water flows out of the water outlet, indicating that the water seal is built up. Then stop the water feed, open the oil inlet valve gradually and start separating. If the separator is used as a clarifier, open the oil inlet valve gradually and start separating. Bear in mind that no seal water should be fed into the bowl, otherwise separation would be seriously affected by the unwanted seal water.

4)

Should abnormalities such as unusual noise and vibrations occur, stop the machine immediately for inspection.

Sludge discharge The sludge discharge process is carried out as follows:

1)

Close the oil inlet valve.

2)

Open the hot water valve to drive out a part of the residual oil; (for clarifier, make sure that flushing water is not fed to the extent that water mixes with, clean oil.).

3)

Turn the, control valve to “Open” position until the discharge is completed, then turn the control valve to “Idle” position.

4)

If the, process oil has a higher viscosity or contains relatively more sludge, then water-flushing as well as the sludge-discharge operation should be repeated in succession to clean the bowl thoroughly.

Page 8.

Keep the control valve at “Idle” position for about 30 seconds before the next cycle to enable the operating water in the space above operating slide to leave.

5)

After the sludge discharge operation is completed, turn the control valve to “Seal” position for resumption of separation.

Inspection during running

1)

Note the quantity and quality of lubricating oil in the gear box. Change it whenever necessary.

2)

Check the oil pump for leakage.

3)

Check from time to time the rotating speed of the speed indicator, which should be within 72 —75 rpm.

4)

Check the operating temperature of the motor and oil temperature in the gear box The lubricating oil temperature should not exceed 60 degrees C, at an ambient temperature of 40 degrees and process oil temperature of 95 degrees C.

5)

Whenever unusual vibrations or noise is detected, stop the machine.

6)

Check the water outlet for oil escape (a trace of oil in water is permissible) as well as the sight class for any oil overflow. Take remedial actions whenever necessary.

Page 9.

7)

Normally no oil and water should he discharge from the sludge outlet. Otherwise it indicates problem within piston seal. Repair the sealing surface or replace the nylon seal.

8)

Check the separating temperature and separating rate. Keep them as constant as possible.

Stopping the Machine 1)

Switch off oil the pre-heater. Continue feeding oil for a few minutes since preheater continues to heat.

2)

Cut off oil feed. Drain off oil completely to prevent agglomeration

3)

Open hot water valve to drive out residual oil.

4)

Turn control valve to “Open “ position, carry out water flushing and sludge discharge. Repeat the operations till the bowl is clean.

5)

Turn control valve to “Idle” position.

6)

Switch off electric supply.

Maintenance 1)

After each operation, repeat flushing and discharge until the bowl is clean. Clean the strainer from time to time.

2)

Check the water distributing holes blockage at an interval of about clean them periodically.

3)

Check control valve regularly, apply lubricating grease to prevent rust.

4)

The assembly should be dynamically balanced again should any of the main parts, such as bowl body, piston, bowl hood, distributor, top disc, large locking ring, etc., be replaced. The allowable residual unbalanced moment is M< 0.4 x W, where W is the weight of the bowl assembly (Kg).

5)

When the sealing surface A of piston is damaged, shut down machine and carry out repair immediately.

Page 10.

Lubrication All bearings of the separator are splash lubricated from a central oil bath. Before the initial startup of the separator fill the gear chamber with about 10 litres of lubricating oil, till it reaches the “red line” within the sight class.

This must be maintained during operation, refill oil when necessary. From time to time check to see if oil contains water. To do this loosen the oil drain screw to drain off a small amount of oil.

Change the oil immediately when it is milky (emulsified). The first oil change should be made after about 50 working hours. Do not run the gear pumps without load for a long duration as they are lubricated by the oil flowing through them.

Grease the nipples of the gear pump before running the separator.

Lubricate the following parts when the bowl is reassembled: 1)

Threads of both the small locking ring and the bowl hood with molybdenum disulphide lubricant.

2)

Threads of both the large locking ring and the bowl body with molybdenum disulphide lubricant.

3)

Fitting surfaces of both the large locking ring and bowl hood with molybdenum disulphide lubricant.

4)

Fitting surface of the inner piston hole and bowl body as well as the outer piston rim and the bowl body with lubricating oil.

5)

Fitting surfaces between the operating slide and the bowl body with lubricating oil.

6)

Tapered hole of the bowl body and the taper of spindle, with lubricating oil.

7)

Threads of the 3 bolts fastening the bowl body and the paring chamber with lubricating oil.

WESTFALIA PALM OIL PURIFIER OSC 30

SLUDGE CENTRIFUGE SEPARATOR

1

SLUDGE CENTRIFUGE SEPARATOR.

The Star bowl type sludge centrifuge separator has been successfully in operation in Oil Palm Mills for more than Sixty years, in Malaysia, Indonesia, Papua New Guinea, South America and West coast Africa region. The Sludge centrifuge separator is designed to recover residual oil present in the sludge of the clarification process. This separator can handle a sludge discharge capacity of 6,000 litres per hour with an oil loss of 12.5% on solid based of sample. It has limited use in modern mills where operation requirement are capacities above 15,000 litres per hour in a single unit. The main components with details of the Sludge centrifuge separator are :

A SLUDGE CENTRIFUGE SEPARATOR ‘STAR BOWL TYPE’


2

The main components with details of the Sludge centrifuge separator are : Cast iron housing This comprised a lower section (the flame) ad an upper section (the hood), which arc bolted together. In addition to supporting the rotor the flame also forms the base for fastening the separator to the foundation. Both lower and upper sections of the cast iron housing are fitted internally with protective wearing strips opposite the nozzle to receive the strong jets of discharged sludge emerging from the nozzles. The ‘discharge sludge’ flows to the outlet of the separator housing and thence into the clarification station discharge drainpipe. At the top of the hood an inspection cover enables the operator to examine clean or change of nozzles. The cast iron housing has provision permitting connection of all liquid flows to and from the separator. SCHEMATIC.

TOP COVER

CAST IRON HOUSING

STAR BOWL ROTOR SHAFT


3

Stainless steel star-shaped rotor The star-shaped rotor of the Sludge centrifuge separator has 6 cones. The rotor is enclosed in a cast iron housing. The rotor rotate, in a -vertical plane, is bolted to two horizontal shaft journals machined from cast steel material of solid CS32 shaft. One of these is hollow, and serves to admit the untreated sludge (mixed if necessary with hot dilution water) to the rotor body. The other journal is solid and has the function of driving the rotor fitted with a V-belt pulley. Both shaft journals are provided with dust-tight bearings. The oily sludge constitutes the light fraction and accumulates in the centre of the rotor and discharges through a center pipe incorporated in the hollow shaft journal. The tips of the 6 rotor cones are fitted wit nozzle holders, each provided with a readily exchangeable nozzle made of a special, wear-resistant alloy. Through these nozzles, the heavy fraction (i.e. the oil-free waste sludge ) Is ejected out of the rotor bowl by the centrifugal force of the revolving rotor.

Drive assembly Comprising of a 30HP Elektim TEFC squirrel cage motor 415V/ 3P11150 Hz 4 pole motor tropically rated with class F insulation coupled on to a Benzler KSD 12 hydrodynamic coupling incorporated with 4SPB by 305mm PCD pulley mounted on a rigid adjustable ms base plate. A minimum distance of 1470mm s required between drive and driven pulleys.


4

Additional Features The scope of supply also includes: a) 1 set of 6- l.9mm Hexoloy nozzles per centrifuge separator in addition to the set of 1.9mm nozzles fitted to the rotor as standard supply. b) a standard set of tools

WESTFALIA DA 45 NOZZLE BOWL CENTRIFUGE.

HYDRO CLAYBATH

1

Use and Maintenance of the Hydro Claybath Separator The separator is specifically designed for cracked mixture derived from nuts of Tenera origin. It is equally suitable however for material from Dura origin or for a mixture of Tenera and Dura. The separator delivers

•

washed and separated kernels suitable for direct feeding to the kernel dryer.

•

washed shell suitable for direct feeding to the boiler or shell silo.

•

washed un-cracked nuts for recycling.

The hydro-claybath consists of an upper conical. inlet tank receiving the cracked mixture that preferably comes from a dust separator column. A special pump maintains a continuous flow of dense liquid in closed circuit. The dense liquid is obtained by adding clay or salt to water so as to have a density between the one of the kernels ( 1,06 - 1,09 ) and the one of the shells and nuts ( l,25 - l,k5 ). Separating follows at once: the kernels are floating on the surface while the shells sink to the bottom of the cone. The over and underflow are collected separately and lead by short pipes to two rotating drums, where the products are washed and dewatered. The kernels may still be sterilized by steam injection. The liquid coming from the drums is collected in a lower tank where, when necessary, water, salt or clay is added in order to maintain a constant level and to adjust the density at the required value. Principles of Operation The operation employs a dynamic hydraulic movement together with density operation. The water suspended clay is circulated and kept in continuous movement. The condition of the clay is far less critical than with the once popular clay bath separator. The quantity of clay require is considerably less than for Hydro claybath separators which needs only 30 to 50 kgs of clay per ton of nuts, depending on the quality used.

2

HYDRO CLAYBATH

The unit has the following advantages over clay bath separators. q higher kernel recovery q low mud requirement q less critical mud quality q more compact q clean in operation The unit has the following advantages over hydro cyclone separators

a)

higher kernel recovery In this respect it must be remembered that in any case the hydro cyclone separator is not as efficient as a well controlled clay bath separator.

b) the power requirement is considerably less. c)

the upkeep and wear and tear is much less.

Capacity The unit will easily deal with the cracked mixture from 3-5 ton of nuts per hour. When working with Tenera material it is adequate for a 25 ton per hour FFB throughput and a 45 ton per hour FFB will require 2 units. Power Requirement The hydraulic equipment is driven by a 5.5 hp motor. The cleaning equipment is fitted with a 1 hp motor. The complete power requirement is approximately 4 kw.

3

HYDRO CLAYBATH

SCHEMATIC OF THE HYDRO-CLAYBATH

AIR

WATER

STEAM

KERNEL

SHELL

1. Cracked mixture inlet 2. Upper conical tank 4. Shell overflow 5. Regulating gate valve 7. Dense liquid inlet in the upper tank 8. Rotary strainer for Kernel 10. Gearmotor 11. Washing pipes and nozzles

3. Kernel overflow 6. Armored pump 9. Rotary strainer for Shell 12. Base plate.

4

HYDRO CLAYBATH

INSTALLATION. The Hydro-claybath separator is easy to install. separator should be installed on a level foundation.

In order to avoid distortion of the base plate, the

Room enough has to be foreseen around the separator in order to provide easy access and maintenance as well as cleaning possibilities of the discharge ends. The separator has to be emptied and washed with water at regular intervals. Therefore it is advisable to foresee a suitable sewage system in its vicinity for the evacuation of the dense liquid and the washwater. The following checks have to be made prior to the first starting up of the Hydro claybath separator. 1.

Visual inspection around the separator. Check whether all nuts and bolts are correctly tightened, and no foreign parts may prevent a normal running of the machine.

2.

Check inside of drums for absence of foreign parts.

3.

Inspect bottom of lower tank for absence of foreign parts that could be suck by the pump.

4.

Check lubrication of bearings of the rotary strainer.

5.

Inspect fixing of pump and electric motor as well as rotational sense. Check particularly whether stuffing boxes are correctly tightened as described under § VII. Too tight a stuffing box may damage the shaft.

6.

Check correct set up of water and steam sprayers.

7.

Check whether the electrical installation is correct and according to security norms. Repeat controls at regular intervals after starting up. This requests a minimum of time may avoid production breakdown.

8.

Check regularly while the machine is running whether o the pump is rotating correctly o the motor and V—belts arc trouble-free o the drum rotates freely without any bending of the shafts.

HYDRO CLAYBATH

STARTING UP OF THE SEPARATOR The dense liquid is prepared either in a separate mixer or directly in the Hydro-claybath. Whenever it is done in the separator, first fill the lower tank with water, then start the pump and add progressively clay in small pieces having the size of a fist. Measure the density of the suspension at regular intervals until it reaches about 1,10 — 1,12. Whenever the Suspension is thoroughly homogenized, feed the cracked mixture to the upper tank and after a while observe the kernels and shells at the outlet of their respective drums. If kernels in shells exceed 1 or 2%, the density of the bath will be increased by adding clay ( by 0,02 points for instance). If, on the contrary, the content of shells or partially cracked and uncracked nuts in kernels is too high, add water in order to dilute the clay-bath (by 0,02 points for instance). After a few operating hours stop the machine and inspect the bottom of the lower tank for sand deposits. If any, this means the clay is of poor quality and it is necessary to remove sonic via drain cock or by hand. If the clay is slight1y acid, the suspension may be stabilized by adding a few pounds of caustic soda or soda carbonate. This alkalinity presents no danger for the steel parts of the machine.

MAINTENANCE Clean the drum regularly and remove pieces of shells and kernels from the holes Once a month empty the separator completely and wash thoroughly. If the clay is of poor quality, i.e. containing much sand, this process has to be repeated every week as sand badly affects the clay suspension and increases the wear of the pump. The bearings of the drums have to be cleared and checked once a year. For cleaning use white spirit or water white, petrol or benzol. Particular care has to be taken when using petrol or benzol because of their inflamability. After cleaning, do not leave the bearings a long time without lubricating them with oil or grease. In order to secure a good penetration, rotate the bearing several times. This procedure is of particular importance whenever the machine is considered to remain out of operation for a long time.

5

6

HYDRO CLAYBATH

SPARE PARTS. To ensure safe operation it is advisable to have the following spare parts on stock. 1) 2) 3) 4) 5)

1 set of bearings 2 sets of perforated drums 3 sprockets: 23 teeth, prim dia. 186,5 mm 2 V-belts for the drive of the pump. 1 set for the armored pump including: Liquid seal it. 2 and/or sealing ring item 2.4 Liquid seal item 2.1 Front armor half item 3 Rear armor half item 3.1 Armor neck extension item 4 Stuffing box gland item 7 Impeller nut item 13 Shaft protection jacket item 14 Shaft nuts item 15 Impeller item 16 Roller bearing item 18 2 inclined ball bearings BUA item 19 1 Box with packing rings item 22 Packing rings AKA item 23 0—rings item 24

SIDE ELEVATIONS

PLAN VIEW

STEAM BOILER

1

STEAM BOILER (Generator) “THE DESIGNth CONSIDERATIONS, THE OPERATION AND MAINTENANCE” By Noel Wambeck 25 August 2000.

The writer hopes that the brief overview in this design considerations, the use and maintenance write up will provide the reader, engineer or knowledge seeker with a better understanding of the importance of the steam boiler and its function in the oil palm mill design and operation.

The modern steam generator or commonly called a “ Steam Boiler” is an integrated assembly of several essential components. It function is to convert water into steam at a predetermined pressure and temperature. Heat transfer and the containment of fluid pressure are the chief functions of a steam generator or more commonly called a Boiler. Waste solid fuel or Biomass Boiler is used in the oil palm mill. The principal objectives for the design of the Biomass boiler are as follows: 1. Designed for Oil palm mill operation The steam boiler shall be water tube type, designed specifically to burn palm oil solid waste of fibre, shell and empty bunches. 2. High availability for service The tendency to build Biomass boiler of sufficient capacity per unit, unaided by other Boilers, emphasizes the need for inbuilt ability to remain on the line continuously. 3. Quality steam Ability to deliver clean and dry steam. 4. Properly rated. Ability to accommodate variations in rate of steaming without unsteadiness in steam pressure, surging of water levels, development of localized overheating and other transient phenomena. In boiler selection, thermal, hydraulic and structural factors are to be considered and duly weighed. Heat transfer is the primary purpose of the boiler. In spite of the wide variations in designs there are certain requirements fundamental to all boilers. The plant designer may turn to these for guidance in investigating the boilers offered for his particular installation, for such requirements should be met by any design deserving consideration. First, there are the conditions governing behaviour of the water within the boiler.

STEAM BOILER

2

Most important of these is good water circulation. The process of evolution in boiler development has eliminated types with faulty water circulation; yet “tube starvation” is a condition not unknown in the upper tubes of some of the most modern boilers.

STANDARD WASTE FUEL FIRED “COCHRAN BOILER” OF 1939 USED IN THE OIL PALM MILL.

STEAM BOILER

3

The disengagement surface, where the steam breaks through the surface, of water in the drum, should be unrestricted. Priming may he due to faulty design in this respect. Provision of suitable storage space for steam within the boiler is a requirement indirectly connected with the water conditions. The volume of steam storage should be equal to the demands of the load served. Engine loads with their pulsating cutoff will require more steam space than turbines to which the same amount of steam is supplied. Insufficient storage space has an adverse effect on the steadiness of steam pressure under variable lead. Another point to which attention should be given is the baffling. The path of the gases through the boiler should be so baffled that they pass the tubes a sufficient number of times to give up their heat to the required degree. This degree is less when auxiliary best transfer surfaces are provided. Practice has determined the best baffle arrangement for most standard boilers under ordinary tiring conditions. Certain features of a boiler should be investigated with rowed to the possibility of undetermined thermal stresses being set up. Feed water should discharge into the boiler at as near the saturation temperature as possible. Cold water discharged against the boiler shell sets up contraction stresses. Joints and seams should be well protected from the direct action of flames or hot gas. The setting of burners should never be made, in such a way that the flames may play directly upon tube surfaces. To provide for intelligent and safe operation of the boiler, the engineer should see to it that a full complement of leads, gauges, and safety devices is provided. These include blow-off, steam lead, feed water lead, water gauge pressure gauge, superheated steam thermometer, safety valves and fusible plugs. The setting of a boiler should provide for the introduction of hand or mechanical soot-blowing devices. Last, but not least, is the necessity of having an accessible boiler by providing properly designed staircase, ladders, walkways and platforms. This provision is a requirement of all boilers which are expected to be insured so that the Insuring company inspectors may determine from time to time the state of the risk, Also accessibility should he provided for maintenance, inspection, and repair by the regular operating workforce of the plant. The design should conform to the DIN, BS or ASME Boiler Construction Code in accordance to the local authority requirements but within the limits of the Code there is much latitude allowed the designer. The purchaser of a steam generator naturally wants his new equipment to be able to deliver the necessary quantity of steam, but will not want to invest in unnecessary surplus capacity; hence, means for describing the production capacity are needed. In the pressure boiler field a primary classification would be according to contents of the tubular Heating surface, water or gas. The result is a grouping into fire-tube and water-tube boilers.

STEAM BOILER

4

Fire-tube boilers are those in which the products of combustion pass through the tubes and the water lies around the outside of them.

This requires that the tubes be surrounded by a shell so as to confine the water and contain the pressure. The shell thus becomes a support for the heating surface and sometimes for the combustion equipment. If the required capacity is not above that for which this principle is practical, the fire-tube boiler has advantages of compactness, unit construction, portability, and inexpensiveness that are continuing it in use in spite of certain disadvantages. In most fire-tube boiler construction a nest of tubes is built into a shell. The tubes are straight and parallel to each other, and to the axis of the shell. Variations are: (1) horizontal or vertical axes; (2) external or internal furnaces; (3) fully cylindrical or partially cylindrical shells. Typical arrangements of the pressure parts of straight tube boilers for both horizontal and vertical designs are shown below.

TYPICAL SOLID FUEL FIRE TUBE BOILERS USED IN OIL PALM MILL UP TO THE 1970’S.

For low design pressure, some shells are built as a combination of cylindrical and oval sections, the latter having to be internally stayed to hold their shape. The building in of a furnace section may also require a variation from the cylindrical, and again internal stay bolts are always much in evidence. Fire-tube boilers have a relatively large ratio of water content to steaming capacity; hence fluctuations of steam demand cause only little unsteadiness of steam pressure or water level.

STEAM BOILER

5

TYPICAL SETTING OF AN HRT BOILER, AND ABOVE THE BOILER ITSELF.

Simple automatic combustion control systems may be employed, or if the control is manual the supervision does not have to be so close and continuous as with water-tube boilers, which can boil dry during a few minutes of inattention if under manual operation. The most common representative of the fire tube boiler in the oil palm industry of the early 1900’s are the horizontal return tubular (HRT) boiler, the horizontal two-pass or economical boiler, the locomotive type, the round upright type and the multi pass or modified Scotch marine type. The HRT boiler is characterized by simplicity and cheapness. As the furnace is external to the shell, almost any kind of combustion equipment can be accommodated. The pressure parts consist of a long cylindrical shell with flat end sheets, which are bored to receive longitudinal tubes. The boiler itself is usually suspended from overhead girders and a brick setting built around it as shown in the above. The tubes themselves act to stay the end sheets, but where in the upper part there are no tubes, there must be stay braces to resist deformation of the ends by steam pressure. The water level is carried high in the shell, well above the highest tube. The furnace gases flow horizontally in contact with the lower half of the shell, then reverse direction and pass back through the fire tubes, finally leaving at the front or firing end, where a cylindrical metal extension of the shell serves to guide them into the smoke pipe or breeching. Heating surface is partly the shell and partly the tubes.

STEAM BOILER

6

Water-tube boilers, which consist of tubes and drums, may be classified as straight or bent tube. Straight tube boilers have a parallel group of straight equal-length tubes, arranged in a uniform pattern and joined at either end to headers. These headers in turn are joined to one or more horizontal drums- According to their construction, headers may be classified as box or sectional types. Their chief characteristics are: Box header. Least expensive; must be internally stayed against the fluid pressure; header surface must be perpendicular to tube axis, hence cannot be vertical, since tubes must be inclined to the horizontal in order to control circulation.

TYPICAL SOLID FUEL WATER TUBE BOILERS USED IN OIL PALM MILL UP TO THE 1990’S.

The box header is seen to resemble a large, shallow, structural steel box, whereas the sectional header is a vertical casting or forging of small transverse dimensions, each section accommodating a group of tubes in a vertical row, the width of the tube hank being determined by the number of sections stacked side by side. Sectional header. Suitable for highest pressures; since header surface is not a flat sheet, the section can be so east or forged that although the header is vertical it has a surface at the tube hole that is normal to the tube axis. Sections are made sinuous in order to stagger tubes vertically.

BOILER PLANT FOR THE OIL PALM MILL OPERATION. The steam and power requirements of a palm oil mill are considerable. Fortunately the residue left after the extraction of the oil and kernel from the fruit provides, in a well-designed mill, ample fuel for the production of the required power and process steam. In the small oil palm mill with capacities of 1 – 5 mt FFB per hour it was customary to use the Locomotive or tubular boilers with large fire boxes such as the “Lancashire” type boilers which were reliable that did not need expensive brickwork and call for expert attention.

STEAM BOILER

7

The table below shows the composition of types of FFB residues, the African DURA DURA Deli and pure TENERA (D X P) .

COMPOSITION Percentage to FFB weight

DURA %

DURA DELI %

TENERA %

Empty bunches Equivalent dry material Dry Shell Dry Fibre Oil Kernel

23 8 31 4 12 8

22 8 19 6 20 5

25 9 7 8 25 5

Total dry residue fuel

43

33

24

The difference in the available fuel from Dura, Dura Deli and Tenera fruit is one of the important considerations in the proper design of the Boiler for small village mill or large modern oil palm mill Fuel is always in excess of the power and steam requirements of the process therefore the selected design of the Boiler require the utilisation of the available heat of only 60% to 75% and in older mills with dirty boilers this efficiency may be as low as 40%. The steam is required for two essential functions. One is the driving of the steam engine or turbine for power supply and the other is for the process heating including the sterilisation process. In the early mill design the boiler supplied the two needs separately. Present day practice is to supply the steam first to the turbine where the pressure is reduced and then to the process heating where the latent heat is utilized. The operating functions of the steam and power co-generation system are explained in the earlier paper in Volume I “ THE OIL PALM MILL, SYSTEMS AND PROCESS”.

A TITAN TOWLER WATER TUBE BIO FUEL BOILER FOR OIL PALM MILL OPERATION.

STEAM BOILER

8

The Combi type Bio fuel Boiler designed and adapted to operate in the palm oil Industry was seen in Africa and Central America in the year 1985 and in Malaysia 1996. The combination or “combi boiler” design incorporate the use of stepgrate, water tube & membrane wall furnace and through the fire tube drum to complete the flue gas path.

COMBI TYPE BIO-FUEL BOILER ( Water tube furnace & fire tube drum arrangement )

The advantages the combi type bio- fuel boiler at a higher cost, had to offer are: q q q q q q

Burning all fibre, shell and empty bunch. Lower furnace temperature < 650 to 850 deg. C Larger drum, surface and furnace area to sustain high steam surge and demand. Automatically controlled air-fuel ratio as a standard feature. Membrane walls in some type or refractory walls combustion chamber . Water cool stepgrate

OPERATION AND PERFORMANCE The operation of a modern oil palm mill steam boiler is a job for trained, intelligent personnel. Present day operations have become mainly supervisory in nature, although hand loading of waste fuel may be required at times and hand removal of ash are frequently to be found in older mills including those of recent design and modern equipment, fully mechanized plants are not always financially justifiable. In the larger mills and in many of the smaller mills, operations are divided into shifts for continuous production. Since loads are usually variable, operation consists not only in ascertaining that the equipment is following the load and functioning normally, but also in making secondary adjustments, which refine the thermal efficiency beyond the normal abilities of the usual complement of automatic equipment.

STEAM BOILER

9

Automatic equipment must be watched through instruments or periodic inspection, loads shifts between multiple units, critical points for pressure, temperature etc. In most mills is taking the log i.e. the record of flows, pressure, material quantities and other physical data. Performance of the boiler as a whole or part of it is computed at intervals from such data. Then there is always a certain amount of maintenance and repairs, this being as true of a boiler house as any other part of a plant. The larger the mill the more the need for division of operation duties between specialized groups such as operation, tests, plant improvements, maintenance, repair etc… The “unaccounted for loss” consist of the superheat taken on by the humidity in the air used for combustion, sensible heat in ashes, free carbon floating in the gaseous products of combustion and some other small items. When test show that one of these losses has become excessive, then a knowledge of the sources of the loss enables the operator to look intelligently for his difficulty among the many items which constitute the total loss. The table below is a resume of the more common causes of thermal loss associated with steam boiler. HEAT LOSSES IN BOILER. A.

Loss due to moisture in fuel

CAUSES OF HEAT LOSS. a. b.

Excessive moisture in fibre Excessive moisture in empty bunch

a. b. c. d. e. f.

High excess air as revealed in low CO2 content of flue gas. High flue gas temperature Dirty heating surfaces Poor water circulation Dead gas pockets Gas velocity too high.

C. Loss due to incomplete combustion

a. b. c. d.

Insufficient air supply Fuel bed in poor condition Under cooling of furnace at low rating Improper setting of boiler.

D.

a. b. c.

Grate or stoker not proportioned to fuel. Too high rate of combustion attempted. Grate dumped or fuel bed sliced too frequently. Furnace temperature is above fusion temperature of ash.

B. Loss due to heat carried away in chimney gas

Loss due to combustible in ash pit

d.

E.

Loss from radiation and convection from boiler and setting

a. b. c.

Boiler drum uninsulated. Wall of setting to thin or poor quality Furnace refractories in need of repair or renewal.

F.

Loss due to moisture in air

a. b.

Moisture laden air as from steam jet Excess air on days of high humidity.

STEAM BOILER

10

FUNCTION OF WATER LOOP. The treated feed water, which is heated, de-aerated and put under pressure by the boiler, feed pump and in some systems the water is preheated in the water circulation loop. Its condition is then is one having a temperature approaching, and a pressure exceeding, that of the boiler water. It is finally regulated for the desired flow into the boiler. The remainder of the water loop consists of the flow at diminishing pressure and enthalpy, but in the form of vapour. At high boiler pressures the feedwater treatment should be adequate to continue the surfaces of the boiler in approximately the same condition as when new. Once in the boiler, the water is first heated to saturation temperature, and then evaporated at the point of contact with heated tube surface. In general, the steam is free of all impurities the water might have contained (except dissolved gases). Impurities are left in the boiler water whose concentration thereby increases. The point of evaporation being the tube surface, there is every opportunity for the impurities to deposit on these surfaces as a scale. When untreated feedwater produces enough scale on the boiler surfaces to interfere with heat transfer or when it contains elements which either corrode or alter the strength of the boiler metal, feedwater analysis and its immediate treatment is necessary. The higher the rate of heat transfer, the more important it becomes to keep that surface scale-free, because the scale can both reduce the steaming capacity and cause overheating of the tubes.

WATER CONTAMINATION. Natural waters usually contain dissolved salts and gases, some organic and inorganic material in suspension. They rarely are neutral in reaction. The dissolved salts are mainly the carbonates, sulfates, chlorides of calcium, sodium and magnesium and occasionally some iron, aluminium and silica salts. Oxygen and carbon dioxide are gases. The suspended matter is usually alumina and silica in the form of mud and salt. When impurities find their way into the water of a boiler, they remain there until; 1. They are removed by boiler water blowdown; 2. They are neutralized by some intentionally produced internal chemical reaction 3. Or they produce operating difficulties, which, if continued unabated, may finally lead to damage of the boiler or even risk of an explosion. The troubles caused by undesirable quality feed water to boiler are scaling, corrosion, forming, priming and embrittlement.

STEAM BOILER

11

SCALING. Primarily scaling results from the decrease of the solubility of some salts with increase of temperature. One chemical mechanism used to explain scaling is reaching of chemical saturation by water in the boiler, then a beginning of precipitation with sedimentation forming a layer of scale on the heating surfaces and loose precipitate in drums. But more likely, heating surface scale is produced by crystallization of scale forming salts from a locally supersaturated layer of water lying on the heating surface. This forms an incrustation at the point of evaporation. Scale is due mainly to salts of calcium and magnesium and to a leaser extent to silicates. Scaling may take place in boiler drum, tubes and feedwater piping. Its effect on the piping system is to choke the flow, requiring an increase of pressure to maintain water delivery. When this condition occurs, overheated tubes, blistering and rupturing may be expected.

The scale that are tightly adherent and tough are the worst from the standpoint of removal.

EXTREME CASES OF SCALING IN BOILER TUBES AND CAUSTIC EMBRITTLEMENT CRACKING OF A BOILER BLOW OFF FLANGE.

The scale that are tightly adherent and tough are the worst from the standpoint of removal. When scales are formed, tubes are cleaned with water or electric powered rotary brushes and cutters, which are pushed through the tubes during boiler shutdown for maintenance or repairs. Rather, scale is dissolved with weak acid baths.

CORROSION. By corrosion is meant the destructive conversion of metal into oxides or salts. It may occur any place in the water loop, but is most feared in the boiler that occurs typically as small pits and depressions and often covered with a crust. Corrosion is due to an acid condition of water or to oxygen, carbon dioxide or chlorides. The most serious factor in corrosion is the dissolved oxygen. The permissible limit of oxygen content varies with the acidity of the water and the amount of scale on the tubes but should not exceed 0.5 cc per litre.

STEAM BOILER

12

Corrosion may be a general loss of metal over the whole tube surface or a localized action. The latter is more serious as it produces pitting and grooving. There is no positive way to discover and assess corrosion damage other than to remove the surfaces from service and examine them carefully. Corrosion is a complex subject and a highly important one, probably the most frequent cause of damage to boiler in the oil palm mill.

FOAMING AND PRIMING. Foaming refers to that condition of boiler operation where stable foam is produced. It may or may not be accompanied by priming, which is the production of wet steam or in the aggravated case, slugs of water. Wet steam is indicative of faulty operating conditions in a power boiler; slugs of water are liable to be very destructive to piping, engines, or turbines. Priming can be produced by other causes than foaming, for instance, carrying too high a water level, insufficient disengagement area, or a pulsating steam demand that overtaxes the boiler steam storage. A disturbed disengagement area also frequently causes priming for instance, on high-capacity boilers where tubes entering drums from water walls discharge at such high velocities as to disturb the water surface. The source of foaming resides in the condition of the boiler water itself. Too high a concentration of dissolved salts is a frequent cause of foaming. Foaming results also from saponification of the boiler water through mixture of oil or grease with the alkali. Floating organic matter is another source of foam. When foaming is due to concentration of salts in the water, the condition is relieved by altering the treatment or by blowing down more of the concentrated water. Normally, a steam boiler without drum internals will produce from 0.5 to 1.5% moisture in the steam in the form of a mist or fog. This is not permissible in the high-temperature, high-pressure power plant. There the steam generator has special internal purifiers in the drum. Then less than 0.1% moisture can be normal for the steam. Leakage past faulty internals could be the cause of abnormally wet steam, as well as foaming or priming. Whatever the cause, the result is carryover, that is, the presence of impurity bearing droplets of water in the steam flow. As this passes through a super-heater the water is vaporized, leaving the solid carryover as a deposit on superheater tubes, or a dust which will float with the steam as far as the turbine stage where the expanding steam enters the saturated steam regime.

STEAM BOILER

13

There it may form troublesome deposits on the turbine blading. Carryover can be qualitatively measured by recording conductivity meters which determine the micromhos of the saturated steam flowing past electrodes located in a steam pipe. Quantitative determination (ppm solids) requires the withdrawal, condensation, and analysis of steam samples. Foaming is the most common source of carryover on boilers equipped with drum internals.

Tests have sometimes revealed foam blankets of 12 in. or more thickness above the drum water level.

FACTORS AFFECTING CARRYOVER* Mechanical Conditions

Water Conditions

Operating Conditions

Boiler design Drum sizes Number of drums Drum internals Circulation Radiant vs. convection heating surface

Source and makeup Concentration Alkalinity Organic matter Suspended matter Chemical feed Inherent foaminess

Rating Changes in rating Pressure Water level Changes in level Blowing flues Blowing safety valve

EMBRITTLEMENT. Although this is the rarest of all boiler “diseases,” it cannot be said to be so rare as to be unimportant. A serious feature of embrittlement is that, when failure occurs, it may come as a disastrous explosion, because embrittlement affects the drums and its presence is not detectable except on minute scrutiny. Embrittlement is attributed to the presence of a certain concentration of sodium hydroxide in the absence of inhibiting agencies. The steel loses its toughness and cracks appear along the seams below the water line. They generally run from rivet to rivet, following the intercrystalline structure. In cases of embrittlement it has always been found that the feed water was high in sodium bicarbonate which broke down into sodium carbonate in the boiler and partially hydrolized. Prevention of embrittlement consists of reducing the causticity or adding inhibiting agents. Formerly sodium sulfate was considered to be an inhibitor. Recent researches have cast doubt on the reliability of sulfate, meantime indicating sodium nitrate as an efficient inhibitor of caustic embrittlement.

STEAM BOILER

This is added to maintain in the boiler a ratio of sodium nitrate to total alkalinity (as NaOH) of 0.3 minimum. It can be steadily added to feed water either by a chemical proportioner or by doses to the boiler drum via an internal chemical feeder. Water testing will control frequency of dosages required. Embrittlement is most likely to occur in riveted drum boilers. It is not unknown in welded drums, a vulnerable spot being where the tube end is rolled into the drum. Concentration of caustic at a highly stressed point is a forerunner of embrittlement. Where embrittlement is a likelihood, boiler inspectors are careful to examine vulnerable points, even resorting to acid etching, and inspecting

GENERAL HINTS. q

Should a boiler be laid up, that is not kept at work for a time., fill it with right to the top with fresh non-acid water and let out all air. This filling up is recommended for damp situations.

q

If the Boiler is in a dry place it can be emptied, all man and mud doors taken out, and left out and a gentle wood fire lighted in it occasionally.

q

Never leave a boiler standing partly filled with water for any length of time.

q

Do not use rubber for making the man and mud hole joints; asbestos rings, the correct size of the door and covered with black lead are the best.

q

Do not clean the insides of a new gauge glass before putting them in, and screw up the gland nuts gradually when fitting them.

q

Never open any valves suddenly, particularly steam stop valves.

q

Keep the water level just at half-glass and watch it.

q

Remember that the job of a fireman or stoker is a very skilled one, and should be so regarded.

SAFETY. A Boiler which is a potential danger to life, limb and property is a good investment. It is even a nerve racking thing to possess. The ideal boiler is so simple in construction that it cannot be make unsafe.

14

STEAM BOILER

RECORDS AND THEIR USE. Much time is spent in collecting records, which are almost useless for a guide in intelligently following boiler performance, for giving information, which readily shows where losses are occurring, or for showing the operator how to correct these conditions. In many systems standard forms have been developed that satisfy the requirements of all stations and are made not only to contain the information that is required in the management office but also such information as might be termed pertinent only to the station. These standard forms are delivered daily to the management where necessary records are copied and are then returned to the station where they are keep on file. Readings of indicating or integrated meters are recorded on log sheets at regular intervals, often hourly. Supplementing these log sheets are the charts of the recording instruments. These charts should be filed in a systematic and logical way so that the record of any instrument for any specified day may be found quickly. All entries in the management office are made on forms for circulation to the operation supervisor, shift engineer, maintenance supervisor, and quality controller.  Noel Wambeck – 25th, Aug 2000.

15

NUT CRACKER USE AND MAINTENANCE

1

NUT CRACKER USE AND MAINTENANCE. Until the introduction of Tenera material a reliable processing system had been established and a reasonable recovery of kernels prevailed throughout the industry. Unfortunately the kernel processing system employed for Dura material was not suitable for Tenera material. The direct outcome of this was a fall in efficiency and the emergence of a number of novel experimental kernel plants. The basic requirements, use of and maintenance for a modern kernel plant for processing Tenera or a mixture of Tenera and Dura nuts are discussed in this paper.

Relative Characteristics of Tenera and Dura Nuts In terms of percentage to FFB Dura nuts constitute 27% including 5.4% kernels, 18.9% shell plus 2.7% moisture. For Tenera there is 17.2% of nuts composed of 5.5% kernels, 6.2% shell and 2.5% moisture. For Tenera there is a third Of shell but the difficulty of separating the shell from the kernel is greater. For Dura nuts, the thickness of the shell is comparative uniform whereas with Tenera material there is a large variation in shell thickness and the system of grading by size before nut cracking is advantageous. The Rotor Ring Type Cracker. The Nut cracker of the rotor and ring type described here has a capacity of 4 tons of nuts per hour and providing the feed is constant it is almost sufficient for a 30 ton line.


2

Two nut crackers are the minimum that should be used with one line. A nut cracker must have a sufficient diameter to permit the nuts to Lake up a proper position during flight before striking the cracking ring. The nuts should strike the cracking ring with their tails behind them.

The nut cracker must be fitted with a variable speed drive to facilitate the adjustment of the nut cracker speed while the nut cracker is in use. The speed has to he regularly adjusted to attain the optimum condition of minimum of broken kernels and the minimum of uncracked nuts. For Dura materials this will require different speeds for differ nut sizes. Tenera material or a mixture of Tenera or Dura material the cracking speed for optimum results will be the same for different sizes of nuts. This is because the nut size is a more important factor in the cracking of pure Dura nuts and because the shell thickness is a more important factor in the cracking of Tenera nuts or a mixture of Dura and Tenera nuts.

Here is a well-known Nut Cracker operating in Oil Palm Mills, since 1960.

USINE DE WECKER 72S NUT CRACKER


3

1. CRACKER CAPACITY The capacity is about 4 tons of nuts per hour. 2. FEEDING FUNNEL The diameter of the top of the feeding funnel is 320 mm. The discharge opening of the bottom of the funnel is 95 mm. Sufficient room should be left at the top of the nutcracker to permit the inspection of the nuts. Installation of a sliding cylinder which can be quickly raised end lowered is recommended. 3. CRACKER DISCHARGE OPENING The diameter of the cracker discharge is 232 mm. There is a tendency for air to be drawn in at the top of the nutcracker with the nuts and to be expelled through the discharge opening with the cracked mixture. 4. ROTOR SPEED The rotor speed may be varied from 500 to 1,950 rpm. 5. VARIABLE SPEED DRIVE. The drive is fitted with a 4 kW 1420 rpm motor. It is usual to arrange this motor for direct on starting. The speed is adjustable by moving the sliding motor base plate by rotating the hand wheel. The speed of the nutcracker should be adjusted to give the required standard of nutcracking. Daily variation in the condition of the nuts is to be expected and the regular adjustment of the nutcracker speed to prevailing condition of the nuts is highly desirable. It is important to note that the adjustment of the speed regulator should only be made whilst the motor is running. It is also to be noted that by moving the motor in an outward direction the speed is decreased And increased by moving the motor in an inward direction. If the motor is moved inwards too far the speed will fall due to excess belt slip and this will reduce the life of the belt. The nutcracking efficiency will be affected by the condition of the nut in respect to moisture content, temperature, nut size, shell thickness and surface free fibre. The higher the nutcracking speed the lower will be the percentage of the uncracked nuts but the higher will be the percentage of broken kernel.


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The percentage of broken kernels is the factor which normally determines the nutcracking speed. It is recommended that the initial speed be set at 1300 rpm and that the speed be adjusted up and down in increments of 100 rpm to attain the optimum cracking condition. The final setting will of course depend upon the arrangement of the rest of the machinery. Where there are facilities for recycling uncracked nuts it is usually advisable to crack at a speed which will require 10 – 20 percent of the nuts to be recycled.

6. NUTCRACKINO WEAR RING The ring has an approximate diameter of 1250 mm. Its sturdy and heavy construction is necessary for the proper cracking of the nuts. It is constructed from a special wear-resistant steel and should be sufficient for a minimum of one year operation. When the groove in the ring wears to depth of 6mm the cracking ring should be replaced. If this is not don the cracking efficiency will fall.

7. ROTOR ASSEMBLY The rotor Is fitted with special wear resistant steel liners. Under normal conditions the liners should last for a minimum of one year. The liners should be replaced when the depth of the wear groove is 5 mm. 8. FLANGED BEARING ASSEMBLY The Flanged bearing is completely sealed which is life time lubricated. The unit should not be opened under normal circumstances and no maintenance is necessary. In the event that the bottom oil seal should leak grease or should the running of the bearings become excessively noisy due to wear the unit should be dismantle and all the bearings and oil seals replaced and the unit refilled with MOLUB ALLOY BRB 572 grease. 9. GENERAL During the first month of operation the inside of the cracker housing should be regularly inspected to ascertain if periodic cleaning Is necessary. After a few days operation the inside of the nutcracked becomes polished and cleaning Is usually not required. Where for some reasons an excessive amount of fibre and moisture is present, periodic cleaning of accumulated dirt and fibre may be necessary.


10. DIRECTION OF ROTATION Unlike many older types of nutcracker the UDW 72 S may be run in either direction. It Is recommended that the direction of the rotation be reversed every six months to promote even wear and a longer life of the wearing parts. All moving part are life time lubricated and no routine lubrication is required. NUT CRACKER SECTION VIEW.

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ROTOR ASSEMBLY PARTS LIST.

30th October 1999 Noel Wambeck

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THE RIPPLE MILL USE AND MAINTENANCE.

The Ripple mill or de-hulling machine made its appearance in the oil palm mill in the late 1980’s and has been operating satisfactorily. The Ripple mill is an adaptation from the Grains and oil seeds products process. The RIPPLE MILL main components consist of : q Rippler shell or body q A rotatory roller bars cage q Stator jaws q And electric motor drive.

The schematic of a Ripple Mill.

RIPPLE BODY

ROTOR ASSEMBLY SIDE PLATE

STATOR JAW

The function of the ripple mill is determined by the speed and clearance of the rotor. The rotor assembly provides the velocity and forces to dehull or crack the wet nuts in the process of impact between the stator jaws and rotor.

The basic machine is simple to fabricate and its installation can be carried out without special attendance of an engineer. The unchecked processing of stones and metal objects will cause sever damage to the roller bars and stator jaws. The cracking efficiency is about 92% on the total input of wet nuts that would decrease in efficiency to approximately 88% before realisation that the rippler rollers or jaws would require re-surfacing or replacement in some cases.

© Perunding AME / Nov. 1999 / NW

GEARBOX AND GEARMOTORS

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GEAR BOX & GEARMOTORS USE AND MAINTENANCE Gear-motors, Reduction & Transmission devise and other variable speed reducers drives are common features in an Oil Palm Mill or Palm Products Factory. Failer of drive units contribute more than 50% of the down time in processing due to incorrect selection of the type of gear drive, undersized or lack of lubrication and no maintenance. Therefore the use and maintenance of gear drive units are of utmost importance. Common types of gear drives used in Palm Oil Processing Industry, are shown below :

VARIABLE SPEED GEAR DRIVES


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GEARBOX SELECTION. The following facts must be determined when selecting a gearbox. i.

Horsepower required by the driven machine.

ii.

Output speed at which the gearbox must drive the driven machine.

iii.

Working hours per day.

iv.

The sort of service, 8, 16, 24 hours per day running time and the nature of load. i.e. Class 1 - Uniform, Class 2 -Moderate shock or Class 3 -Heavy shock.

v.

Is the gearbox subject to overhung load.

vi.

Type of gearbox such as foot or flanged mounted.

After determining the above factors, Check if the torque indicated corresponds to your requirements.

Example . A 4 kw (5.5 HP ) horizontal mounted gearmotor is connected by 2:1 ratio chain drive to the headshaft of a uniform load bucket elevator. Headshaft speed is 28 rpm, duty 24 hours per day. The pitch circle diameter of the chain drive pinion is 4 ½ inches. The motor is to be TEFC and suitable for 415 volts 3 phase, 50 Hz operation. Chain drive pinion is located mid-way along the output shaft length. 1. 2. 3. 4.

A foot mounted gearmotor is required The load classification is Class 2. The gearmotor output speed is 57 rpm The imposed overhung load =

5.5 x 126,034 = 2702.4 lb 57 x 4.5

5.

4 kW TEFC motor, 415 V 3 ph 50 Hz


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HOW TO ASSEMBLE A GEARMOTOR. A step-by-step talk through description of how to assemble a gear motor. 1.

Clean box internally. Fit necessary drain plugs level and nylon washers.

2.

Fit abutment plate to gearbox with larger cutout at 3rd pinion and shaft position using shakeproof washers to lock screws.

3.

Fit 1 ball bearing to intermediate bore in inter wall of gearbox and 1 balI bearing to output bore in inner wall of gearbox.

4.

Check pinions and gear teeth for damage and rectify where necessary.

5.

Press fit 1 ball bearing to outer end of 2nd pinion and shaft and 3rd pinion and shaft. Press fit 1 ball bearing to inner end of 2nd pinion and shaft; also fit spacing collar and 2nd pinion and shaft key into place. Press fit spherical roller bearing on to output shaft.


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6.

Assemble 2nd pinion and shaft through bearing bore in gear case, place 1st gear and spacing collar in position and push 2nd pinion and shaft through to shoulder location.

7.

Fit circlip to retain first gear.

8.

Fit key to 3rd pinion and shaft and assemble through bearing bore in gear case, after having first placed 2nd gear and spacing collar in position in the gear case

9.

Fit spacing collar and key to output shaft, place output gear and ‘pacing collar in position in gearbox, assemble in position.


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10.

Press oil seal into bore of oil seal housing with sealing lip towards the gearbox. Smear inside face of oil seal with grease (Shell Alvania RA )

11.

Measure by depth micrometer the protrusion of the output bearing and depth of the oil seal housing recess and shim it necessary to allow .003” - .005” end play.

12.

Treat oil seal housing faces and gear case with jointing compound and fit oil seal housing to gearbox. Screw threads should be dipped in jointing compound.


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13.

Fit oil filler and breather plug into the top cover plate, fit both top cover plate and gasket. Treat all faces with jointing compound. Fit output Shaft key in the shaft and stamp serial number of unit into the top of the gear case. Fit adaptor plate to gear case if required, again using jointing compound on both faces.

14.

Determine position of motor pinion, measure depth of first gear relative to mounting face and position motor pinion accordingly.

15.

Fit 1st pinion to motor shaft or input shaft with suitable key. Drill shaft for dog point screw. ( Fit screw having drilled head and lock with iron wire where supplied.


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16.

Treat joint face or gearbox and motor or input flange with jointing compound and assemble to gearbox. Screw Threads should be dipped in jointing compound.

17.

Fill. gearbox with Shell Macoma R77 to oil level. After test drain completely. Treat mating surfaces of top covet plate and gearbox with jointing compound and fit top cover plate to gearbox.

18.

Clean unit and spray with appropriate paint. Fix data plate, oil level plate and attach appropriate dispatch instructions.

CONGRATULATION you have now assembled a GEARMOTOR. Check and see if it works ?

© Noel Wambeck / Nov. 1999.


SPARE PARTS LIST.

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Lubrication. The gearbox must be filled to the oil level with the correct grade of oil before use. To fill the gearbox, remove the oil level plug and filler / breather plug and pour new oil in until it flows from the level hole. Replace the oil level plug and filler / breather plug ; in which the vent holes must always be clean. The oil in a new unit should be drained after 500 hours duty and the case thoroughly flushed with light flushing oil and filled with new oil. It is advisable to drain, flush and refill with new oil after every 6 months or more often if operating conditions are severe.

Note all bearings, coupling, pulley, gear or sprocket fitted to the output shaft must be fitted by screw pressure and must not be forced on.

GLOSSARY OF MAINTENANCE MANAGEMENT TERMS

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Glossary of Maintenance Management Terms This glossary is taken from the book Managing Factory Maintenance by Joel Levitt.

Asset: Either a machine, building, or system. It is the basic unit of maintenance. Autonomous maintenance: Routine maintenance and PM's are carried out by operators in independent groups. These groups, which may include maintenance workers, solve problems without management intervention. The maintenance department is only officially called for bigger problems that require more resources, technology, or downtime. Backlog: All work available to be done. Backlog work has been approved, parts are either listed or bought, and everything is ready to go. BNF equipment: Equipment left off of the PM system, left in the Bust 'N Fix mode (it busts and you fix-no PM at all). Call back: Job where the maintenance person is called back because the asset broke again or the job wasn't finished the first time. (See Rework.) Capital spares: Usually large, expensive, long-leadtime parts that are capitalized (not expensed) on the books and depreciated. They are protection against downtime. Certificate of insurance: A document from the insurance company that verifies insurance coverage for contractors on larger jobs. It will have dates that coverage is in effect, and the dollar limits and types of the coverage. Charge-back: Maintenance work that is charged to the user. All work orders should be costed and billed back to the user's department. The maintenance budget is then included with the user budgets. Also called rebilling. Charge rate: This is the rate in dollars that you charge for a mechanic's time. In addition to the direct wages, you add benefits and overhead (such as supervision, clerical support, shop tools, truck expenses, supplies). You might pay a tradesperson $15/hr and use a $35/hr (or greater) charge rate. CM: See Corrective maintenance. Computerphobia: Irrational fear or dread of computers. Continuous improvement: Reduction to the inputs (hours, materials, management time) to maintenance to provide a given level of maintenance service. Increases in the number of assets, or use of assets with fixed or decreasing inputs. Core damage: When a normally rebuildable component is damaged so badly that it cannot be repaired. Corrective maintenance (CM): Maintenance activity that restores an asset to a preserved condition. Normally initiated as a result of a scheduled inspection. (See Scheduled work.) Deferred maintenance: This is all of the work you know needs to be done that you choose not to do. You put it off, usually in hope of retiring the asset or getting authorization to do a major job that will include the deferred items. DIN work: "Do It Now" means nonemergency work that you have to do now. An example would be moving furniture in the executive wing.


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Emergency work: Maintenance work requiring immediate response from the maintenance staff. Usually associated with some kind of danger, safety, damage, or major production problems. FAS: Shipping term meaning Free Along Side (you are responsible for the loading charge), commonly used for ships or very large freight. Feedback: When used in the maintenance PM sense, feedback means information from your individual failure history is accounted for in the task list. The list is increased in depth or frequency when failure history is high, the list is decreased when failure history is low. FOB (City, Shipping point, or Delivered): Free On Board (seller will load truck or rail car). The FOB point is important because of both the responsibility for the shipment and the freight charges. "FOB delivered" keeps the vendor responsible for the shipment until it reaches your door. "FOB shipping point" or "FOB originating city" makes you responsible for the shipment. If there is a problem with an FOB originating city shipment, you still have to pay the vendor and file a claim with the carrier. Frequency of inspection: How often do you do the inspections? What criteria do you use to initiate the inspection? (See PM clock.) Future benefit PM: PM task lists that are initiated by a break-down rather than a usual schedule. The PM is done on a whole machine, assembly line, or process after a section or subsection breaks down. This is a popular method with manufacturing cells where the individual machines are closely coupled. When one machine breaks, then the whole cell is PM'ed. GLO: Generalized Learning Objective means the general items necessary to know to be successful in a job. Each job description would be made up of a series of GLO's. Iatrogenic: Failures that are caused by your own service person. IBM® compatible: A personal computer that follows the rules of the IBM®-type machine. The rules include type of microprocessor chip, setup of internal wiring, ways to communicate, and others. All of the software examples in this text are based on this standard. It is also the most common standard in business. The other standard is based on the Apple Macintosh®. Many of the programs are also available for Apple systems. In-bin work: Maintenance jobs which are not ready to release to the mechanic because you haven't approved or gotten money, parts are on order and not in, or other problem. Inspection list: See Task list. Inspectors: The special crew or special role that has primary responsibility for PM's. Inspectors can be members of the maintenance department or of any other department (machine operators, drivers, security officers, custodians, etc.). Interruptive (task): Any PM task which interrupts the normal operation of a machine, system, or asset. Labor: Physical effort a person has to expend to repair, inspect, or deal with a problem. It is expressed in hours, and can be divided by crafts or skills. Life cycle: This denotes the stage in life of the asset. Three stages are recognized by the author: startup, wealth, breakdown. Life cycle cost (LCC): A total of all costs throughout all of the life cycles. Costs should include PM, repair (labor, parts, and supplies), downtime, energy, ownership, overhead. An adjustment can be made for the time value of money. Log sheet: A document where you make log entry of all small jobs or short repairs. MTBF: Mean Time Between Failures. Important calculation to help set up PM schedules and to determine reliability of a system.


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MTTR: Mean Time To Repair. This calculation helps determine the cost of a typical failure. It also can be used to track skill level, training effectiveness, and effectiveness of maintenance improvements. Maintainability improvement: Also called maintenance improvement. Maintenance engineering activity that looks at the root cause of breakdowns and maintenance problems and designs a repair that prevents breakdowns in the future. Also includes improvements to make the equipment more easily maintained. Maintenance: The dictionary definition is "the act of holding or keeping in a preserved state." The dictionary doesn't say anything about repairs. It presumes that we are acting in such a way to avoid the failure by preserving the asset. Maintenance prevention: Maintenance-free designs resulting from increased effectiveness in the initial design of the equipment. Management: The act of controlling or handling. Meter master: Form designed to record meter readings. There is also space for the subtraction for usage calculations. MSDS: Material Safety Data Sheets. These sheets should come with any chemicals that you purchase. They give the formal name of the chemical, describe its toxicity, and have warnings on use. One master copy should be kept in the maintenance technical library. Noninterruptive task list: PM task list where all of the tasks can safely be done without interrupting production of the machine. Nonscheduled work: Work that you didn't know about and plan for at least the day before. Work falls into three categories: 1) emergency, 2) DIN, 3) routine. Parts: All of the supplies, machine parts, and materials to repair an asset, or a system in or around an asset. PCR: Planned Component Replacement. Maintenance schedules component replacement to a schedule based on MTBF, downtime costs, and other factors. Technique for ultrahigh reliability favored by the aircraft industry. Pending work: Work that has been issued to a mechanic or contractor that is unfinished. It is important to complete all pending work. Planned maintenance: See Scheduled work. PM: Preventive Maintenance is a series of tasks that either extend the life of an asset, or that detect that an asset has had critical wear and is going to fail or break down. PM clock: The parameter that initiates the PM task list for scheduling; usually buildings and assets in regular use (for example, PM every 90 days). Assets used irregularly may use other production measures such as pieces, machine hours, or cycles. PM frequency: How often the PM task list will be done. Frequency is driven by the PM clock. (See Frequency of inspection.) Predictive maintenance: Maintenance techniques that inspect an asset to predict if a failure will occur. For example, an infrared survey might be done of an electrical distribution system looking for hot spots (which would be likely to fail). In industry, predictive maintenance is usually associated with advanced technology such as infrared or vibration analysis. Priority: The relative importance of the job. A safety problem would come before an energy improvement job. Proactive: Action before a stimulus (opposite of reactive). A proactive maintenance department acts before a breakdown. Reason for write-up (also called reason for repair): Why the work order was initiated. Reasons could include PM activity, capital improvements, breakdown, vandalism, and any others needed in that industry.


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Rework: All work that has to be done over. Rework is bad and indicates a problem in materials, skills, or scope of the original job. (See Call back.) RM: Replacement/ Rehabilitation/ Remodel Maintenance. All activity designed to bring an asset back into good shape, upgrade an asset to current technology, or make an asset more efficient/productive. Root cause (root cause analysis): The root cause is the underlying cause of a problem. For example, you can snake out an old cast or galvanized sewer line every month and never be confident that it will stay open. The root cause is the hardened buildup inside the pipes which necessitates pipe replacement. Analysis would study the slow drainage problem and determine what was wrong and also estimate the cost of leaving it in place. Some problems (not usually this type of example) should not be fixed. Root cause analysis will show this. Route maintenance: Mechanic has an established route through your facility to fix all the little problems reported to them. The route mechanic is usually very well equipped so he/she can deal with most small problems. Route maintenance and PM activity are sometimes combined. Routine work: Work that is done on a routine basis where the work and material content is well known and understood, for example, daily line startups. Scheduled work: Work that is written up by an inspector and known about at least 1 day in advance. The scheduler will put the work into the schedule to be done. Sometimes the inspector finds work that must be done immediately which becomes emergency or DIN. Same as planned maintenance or corrective maintenance. Short repairs: Repairs that a PM or route person can do in less than 30 minutes with the tools and materials that he/she carries. SLO: Specific Learning Objective is the detailed knowledge, skill, or attitude necessary to be able to do a job. SM: Seasonal Maintenance. All maintenance activities that are related to time of year or time in business cycle. Cleaning roof drains of leaves after the autumn would be a seasonal demand. A swimming pool chemical company might have some November activities to prepare for the next season. String-based PM: Usually simple PM tasks that are strung to-gether on several machines. Examples of string PM's would include lubrication, filter change, or vibration routes. Survey: A formal look around. All of the aspects of the facility are recorded and defined. The survey will look at every machine, room, and throughout the grounds. The surveyor will note anything that looks like it needs work. SWO: Standing Work Order; work order for routine work. A standing work order will stay open for a week, month, or more. The SWO for daily furnace inspection might stay open for a whole month. Task: One line on a task list (see below) that gives the inspector specific instruction to do one thing. Task list: Directions to the inspector about what to look for during that inspection. Tasks could be to inspect, clean, tighten, adjust, lubricate, replace, etc. Technical library (Maintenance Technical Library): The repository of all maintenance information including (but only limited by your creativity and space) maintenance manuals, drawings, old notes on the asset, repair history, vendor catalogs, MSDS, PM information, engineering books, shop manuals, etc. Terotechnology: "A combination of management, financial, engineering, and other practices applied to physical assets in pursuit of economic life-cycle costs (LCC). Its practice is concerned with specification and design for reliability and maintainability of plant machinery, equipment, buildings, and structures with their installation, commissioning, maintenance, modification, and replacement, and with feedback of information on design, performance, and costs" (from the definition endorsed by the British Standards Institute). TPM: Total Productive Maintenance. A maintenance system set up to eliminate all of the barriers to production. It uses autonomous maintenance teams to carry out most maintenance activity.


UM: User Maintenance. This is any maintenance request primarily driven by a user. It includes breakdown, routine requests, and DIN jobs. Unit: The asset that the task list is written for in a PM system. The unit can be a machine, a system, or even a component of a large machine. Work order: Written authorization to proceed with a repair or other activity to preserve a building or asset. Work request: Formal request to have work done. Can be filled out by an inspector during an inspection on a write-up form or by a maintenance user. Work requests are usually time/date stamped.

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MAINTENANCE TERMINOLOGY

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Maintenance Terminology. A Actuarial analysis - Statistical analysis of failure data to determine the age-reliability characteristics of an item. APL - See Applications Parts List Applications Parts List - A list of all parts required to perform a specific maintenance activity. Typically set up as a standard list attached to a Standard Job for Routine Tasks. Not to be confused with a Bill of Materials . Apprentice - a tradesperson (or craftsperson) in training Asset - unlike in the accounting definition, in maintenance this is commonly taken to be any item of physical plant or equipment. Asset Management - the systematic planning and control of a physical resource throughout its life. This may include the specification, design, and construction of the asset, its operation, maintenance and modification while in use, and its disposal when no longer required. Asset Register - a list of all the Assets in a particular workplace, together with information about those assets, such as manufacturer, vendor, make, model, specifications etc. Availability - the proportion of total time that an item of equipment is capable of performing its specified functions, normally expressed as a percentage. It can be calculated by dividing the equipment available hours by the total number of hours in any given period. One of the major sources of disagreement over the definition of availability is whether downtime should be divided by total hours, or by Scheduled Operating Time. For example, if your plant is only scheduled to operate 5 days a week, should downtime incurred over the weekend be included in the calculation of availability? The view I take is that one of the prime goals of any organisation should be to maximise its Return on Assets . This can only be achieved by reducing the total downtime, regardless of whether this downtime was scheduled or not. For this reason, I prefer to use a definition of downtime that considers all downtime, as a proportion of total time, not scheduled operating time. Available Hours - the total number of hours that an item of equipment is capable of performing its specified functions. It is equal to the total hours in any given period, less the downtime hours. Average Life - how long, on average, a component will last before it suffers a failure. Commonly measured by Mean Time Between Failures.

B Backlog - Work which has not been completed by the nominated 'required by date'. The period for which each Work Order is overdue is defined as the difference between the current date and the 'required by date'. All work for which no 'required by' date has been specified is generally included on the backlog. Backlog is generally measured in "crew-weeks", that is, the total number of labour hours represented by the work on the backlog, divided by the number of labor hours available to be worked in an average week by the work crew responsible for completing this work. As such, it is one of the common Key Performance Indicators used in maintenance. Benchmarking - the process of comparing performance with other organisations, identifying comparatively high performance organisations, and learning what it is they do that allows them to achieve that high level of performance. Bill of Materials - a list of all the parts and components that make up a particular asset. Not to be confused with an Applications Parts List.


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BOM - see Bill of Materials . Breakdown - a specific type of failure, where an item of plant or equipment is completely unable to function. Breakdown Maintenance - see No Scheduled Maintenance

C Call-out - To summon a tradesperson to the workplace during his normal non-working time so that he can perform a maintenance activity (normally an emergency maintenance task) CBM - see Condition Based Maintenance CMMS - see Computerized Maintenance Management System Component - a subassembly of an Asset, usually removable in one piece and interchangeable with other, standard components (eg. Truck engine). Computerized Maintenance Management System - a computerized system to assist with the effective and efficient management of maintenance activities through the application of computer technology. It generally includes elements such as a computerised Work Order system, as well as facilities for scheduling Routine Maintenance Tasks, and recording and storing Standard Jobs, Bills of Materials and Applications Parts Lists, as well as numerous other features. Condition Based Maintenance - an equipment maintenance strategy based on measuring the condition of equipment in order to assess whether it will fail during some future period, and then taking appropriate action to avoid the consequences of that failure. The condition of equipment could be monitored using Condition Monitoring, Statistical Process Control techniques, by mo nitoring equipment performance, or through the use of the Human Senses. The terms Condition Based Maintenance, On-Condition Maintenance and Predictive Maintenance can be used interchangeably. Condition Monitoring - the use of specialist equipment to measure the condition of equipment. Vibration Analysis , Tribology and Thermography are all examples of Condition Monitoring techniques. Conditional Probability of Failure - The probability that an item will fail during a particular age interval, given that it survives to enter that age. Contract Acceptance Sheet - A document that is completed by the appropriate Contract Supervisor and Contractor to indicate job completion and acceptance. It also forms part of the appraisal of the contractors performance. Corrective Maintenance - Any maintenance activity which is required to correct a failure that has occurred or is in the process of occurring. This activity may consist of repair, restoration or replacement of components. Craftsperson - Alternative to Tradesperson. A skilled maintenance worker who has typically been formally trained through an apprenticeship program. Criticality - The priority rank of a failure mode based on some assessment criteria.

D Defect - A term typically used in the maintenance of mobile equipment. A defect is typically a potential failure or other condition that will require maintenance attention at some time in the future, but which is not currently preventing the equipment from fulfilling its functions. Discard task - The removal and disposal of items or parts.


Downtime - the time that an item of equipment is out of service, as a result of equipment failure. The time that an item of equipment is available, but not utilised is generally not included in the calculation of downtime.

E Economic Life - the total length of time that an asset is expected to remain actively in service before it is expected that it would be cheaper to replace the equipment rather than continuing to maintain it. In practice, equipment is more often replaced for other reasons, including: because it no longer meets operational requirements for efficiency, product quality, comfort etc., or because newer equipment can provide the same quality and quantity of output more efficiently. Emergency Maintenance Task - a maintenance task carried out in order to avert an immediate safety or environmental hazard, or to correct a failure with signficant economic impact. Engineering Work Order - the prime document used to initiate an engineering investigation, engineering design activity or engineering modifications to an item of equipment. Environmental Consequences - a failure has environmental consequences if it could cause a breach of any known environmental standard or regulation. Equipment Life - this term often isn't very useful, in a practical sense. For example, if I was to tell you that my Aunt has an axe that she uses for chopping firewood, and in the last 40 years it has had 2 new axeheads and 5 new handles, how would you define the life of the axe? Perhaps it makes more sense to talk about Component Life. Also see Economic Life, Useful Life and Average Life for some more practical definitions. Equipment Maintenance Strategies - the choice of routine maintenance tasks and the timing of those tasks, designed to ensure that an item of equipment continues to fulfil its intended functions. Estimated Plant Replacement Value - the estimated cost of capital works required to replace all the existing assets with new assets capable of producing the same quantity and quality of output. This is a key value often used in benchmarking activities. Estimating Index - the ratio of Estimated Labor Hours required to complete the work specified on Work Orders to the Actual Labor Hours required to complete the work specified on those Work Orders, commonly expressed as a percentage. This is a commonly used measure of Labor productivity, particularly when there are welldefined Estimating standards. A figure of greater than 100% for the Estimating Index indicates a higher than standard level of productivity, while a figure of less than 100% indicates a lower than standard level of productivity. EWO - see Engineering Work Order Expert System - a software based system which makes or evaluates decisions based on rules established within the software. Typically used for fault diagnosis.

F Fail-safe - an item is fail-safe if, when the item itself incurs a failure, that failure becomes apparent to the operating workforce in the normal course of events. Failure - an item of equipment has suffered a failure when it is no longer capable of fulfilling one or more of its intended functions. Note that an item does not need to be completely unable to function to have suffered a failure. For example, a pump that is still operating, but is not capable of pumping the required flow rate, has failed. In Reliability Centered Maintenance terminology, a failure is often called a Functional Failure. Would you classify a planned equipment shutdown as a failure? Would you classify a routine equipment shutdown at shift change as a failure? Under this definition, the answer in the first case would be yes, but in the second case would be no. The justification for the inclusion of planned shutdowns as failures is that a failure, as defined,

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causes a disruption to the desired steady-state nature of the production process, and therefore should, ideally, be avoided. Failure Cause - see Failure Mode Failure Code - a code typically entered against a Work Order in a CMMS which indicates the cause of failure (eg. lack of lubrication, metal fatigue etc.) Failure Consequences - a term used in Reliability Centered Maintenance. The consequences of all failures can be classified as being either Hidden, Safety, Environmental, Operational, or Non-Operational. Failure Effect - a description of the events that occur after a failure has occurred as a result of a specific Failure Mode. Used in Reliability Centered Maintenance, FMEA and FMECA analyses. Failure Finding Interval - the frequency with which a Failure Finding Task is performed. Is determined by the frequency of failure of the Protective Device, and the desired availability required of that Protective Device. Failure Finding Task - Used in Reliability Centered Maintenance terminology. A routine maintenance task, normally an inspection or a testing task, designed to determine, for Hidden Failures, whether an item or component has failed. A failure finding task should not be confused with an On-Condition Task, which is intended to determine whether an item is about to fail. Failure Finding tasks are sometimes referred to as Functional Tests. Failure Mode - any event which causes a failure. Failure Modes, Effects and Criticality Analysis - a structured method of assessing the causes of failures and their effect on production, safety, cost, quality etc. Failure Modes and Effects Analysis - a structured method of determining equipment functions, functional failures, assessing the causes of failures and their failure effects. The first part of a Reliability Centered Maintenance analysis is a Failure Modes and Effects Analysis. Failure Pattern - the relationship between the Conditional Probability of Failure of an item, and its age. Failure patterns are generally applied to Failure Modes. Research in the airline industry established that there are six distinct failure patterns. The type of failure pattern that applies to any given failure mode is of vital importance in determining the most appropriate equipment maintenance strategy. This fact is one of the key principles underlying Reliability Centered Maintenance. FFI - pronounced "Fifi", but has nothing to do with a French maid. See Failure Finding Interval FMECA - see Failure Modes, Effects and Criticality Analysis FMEA - see Failure Modes and Effects Analysis Forward Workload - All known backlog work and work which is due or predicted to become backlog work within a pre-specified future time period.

FTA - Fault Tree Analysis Function - The definition of what we want an item of equipment to do, and the level of performance which the users of the equipment require when it does it. Note that an item of equipment can have many functions, commonly split into Primary and Secondary Functions. Note also that the level of performance specified is that required by the users of the equipment, which may be quite different to the original design, or maximum, performance capability for the equipment. Functional Failure - Used in Reliability Centered Maintenance terminology. The inability of an item of equipment to fulfil one or more of its functions. Interchangeably used with Failure. Functional Test - see Failure Finding Task


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G Gantt Chart - A bar chart format of scheduled activities showing the duration and sequencing of activities. Go-line - Used in relation to mobile equipment. Equipment which is available, but not being utilized is typically parked on the Go -line. This term is used interchageably with Ready Line.

H Hazop - a structured process, originally developed by ICI following the Flixborough disaster, intended to proactively identify equipment modifications and/or safety devices required in order to avoid any significant safety or environmental incident as a result of equipment failure. Similar, in some respects to Reliability Centered Maintenance, but not as rigorous as Reliability Centered Maintenance in identifying underlying causes of failure, and does not consider, in any depth, the possibility of avoiding such incidents through applying appropriate Proactive Maintenance tasks. Hidden Failure - a failure which, on its own, does not become evident to the operating crew under normal circumstances. Typically, protective devices which are not fail-safe (examples could include standby plant and equipment, emergency systems etc.)

I Infant Mortality - The relatively high conditional probability of failure during the period immediately after an item returns to service. Inherent Reliability - A measure of the reliability of an item, in its present operating context , assuming adherence to ideal equipment maintenance strategies. Inspection - Any task undertaken to determine the condition of equipment, and/or to determine the tools, labour, materials, and equipment required to repair the item.

J K Key Performance Indicators - A select number of key measures that enable performance against targets to be monitored. KPI - see Key Performance Indicators

L Life - that strange experience you have all day, every day. In a maintenance context, you may want to look at Equipment Life. LCC - see Life Cycle Costing Life Cycle Costing - - a process of estimating and assessing the total costs of ownership, operation and maintenance of an item of equipment during its projected equipment life. Typically used in comparing alternative equipment design or purchase options in order to select the most appropriate option.


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Logistic support analysis (LSA) - A methodology for determining the type and quantity of logistic support required for a system over its entire lifecycle. Used to determine the cost effectiveness of asset based solutions. LSA - see Logistic Support Analysis

M Maintainability - the ease and speed with which any maintenance activity can be carried out on an item of equipment. May be measured by Mean Time to Repair. Is a function of equipment design, and maintenance task design (including use of appropriate tools, jigs, work platforms etc.). Maintainability Engineering - The set of technical processes that apply maintainability theory to establish system maintainability requirements, allocate these requirements down to system elements and predict and verify system maintainability performance. Maintenance - any activity carried out on an asset in order to ensure that the asset continues to perform its intended functions, or to repair the equipment. Note that modifications are not maintenance, even though they may be carried out by maintenance personnel. Maintenance Engineering - a staff function whose prime responsibility is to ensure that maintenance techniques are effective, that equipment is designed and modified to improve maintainability, that ongoing maintenance technical problems are investigated, and appropriate corrective and improvement actions are taken. Used interchangeably with Plant Engineering and Reliability Engineering. Maintenance Policy - a statement of principle used to guide Maintenance Management decision making Maintenance Schedule - a list of planned maintenance tasks to be performed during a given time period, together with the expected start times and durations of each of these tasks. Schedules can apply to different time periods (eg. Daily Schedule, Weekly Schedule etc.) Maintenance Strategy - a long-term plan, covering all aspects of maintenance management which sets the direction for maintenance management, and contains firm action plans for achieving a desired future state for the maintenance function. Mean Time Between Failures - a measure of equipment reliability. Equal to the total equipment uptime in a given time period, divided by the number of failures in that period. Mean Time To Repair - a measure of maintainability. Equal to the total equipment downtime in a given time period, divided by the number of failures in that period. MIL-HDBK- United States Military Handbook MIL-STD- United States Military Standard Model Work Order - A Work Order stored in the CMMS which contains all the necessary information required to perform a maintenance task. (see also Standard Job) Modification - any activity carried out on an asset which increases the capability of that asset to perform its required functions. MTBF - see Mean Time Between Failures MTTR - see Mean Time To Repair

N NDT - see Non-Destructive Testing


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No Scheduled Maintenance - an Equipment Maintenance Strategy, where no routine maintenance tasks are performed on the equipment. The only maintenance performed on the equipment is Corrective Maintenance, and then only after the equipment has suffered a failure. Also described as a Run-to-Failure strategy. Non-Destructive Testing - testing of equipment, which does not destroy the equipment, to detect abnormalities in physical, chemical or electrical characteristics. For some reason which escapes me, vibration analysis and tribology are not generally considered to be NDT techniques, even though they meet the above criteria. Techniques which are considered to be NDT techniques are ultrasonic thickness testing, dye penetrant testing, x-raying, and electrical resistance testing. Non-Operational Consequences - a failure has non-operational consequences if the only impact of the failure is the direct cost of the repair (plus any secondary damage caused to other equipment as a result of the failure. Non-routine Maintenance - Any maintenance task which is not performed at a regular, pre-determined frequency.

O Oil Analysis - see Tribology On-Condition Maintenance - see Condition Based Maintenance Operating Context - the operational situation within which an asset operates. For example, is it a stand-alone piece of plant, or is it one of a duty-standby pair? Is it part of a batch manufacturing process or a continuous production process? What is the impact of failure of this item of equipment on the remainder of the production process? The operating context has enormous influence over the choice of appropriate equipment maintenance strategies for any asset. Operating Hours - the length of time that an item of equipment is actually operating. Operational Consequences - a failure has operational consequences if it has a direct adverse impact on operational capability (lost production, increased production costs, loss of product quality, or reduced customer service) Operational Efficiency- used in the calculation of Overall Equipment Effectiveness. The actual output produced from an asset in a given time period divided by the output that would have been produced from that asset in that period, had it produced at its rated capacity. Normally expressed as a percentage. Outage - a term used in some industries (notably power generation) which is equivalent to a shutdown . Overall Equipment Effectiveness - a term initially coined in connection with Total Productive Maintenance. It provides a measure of overall asset productivity. Is generally expressed as a percentage, and can be calculated by multiplying Availability by Utilization by Operational Efficiency by Quality Rate. Overhaul - a comprehensive examination and restoration of an asset to an acceptable condition.

P P-F Interval - a term used in Reliability Centered Maintenance. The time from when a Potential Failure can first be detected on an asset or component using a selected Predictive Maintenance task, until the asset or component has failed. Reliability Centered Maintenance principles state that the frequency with which a Predictive Maintenance task should be performed is determined solely by the P-F Interval. PdM - see Predictive Maintenance


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Percent Planned Work - the percentage of total work (in labour hours) performed in a given time period which has been planned in advance. PERT Chart - see Project Evaluation & Review Technique (PERT) Chart Planned Maintenance - any maintenance activity for which a pre-determined job procedure has been documented, for which all labour, materials, tools, and equipment required to carry out the task have been estimated, and their availability assured before commencement of the task. Plant Engineering - - a staff function whose prime responsibility is to ensure that maintenance techniques are effective, that equipment is designed and modified to improve maintainability, that ongoing maintenance technical problems are investigated, and appropriate corrective and improvement actions are taken. Used interchangeably with Maintenance Engineering and Reliability Engineering. PM - see Preventive Maintenance Potential Failure - a term used in Reliability Centered Maintenance. An identifiable condition which indicates that a functional failure is either about to occur, or in the process of occurring. PRA - see Probabalistic Risk Assessment Predictive Maintenance - an equipment maintenance strategy based on measuring the condition of equipment in order to assess whether it will fail during some future period, and then taking appropriate action to avoid the consequences of that failure. The condition of equipment could be monitored using Condition Monitoring, Statistical Process Control techniques, by monitoring equipment performance, or through the use of the Human Senses. The terms Condition Based Maintenance, On-Condition Maintenance and Predictive Maintenance can be used interchangeably. Preventive Maintenance - an equipment maintenance strategy based on replacing, overhauling or remanufacturing an item at a fixed interval, regardless of its condition at the time. Scheduled Restoration tasks and Scheduled Discard tasks are both examples of Preventive Maintenance tasks. Primary Function - a term used in Reliability Centered Maintenance. The primary functionality required of an asset - the reason the asset was acquired. For example it is likely that the primary function of a pump is to pump a specified liquid at a specified rate against a specified head of pressure. Priority - the relative importance of a task in relation to other tasks. Used in scheduling work orders. Proactive Maintenance - Any tasks used to predict or prevent equipment failures.

Probabalistic Risk Assessment - A "top-down" approach used to apportion risk to individual areas of plant and equipment, and possibly to individual assets so as to achieve an overall target level of risk for a plant, site or organisation. These levels of risk are then used in risk-based techniques, such as Reliability Centered Maintenance and Hazop, to assist in the development of appropriate equipment maintenance strategies, and to identify required equipment modifications. Probabalistic Safety Assessment - Similar to Probabalistic Risk Assessment, except focused solely on Safety related risks. Project Evaluation & Review Technique (PERT) Chart - Scheduling tool which shows in flow chart format the interdependencies between project activities. Protective Device - Devices and assets intended to eliminate or reduce the consequences of equipment failure. Some examples include standby plant and equipment, emergency systems, safety valves, alarms, trip devices, and guards.


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PSA - see Probabalistic Safety Assessment Purchase Requisition - The prime document raised by user departments authorising the purchase of specific materials, parts, supplies, equipment or services from external suppliers. Purchase Order - The prime document raised by an organisation, and issued to an external supplier, ordering specific materials, parts, supplies, equipment or services.

Q Quality Rate - used in the calculation of Overall Equipment Effectiveness. The proportion of the output from a machine or process which meets required product quality standards. Normally specified as a percentage.

R RCM - see Reliability Centered Maintenance Ready Line - Used in relation to mobile equipment. Equipment which is available, but not being utilized is typically parked on the Ready Line. This term is used interchageably with Go-Line. Redesign - a term which, in Reliability Centered Maintenance, means any one-off intervention to enhance the capability of a piece of equipment, a job procedure, a management system or people's skills Reliability - the capability of an asset to continue to perform its intended functions. Normally measured by Mean Time Between Failures Reliability Centered Maintenance - A structured process, originally developed in the airline industry, but now commonly used in all industries to determine the equipment maintenance strategies required for any physical asset to ensure that it continues to fulfil its intended functions in its present operating context. A number of books have been written on the subject, but none better than Moubray's book, RCM II. Reliability Engineering - - a staff function whose prime responsibility is to ensure that maintenance techniques are effective, that equipment is designed and modified to improve maintainability, that ongoing maintenance technical problems are investigated, and appropriate corrective and improvement actions are taken. Used interchangeably with Plant Engineering and Maintenance Engineering. Repair - any activity which returns the capability of an asset that has failed to a level of performance equal to, or greater than, that specified by its Functions, but not greater than its original maximum capability. An activity which increases the maximum capability of an asset is a modification. Restoration - any activity which returns the capability of an asset that has not failed to a level of performance equal to, or greater than, that specified by its Functions, but not greater than its original maximum capability. Not to be confused with a modification or a repair. Return on Assets - an accounting term. Let's not get into a lengthy discussion of the relative merits of various accounting standards, how assets should be valued (book value, replacement value, depreciation rates and methods etc.), and differences between tangible and intangible assets. This is the stuff that accountants have wet dreams over, but not maintenance engineers. In practical terms, as it impacts on maintenance, Return on Assets is the profit attributable to a particular plant or factory, divided by the amount of money invested in plant and equipment at that plant or factory. It is normally expressed as a percentage. As such, it is roughly equivalent (in principle - please excuse the pun!) to the interest rate that you get on money invested in the bank, except that in this case the money is invested in plant and equipment. Risk - The potential for the realisation of the unwanted, negative consequences of an event. The product of conditional probability of an event, and the event outcomes.


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Rotable - a term often used in the maintenance of heavy mobile equipment. A rotable component is one which, when it has failed, or is about to fail, is removed from the asset and a replacement component is installed in its place. The component that has been removed is then repaired or restored, and placed back in the maintenance store or warehouse, ready for re-issue. Routine Maintenance Task - any maintenance task that is performed at a regular, predefined interval. Run-to-Failure - No Scheduled Maintenance - an Equipment Maintenance Strategy, where no routine maintenance tasks are performed on the equipment. The only maintenance performed on the equipment is Corrective Maintenance, and then only after the equipment has suffered a failure. Also described as a No Scheduled Maintenance strategy.

S Safety Consequences - a failure has safety consequences if it causes a loss of function or other damage that could hurt or kill someone. Schedule Compliance - one of the Key Performance Indicators often used to monitor and control maintenance. It is defined as the number of Scheduled Work Orders completed in a given time period (normally one week), divided by the total number of Scheduled Work Orders that should have been completed during that period, according to the approved Maintenance Schedule for that period. It is normally expressed as a percentage, and will always be less than or equal to 100%. The closer to 100%, the better the performance for that time period. Scheduled Maintenance - any maintenance work that has been planned and included on an approved Maintenance Schedule. Scheduled Discard Task - a maintenance task to replace a component with a new component at a specified, pre-determined frequency, regardless of the condition of the component at the time of its replacement. An example would be the routine replacement of the oil filter on a motor vehicle every 6,000 miles. The frequency with which a Scheduled Discard task should be performed is determined by the Useful Life of the component. Scheduled Operating Time - the time during which an asset is scheduled to be operating, according to a longterm production schedule. Scheduled Restoration Task - a maintenance task to restore a component at a specified, pre-determined frequency, regardless of the condition of the component at the time of its replacement. An example would be the routine overhaul of a slurry pump every 1,000 operating hours. The frequency with which a Scheduled Restoration task should be performed is determined by the Useful Life of the component. Scheduled Work Order - a Work Order that has been planned and included on an approved Maintenance Schedule. Secondary Damage - Any additional damage to equipment, above and beyond the initial failure mode, that occurs as a direct consequence of the initial failure mode. Secondary Function - a term used in Reliability Centered Maintenance. The secondary functionality required of an asset - generally not associated with the reason for acquiring the asset, but now that the asset has been acquired, the asset is now required to provide this functionality. For example a secondary function of a pump may be to ensure that all of the liquid that is pumped is contained within the pump (ie. the pump doesn't leak). An asset may have tens or h undreds of secondary functions associated with it. Shutdown - that period of time when equipment is out of service. Shutdown Maintenance - Maintenance that can only be performed while equipment is shutdown Standard Job - A Work Order stored in the CMMS which contains all the necessary information required to perform a maintenance task. (see also Model Work Order)


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Standing Work Order - a work order that is left open either indefinitely or for a pre-determined period of time for the purpose of collecting labor hours. costs and/or history for tasks for which it has been decided that individual work orders should not be raised. Examples would include Standing Work Orders raised to collect time spent at Safety Meetings, or in general housekeeping activities. Stores Issue - the issue and/or delivery of parts and materials from the store or warehouse. Stores Requisition - The prime document raised by user departments authorising the issue of specific materials, parts, supplies or equipment from the store or warehouse.

T Terotechnology - the application of managerial, financial, engineering and other skills to extend the operational life of, and increase the efficiency of, equipment and machinery. Thermography - the process of monitoring the condition of equipment through the measurement and analysis of heat. Typically conducted through the use of infra-red cameras and associated software. Commonly used for monitoring the condition of high voltage insulators and electrical connections, as well as for monitoring the condition of refractory in furnaces and boilers, amongst other applications. Total Asset Management - an integrated approach (yet to be developed!) to Asset Management which incorporates elements such as Reliability Centered Maintenance, Total Productive Maintenance, Design for Maintainability, Design for Reliability, Value Engineering, Life Cycle Costing, Probabalistic Risk Assessment and others, to arrive at the optimum Cost-Benefit-Risk asset solution to meet any given production requirements. TPM - see Total Productive Maintenance Tradesperson - Alternative to Craftsperson. A skilled maintenance worker who has typically been formally trained through an apprenticeship program. Tribology - the process of monitoring the condition of equipment through the analysis of properties of its lubricating and other oils. Typically conducted through the measurement of particulates in the oil, or the measurement of the chemical composition of the oil (Spectographic Oil Analysis). Commonly used for monitoring the condition of large gearboxes, engines and transformers, amongst other applications. ToSS - see Total System Support Total Productive Maintenance - a company-wide equipment management program, with its origins in Japan, emphasising production operator involvement in equipment maintenance, and continuous improvement approaches. Numerous books have been written on the subject, including Nakajima's authoritative introduction, and a more recent Western hemisphere update by Willmott. Total System Support (ToSS) - The composite of all considerations needed to assure the effective and economical support of a system throughout its programmed life-cycle.

U Unplanned Maintenance - any maintenance activity for which a pre-determined job procedure has not been documented, or for which all labour, materials, tools, and equipment required to carry out the task have been not been estimated, and their availability assured before commencement of the task. Unscheduled Maintenance - any maintenance work that has not been included on an approved Maintenance Schedule prior to its commencement. Uptime - strangely enough, the opposite of downtime. It is defined as being the time that an item of equipment is in service and operating.


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Useful Life - the maximum length of time that a component can be left in service, before it will start to experience a rapidly increasing probability of failure. The Useful Life determines the frequency with which a Scheduled Restoration or a Scheduled Discard task should be performed. Note that for the concept of the Useful Life of a component to hold true, components must, at some consistent point in time, experience a rapidly increasing probability of failure. Research in the airline industry showed that, in this industry at least, this was only true for 11% of the components in modern aircraft. Utilization - the proportion of available time that an item of equipment is operating. Calculated by dividing equipment operating hours by equipment available hours. Generally expressed as a percentage

V Value Engineering - a systematic approach to assessing and analyzing the user's requirements of a new asset, and ensuring that those requirements are met, but not exceeded. Consists primarily of eliminating perceived "non-value-adding" features of new equipment. Vibration Analysis - - the process of monitoring the condition of equipment, and the diagnosis of faults in equipment through the measurement and analysis of vibration within that equipment. Typically conducted through hand-held or permanently positioned accelerometers placed on key measurement points on the equipment. Commonly used on most large items of rotating equipment, such as turbines, centrifugal pumps, motors, gearboxes etc.

W Work Order - The prime document used by the maintenance function to manage maintenance tasks. It may include such information as a description of the work required, the task priority, the job procedure to be followed, the parts, materials, tools and equipment required to complete the job, the labor hours, costs and materials consumed in completing the task, as well as key information on failure causes, what work was performed etc. Work Request - The prime document raised by user departments requesting the initiation of a maintenance task. This is usually converted to a work order after the work request has been authorised for completion. Workload - the amount of labor hours required to carry out specified maintenance tasks.

X,Y,Z.

BEARING GLOSSARY

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GLOSSARY OF BEARINGS.

A.B.E.C. Annular Bearing Engineering Committee. Used as prefix for tolerance grades of bearings as set up by this committee. A.B.E.C. 1-3-5-7-9 Annular Bearing Engineers Committee classes or grades of ball bearing precision. A.F.B.M.A. The Anti-Friction Bearing Manufacturers Association. They have set up standards for the bearing industry. Adapter Assembly Assembly consisting of adapter sleeve, locknut and lockwasher. Adapter Sleeve Axially slotted sleeve with cylindrical bore, tapered outside surface and male screw thread at small end used with locknut and lockwasher for mounting of bearings with tapered bore on cylindrical outside surface of shaft. Also called pull-type sleeve. Aircraft Bearing A term applied generally to bearings used by the aircraft industry or the Air Force. Airframe Bearing A bearing designed for use in the control systems and surfaces of aircraft. Angular Contact Bearing A type of ball bearing whose internal clearances and ball race locations are such as to result in a definite contact angle between the races and the balls when the bearing is in use. Annular Ball Bearing A rolling element bearing designed primarily to support a load perpendicular to the shaft axis. Also: Radial Type Bearing. Anti-friction Bearing Commonly used term for rolling element bearing. Axial In the same direction as the axis of the shaft. Axial Internal Clearance In ball or roller bearing assembly, total maximum possible movement parallel to bearing axis of inner ring in relation to outer ring. Also called bearing end play. Axial Load Load exerted parallel to the axis of the shaft on which the bearing is mounted, also called thrust load. Axis An imaginary line running through the center of a shaft on which a bearing is mounted. Ball A spherical rolling element.

BEARING GLOSSARY

Ball Bearing A bearing using balls as the rolling elements. Ball Cage A device which partly surrounds the balls and travels with them, the main purpose of which is to space the balls. Also Separator: Retainer: Ball Spacer. Ball Complement Number of balls used in a ball bearing. Ball Contact Area of contact between raceway and ball. Ball Diameter The dimension measured across the ball center. Ball Pocket A drilled, stamped, or molded receptacle that holds the ball in a cage. Basic Dynamic Load Rating Basic dynamic load rating, Cr, is the calculated constant radial load (thrust load for thrust bearings) which a group of identical bearings with stationary outer rings can theoretically endure for rating life of 1 million revolutions of inner ring. Bore The smallest internal dimension of inner or outer ring or separator. Also, the surface of the inner ring that fits against the shaft. Boundary Dimensions Dimensions for bore, width, outside diameter and corner radius. Cage See Ball Cage. Cam Follower See Track roller Cartridge Bearing An extra wide double shielded or sealed bearing designed to increase grease capacity of bearing. Concentric Having the same center. Cone Inner ring of tapered roller bearing. Conrad Standard single row deep-groove bearing named for the inventor of its assembly method, Joseph Conrad. Contact Angle Formed by a line drawn between the areas of ball and ring contact and a line perpendicular to the bearing axis. Counterbored Ball Bearing Portion of one race shoulder turned and ground away to facilitate assembly with a greater number of balls. A nonseparable ball bearing with one side of the raceway removed from either or both rings to facilitate manufacturing assembly. Normally the outer ring is counterbored. Double Row Bearing A bearing with two rows of rolling elements. Double Row Maximum Capacity A bearing that has a solid inner and outer with two raceways and filling notches to permit the maximum number of balls to be inserted.

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BEARING GLOSSARY

Drawn Cup Needle Roller Bearing Needle roller radial bearing with thin pressed steel outer ring (drawn cup), which may have one closed end or both ends open. Usually emp loyed without inner ring. Duplex Bearing A duplex bearing is a bearing with controlled axial location of faces of inner and outer rings which makes this bearing suitable for mounting in various combinations with one or more bearings controlled in the same manner. Dynamic Load A load exerted on a bearing in motion. Eccentric Not having the same center. End Play The axial play of the outer ring in a bearing. The measured maximum possible movement parallel to bearing axis of the inner ring in relation to outer ring. External Race The ball path on an inner ring. Also - Inner Raceway, Inner Ring Raceway. Face The side surface of a bearing. See also Thrust Face. Fillet Radius The corner dimension in a bearing housing that the bearing external corner radius or chamfer must clear. Filling Notch A slot or notch cut in the shoulder of a ring to allow the loading of the maximum number of balls. Also Filling Notch; Loading Groove. Finish A term usually applied to the last machining operation on any surface of a bearing, such as "Finish O.D., " "Finish bore, " etc. Fit The amount of internal clearance in a bearing. Fit can also be used to describe shaft and housing size and how they relate to the bore or outside diameter. Fixed Bearing Bearing which positions shaft against axial movement in both directions. Floating Bearing Bearing designed or mounted so as to permit axial displacement between shaft and housing. Full Complement Bearing Rolling bearing without cage in which sum of clearances between rolling elements in each row is less than the diameter of rolling elements and small enough to give satisfactory function of bearing. Hardening Process of heating parts to a high temperature and then quenching in oil, water, air, or solution. Heading Rivets Process of hitting rivets in a press to form the heads.

Housing, Bearing The opening in which a bearing is contained in a machine. The part of a machine that contains this opening.

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BEARING GLOSSARY

Housing Fit Amount of interference or clearance between bearing outside surface and housing bearing seat. Hydraulic Nut Collar temporarily fixed to shaft which incorporates hydraulic annular piston to transmit axial mounting or dismounting force to bearing inner ring. ISO International Standards Organization. Inch Dimension Bearing A bearing having boundary dimensions made to integral or/and fractional inch figures rather than metric figures. Inner See Inner Ring Inner Ring The inner part of a bearing that fits on a shaft and contains the external raceway for the rolling elements. Sometimes the shaft is stationary and the housing rotates. Inner Ring Raceway See External Race. Internal Clearance See Radial Clearance. Internal Race The ball or roller path on the bore of the outer ring. Outer Ring Raceway. Outer Raceway. Land Commonly called the O.D. of the inner and the I.D. of the outer. Lapping An abrading process for refining the surface finish and the geometrical accuracy of a surface. Life "Life" of individual rolling bearing is the number of revolutions (or hours at some given constant speed) which bearing runs before first evidence of fatigue develops in the material of either ring or washer or any of rolling elements. Limits Maximum and minimum allowable dimensions, resulting from the application of predetermined tolerances to a specified dimension. Lock Nut A nut used in combination with a lock washer to hold a bearing in place on a shaft. Lock Washer A washer with tongue and prongs to hold a lock nut in place. Locking Collar, Concentric Ring fitting over extended inner ring of insert bearing and having setscrews which pass through holes in inner ring to make contact with shaft.

Locking Collar, Self Ring having recess on one side which is eccentric in relation to bore and fits over equally eccentric extension of inner

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BEARING GLOSSARY

ring insert bearing. Collar is turned in relation to inner ring until it locks and then secured to shaft by tightening of setscrews. Loose Fit A fit or fit up of inner ring, balls, and outer ring which results in the existence of appreciable radial clearance. Maximum Capacity Bearing A bearing with filling notches to allow the loading of the maximum number of balls. Misalignment Lack of parallelism between axis of rotating memeber and stationary member. Needle Roller Cylindrical roller of small diameter with large ration of length to diameter. Generally accepted that length is between three and ten times diameter which is usually less than 5 mm. O.D. Outer Diameter; Outside Diameter. Outer See Outer Ring. Outer Raceway See Internal Race. Outer Ring The outer part of a bearing that fits into the housing and contains the internal raceway for the rolling elements. Outer Ring Raceway See Internal Race. Pocket The portion of a cage shaped to hold the ball or roller. Also Ball Pocket; Roller Pocket. Preload An internal loading characteristic in a bearing which is independent of any external radial and/or axial load carried by the bearing. Prelubricated Bearing A shielded, sealed, or open bearing originally lubricated by the manufacturer. RBEC-1, -5 Class or degree of precision of anti-friction roller bearings. Raceway The ball or roller path; cut in the inner and outer ring in which the balls or rollers ride. Also Guide Path; Race; Ball Path; Roller Path. Raceway Diameter Inner Ring -- the outer dimension across the diameter from raceway bottom to raceway bottom. Outer Ring -- the inner dimension across the diameter from raceway bottom to raceway bottom. Radial Clearance The radial internal clearance of a single row radial contact ball bearing is the average outer ring race diameter, minus the average inner ring race diameter, minus twice the ball diameter.

Radial Load A load exerted perpendicular to the axis.

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BEARING GLOSSARY

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Radial Play See Radial Clearance. Radial Type Bearing In general, a rolling element bearing primarily designed to support load perpendicular to the axis. Also: Annular Bearing. Rating Life L10 of group of apparently identical bearings is the life in millions of revolutions that 90% of the group will complete or exceed. Relieved End Roller Roller with slight modification of diameter at ends of outside surface to reduce stress concentrationat contacts between rollers and raceways. Retainer See Ball Cage. Riveted Type Ball Cage A type of cage in which the two halves are riveted together around the balls after the balls have been assembled in the rings. Runout, of Assembled Bearing Displacement of surface of bearing relative to fixed point when one raceway is rotated with respect to other raceway. Seal A soft synthetic rubber washer with a steel core fixed in the outer ring (in the seal groove) in contact with the inner ring to retain lubricant and keep out contamination. Self Aligning Ball Bearing Spherical outside diameter ball bearing which can accommodate initial angular misalignment between the outer ring and its mating spherical aligning ring or housing seat. Separable A bearing that may be separated comp letely or partially into its component parts. Separator See Ball Cage. Shaft Fit Amount of interference or clearance between bearing inside diameter and shaft bearing seat outside diameter. Shield A metal formed washer attached to the outer ring and set so it rides close to, but not contacting, the inner ring, to retain lubricant and prevent contamination. Shoulder The side of a ball race, also a surface in a bearing application or shaft which axially positions a bearing and takes the thrust load. Single Row Bearing with one row of rolling elements. Snap Ring A removable ring used to axially position a bearing or outer ring in a housing. Also used as a means of fastening a shield or seal in a bearing.

Solid Cage A solid ring type separator used in a radial or angular contact type bearings.

BEARING GLOSSARY

Spacer Sleeve or sleeves serving to space different bearings on same shaft or different rows of rolling elements in multi-roll bearing. Spherical Roller Bearing Self-aligning, radial rolling bearing with convex rollers or concave rollers as rolling elements. With convex rollers outer ring has spherical raceway, with concave rollers inner ring has spherical raceway. Standard Bearing Bearing which conforms to the basic plan for boundary dimensions of metric or inch dimensions. Static Load A load exerted on a bearing not in motion. Stay Rod A flat elongated rivet used in the cages of maximum capacity bearings. Stay Rod Type Ball Cage Type cage in which the two halves are held together with special stay rod rivets. Thrust Load See Axial Load. Thrust Bearing A bearing designed primarily for thrust loads. Thrust Face Face of thrust bearing against which housing or shaft shoulder pushes. Tolerance The range between two limiting sizes as a means of specifying the degree of accuracy. The amount a given bearing dimension may vary from specifications. The difference between the upper and lower limits of a dimension or a specification. A means of specifying the degree of accuracy. Track Roller Radial roller bearing with heavy section outer ring, intended to roll on track, a.k.a. cam follower. Wide Inner Ring Bearing Bearing with inner ring extended on one or both sides in order to achieve greter shaft support and permit addition of locking device and provide additional space for sealing devices. Withdrawal Sleeve Axial slotted sleeve with cylindrical bore, tapered outside surface and male screw thread at large end. Used for mounting and dismounting (by means of nut) of bearing with tapered bore on cylindrical outside surface of shaft. Also called push-type sleeve.

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Glossary of Pipefitting Terms

Alloy Steel A steel which owes its distinctive properties to elements other than carbon. Area of a Circle The measurement of the surface within a circle. To find the area of a circle, multiply the product of the radius times the radius times Pi (3.142). Braze Weld or Brazing A process of joining metals using a nonferrous filler metal or alloy, the melting point of which is higher than 800 degrees F(427 degrees C) but lower than that of the metals to be joined. Butt Weld A circumferential weld in pipe fusing the abutting pipe walls completely from inside wall to outside wall. Carbon Steel A steel which owes its distinctive properties chiefly to the various percentages of carbon (as distinguished from the other elements) which it contains. Circumference of a Circle The measurement around the perimeter of a circle. To find the circumference, multiply Pi (3.142) by the diameter. Coefficient of Expansion A number indicating the degree of expansion or contraction of a substance. The coefficient of expansion is not constant and varies with changes in temperature. For linear expansion it is expressed as the change in length of one unit of length of a substance having one degree rise in temperature. Corrosion The gradual destruction or alteration of a metal or alloy caused by direct chemical attack or by electromechanical reaction. Creep The plastic flow of pipe within a system; the permanent set in metal caused by stresses at high temperatures. Generally associated with a time rate of deformation. Diameter of a Circle A straight line drawn through the center of a circle from one extreme edge to the other. Equal to twice the radius. Ductility The property of elongation, above the elastic limit, but under the tensile strength. A measure of ductility is the percentage of elongation of the fractured piece over its original length. Elastic Limit The greatest stress which a material can withstand without a permanent deformation after release of the stress.

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Erosion The gradual destruction of metal or other material by the abrasive action of liquids, gases, solids or mixtures thereof Radius of a Circle A straight line drawn from the center to the extreme edge of a circle. Socket Fitting A fitting used to join pipe in which the pipe is inserted into the fitting. A fillet weld is then made around the edge of the fitting and the outside wall of the pipe. Soldering A method of joining metals using fusable alloys, usually tin and lead, having melting points under 700 degrees F(371 degrees C). Strain Change of shape or size of a body produced by the action of a stress. Stress The intensity of the internal, distributed forces which resist a change in the form of a body. When external forces act on a body they are resisted by reactions within the body which are termed stresses. Stress, Compressive One that resists a force tending to crush a body. Stress, Shearing One that resists a force tending to make one layer of a body slide across another layer. Stress, Tensile One that resists a force tending to pull a body apart. Stress, Torsional: One that resists forces tending to twist a body. Tensile Strength The maximum tensile stress which a material will develop. The tensile strength is usually considered to be the load in pounds per square inch at which a test specimen ruptures. Turbulence Any deviation from parallel flow in a pipe due to rough inner walls, obstructions or directional changes. Velocity Time rate of motion in a given direction and sense, usually expressed in feet per second. Volume of a Pipe The measurement of the space within the walls of the pipe. To find the volume of a pipe, multiply the length (or height) of the pipe by the product of the inside radius times the inside radius times Pi (3.142). Welding A process of joining metals by heating until they are fused together, or by heating and applying pressure until there is a plastic joining action. Filler metal may or may not be used. Yield Strength The stress at which a material exhibits a specified inciting permanent set.

VALVE & FITTINGS TERMINOLOGY.

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GLOSSARY OF VALVE TERMINOLOGY.

ACTUATOR: A fluid-powered or electrically powered device that supplies force and motion to a VALVE CLOSURE MEMBER. AIR SET: Also SUPPLY PRESSURE REGULATOR. A device used to reduce plant air supply to valve POSITIONERS and other control equipment. Common reduced air supply pressures are 20 and 35 psig. AIR-TO-CLOSE: An increase in air pressure to the ACTUATOR is required to cause the valve to close. This is another way of saying the valve is Fail Open or Normally Open. AIR-TO-OPEN: An increase in air pressure to the ACTUATOR is required to cause the valve to open. This is another way of saying the valve is FAIL CLOSED or NORMALLY CLOSED. ANSI: An abbreviation for the American National Standards Institute. ANTI-CAVITATION TRIM: A special trim used in CONTROL VALVES to stage the pressure drop through the valve, which will either prevent the CAVITATION from occurring or direct the bubbles that are formed to the center of the flow stream away from the valve BODY and TRIM. This is usually accomplished by causing the fluid to travel along a torturous path or through successively smaller orifices or a combination of both. API: An abbreviation for the American Petroleum Institute. ASME: An abbreviation for the American Society of Mechanical Engineers. ASTM: An abbreviation for the American Society for Testing and Materials. BALANCED TRIM: A trim arrangement that tends to equalize the pressure above and below the valve plug to minimize the net static and dynamic fluid flow forces acting along the axis of the stem of a GLOBE VALVE. Some regulators also use this design, particularly in high pressure service. BELLOWS SEAL BONNET: A BONNET which uses a BELLOWS for sealing against leakage around the valve plug stem. BENCH SET: The proper definition for bench set is the INHERENT DIAPHRAGM PRESSURE RANGE, which is the high and low values of pressure applied to the diaphragm to produce rated valve plug travel with atmospheric pressure in the valve body. This test is often performed on a work bench in the instrument shop prior to placing the valve into service and is thus known as Bench Set. BODY: The body of the valve is the main pressure boundary. It provides the pipe connecting ends and the fluid flow passageway. It can also support the seating surface and the valve CLOSURE MEMBER. BONNET: The bonnet or bonnet assembiy is that portion of the valve pressure retaining boundary which may guide the stem and contains the PACKING BOX and STEM SEAL. The bonnet may be integral to the valve body or bolted or screwed. The bonnet, if it is detachable, will generally provide the opening to the valve body cavity for removal and replacement of the internal TRIM. The bonnet is generally the means by which the actuator is connected to the valve body. BOOSTER: A pneumatic relay that is used to reduce the time lag in pneumatic circuits by reproducing pneumatic signals with high-volume and or high-pressure output. These units may act as volume boosters or as amplifiers. A 1:2 booster will take a 3 to 15 psig input signal and output a 6 to 30 psig signal. It has also been shown that a booster may improve the performance of a control valve by replacing a positioner. It can provide the same stroking speed and can isolate the controller from the large capacitive load of the actuator.


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BUBBLE TIGHT: A commonly used term to describe the ability of a control valve or regulator to shut off completely against any pressure on any fluid. Unfortunately, it is completely unrealistic. Control valves are tested to ANSI B16.104 and FCI 70-2-1976 which is the American National Standard for Control Valve Seat Leakage. This standard uses 6 different classifications to describe the valves seat leakage capabilities. The most stringent of these is Class VI which allows a number of bubbles per minute leakage, depending on the port size of the valve. The correct response to the question "Will that valve go "Bubble Tight"? is to say this valve is tested to meet Class VI shutoff requirements. BUTTERFLY VALVE: A valve with a circular body and a rotary motion disk closure member which is pivotally supported by its stem. Butterfly valves come in various styles including eccentric and highperformance valves. Butterfly valves are HIGH RECOVERY valves and thus tend to induce CAVITATION in liquid services at much lower pressure drops and fluid temperatures than the globe style valve. Due to instability problems with the older design butterfly valves, many people will limit the travel of the valve at 60 degrees of rotation on throttling services. This can also help keep the valve out of CAVITATION problems. CAGE: A hollow cylindrical trim element that is sometimes used as a guide to align the movement of a VALVE PLUG with a SEAT RING. It may also act to retain the seat ring in the valve body. On some types of valves, the cage may contain different shaped openings which act to characterize the flow through the valve. The cage may also act as a NOISE ATTENUATION or ANTI-CAVITATION device. CAGE GUIDED VALVE: A type of GLOBE STYLE valve trim where the valve plugs with the seat. CAVITATION: Occurs only in liquid service. In its simplest terms cavitation is the two-stage process of vaporization and condensation of a liquid. Vaporization is simply the boiling of a liquid, which is also known as FLASHING. In a control valve this vaporization takes place because the pressure of the liquid is lowered, instead of the more common occurrence where the temperature is raised. As fluid passes through a valve just downstream of the orifice area, there is an increase in velocity or kinetic energy that is accompanied by a substantial decrease in pressure or potential energy. This occurs in an area called the VENA CONTRACTA. If the pressure in this area falls below that of the vapor pressure of the flowing fluid, vaporization (boiling) occurs. Vapor bubbles then continue downstream where the velocity of the fluid begins to slow and the pressure in the fluid recovers. The vapor bubbles then collapse or implode. Cavitation can cause a Choked Flow condition to occur and can cause mechanical damage to valves and piping. CHOKED FLOW: Also known as CRITICAL FLOW. This condition exists when at a fixed upstream pressure the flow cannot be further increased by lowering the downstream pressure. This condition can occur in gas, steam, or liquid services. Fluids flow through a valve because of a difference in pressure between the inlet (Pl) and outlet (P2) of the valve. This pressure difference (Delta-P) or pressure drop isessential to moving the fluid. Flow is proportional to the square root of the pressure drop. Which means that the higher the pressure drop is the more fluid can be moved through the valve. If the inlet pressure to a valve remains constant, then the differential pressure can only be increased by lowering the outlet pressure. For gases and steam, which are compressible fluids, the maximum velocity of the fluid through the valve is limited by the velocity of the propagation of a pressure wave which travels at the speed of sound in the fluid. If the pressure drop is sufficiently high, the velocity in the flow stream at the VENA CONTRACTA will reach the velocity of sound. Further decrease in the outlet pressure will not be felt upstream because the pressure wave can only travel at sonic velocity and the signal will never translate upstream. Choked Flow can also occur in liquids but only if the fluid is in a FLASHING or CAVITATING condition. The vapor bubbles block or choke the flow and prevent the valve from passing more flow by lowering the outlet pressure to increase the pres-sure drop. A good Rule Of Thumb on Gases and Steam service is that if the pressure drop across the valve equals or exceeds one half the absolute inlet pressure, then there is a good chance for a choked flow condition. Example: P1 100 psig P2 25 psig _________ Delta P = 75 P1 (ABS) = 100 + 14.7 or 114.7 1/2 of 114.7 = 57.35 Actual pressure drop = 75 Choked Flow is probable.


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The style of valve (that is whether it is a HIGH RECOVERY or a LOW RECOVERY style) will also have an effect on the point at which a choked flow condition will occur. CLOSURE MEMBER: The movable part of the valve which is positioned in the flow path to modify the rate of flow through the valve. Some of the different types of closure members are the Ball, Disk, Gate, and Plug. COEFFICIENT FLOW: A constant (Cv ) that is used to predict the flow rate through a valve. It is related to the geometry of the valve at a given valve opening. See Cv . CONTROL VALVE: Also known as the FINAL CONTROL ELEMENT. A power-operated device used to modify the fluid flow rate in a process control system. It usually consists of a BODY or VALVE and an ACTUATOR, which responds to a signal from the controlling system and changes the position of a FLOW CONTROLLING ELEMENT in the valve. CONTROL VALVE GAIN: The relationship between valve travel and the flow rate through the valve. It is described by means of a curve on a graph expressed as an INSTALLED OR INHERENT CHARACTERISTIC. CONTROLLER: A device which tells a CONTROL VALVE what to do. Controllers can be either pneumatic or electronic. There are pressure, temperature, ph, level, differential, and flow controllers. The job of the controller is to sense one of the above variables and compare it to a set point that has been established. The controller then outputs a signal either pneumatic or electronic to the control valve, which then responds so as to bring the process variable to the desired set point. CRITICAL FLOW: See the definition for CHOKED FLOW. CV: The VALVE FLOW COEFFICIENT is the number of U.S. gallons per minute of 60 degree F water that will flow through a valve at a specified opening with a pressure drop of 1 psi across the valve. DELTA-P: Differential Pressure. The inlet pressure (Pl) minus the outlet pressure (P2). Example: P1 = 100 psig P2 = 25 psig. ___________ Delta-P = 75 DIAPHRAGM: A flexible pressure-responsive element that transmits force to the diaphragm plate and actuator stem. DIAPHRAGM ACTUATOR: Is a fluid (usually pneumatic) pressure-operated, spring-opposed diaphragm assembly which positions the valve stem in response to an input signal. DIAPHRAGM PRESSURE: See Bench Set. DIAPHRAGM VALVE: A valve with a flexible linear motion CLOSURE MEMBER that is forced into the internal flow passageway of the BODY by the ACTUATOR. Pinch or Clamp valves and Weir-type valves fall into this category. DIRECT ACTING: This term has several different meanings depending upon the device it is describing. A DIRECT-ACTING ACTUATOR is one in which the actuator stem extends with an increase in diaphragm pressure. A DIRECT-ACTING VALVE is one with a PUSH-DOWN-TO-C LOSE plug and seat orientation. A DIRECT-ACTING POSITIONER or a DIRECT-ACTING CONTROLLER outputs an increase in signal in response t o an increase in set point. DIRECT ACTUATOR: Is one in which the actuator stem extends with an increase in diaphragm pressure.


DUAL SEATING: A valve is said to have dual seating when it uses a resilient or composition material such as TFE, Kel-F, or Buna-N, etc. for its primary seal and a metal-to-metal seat as a secondary seal. The idea is that the primary seal will provide tight shut-off Class VI and if it is damaged the secondary seal will backup the primary seal with Class IV shut-off. DYNAMIC UNBALANCE: The total force produced on the valve plug in any stated open position by the fluid pressure acting upon it. The particular style of valve, i.e. single-ported, double-ported, flow-to-open, flow-toclose, has an effect on the amount of dynamic unbalance. EFFECTIVE AREA: For a DIAPHRAGM ACTUATOR, the effective area is that part of the diaphragm area that is effective in producing a stem force. Usually the effective area will change as the valve is stroked - being at a maximum at the start and at a minimum at the end of the travel range. Flat sheet diaphragms are most affected by this; while molded diaphragms will improve the actuator performance, and a rolling diaphragm will provide a constant stem force throughout the entire stroke of the valve. ELECTRIC ACTUATOR: Also known as an Electro-Mechanical Actuator uses an electrically operated motor-driven gear train or screw to position the actuator stem. The actuator may respond to either a digital or analog electrical signal. END CONNECTION: The configuration provided to make a pressure-tight joint to the pipe carrying the fluid to be controlled. The most common of these connections are threaded, flanged, or welded. EQUAL PERCENTAGE: A term used to describe a type of valve flow characteristic where for equal increments of valve plug travel the change in flow rate with respect to travel may be expressed as a constant percent of the flow rate at the time of the change. The change in flow rate observed with respect to travel will be relatively small when the valve plug is near its seat and relatively high when the valve plug is nearly wide open. EXTENSION BONNET: A bonnet with a packing box that is extended above the body to bonnet connection so as to maintain the temperature of the packing above (cryogenic service) or below (high-temp service) the temperature of the process fluid. The length of the extension depends on the amount of temperature differential that exists between the process fluid and the packing design temperature. FACE-TO-FACE: Is the distance between the face of the inlet opening and the face of the outlet opening of a valve or fitting. These dimensions are governed by ANSI/ISA specifications. The following Uniform Face-to Face Dimensions apply. SPECIFICATION VALVE TYPE ANSI/ISA S75.03 INTEGRAL FLANGED GLOBE STYLE CONTROL VALVES ANSI/ISA S75.04 FLANGELESS CONTROL VALVES ANSUISA S75.20 SEPARABLE FLANGE GLOBE STYLE CONTROL VALVES FAIL-CLOSED: Or NORMALLY CLOSED. Another way of describing an AIR-TO-OPEN actuator. Approximately 80% of all spring return diaphragm operators in the field are of this construction. FAIL-IN-PLACE: A term used to describe the ability of an actuator to stay at the same percent of travel it was in when it lost its air supply. On SPRING RETURN ACTUATORS this is accomplished by means of a LOCKUP VALVE. On PISTON ACTUATORS a series of compressed air cylinders must be employed. FAIL-OPEN: Or NORMALLY OPEN. Another way of describing an AIR-TO-CLOSE actuator. FAIL-SAFE: A term used to describe the desired failure position of a control valve. It could FAIL-CLOSED, FAIL-OPEN, or FAIL-IN-PLACE. For a spring-return operator to fail-in-place usually requires the use of a lock-up valve. FEEDBACK SIGNAL: The return signal that results from a measurement of the directly controlled variable. An example would be where a control valve is equipped with a positioner. The return signal is usually a mechanical indication of valve plug stem position which is fed back into the positioner.

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F1 : Or PRESSURE RECOVERY FACTOR. A number used to describe the ratio between the pressure recovery after the VENA CONTRACTA and the pressure drop at the vena contracta. It is a measure of the amount of pressure recovered between the vena contracta and the valve outlet. Some manufacturers use the therm Km to describe the pressure recovery factor. This number will be high (0.9) for a GLOBE STYLE VALVE with a torturous follow path and lower (0.8 to 0.6) for a ROTARY STYLE VALVE with a streamlined flow path. On most rotary products the F1 factor will vary with the degree of opening of the VALVE CLOSURE MEMBER. Note! F1 does not equal Km. FLANGELESS: A valve that does not have integral line flanges. This type of valve is sometimes referred to as a Wafer Style valve. The valve is installed by bolting it between the companion flanges with a set of bolts or studs called line bolting. Care should be taken that strain-hardened bolts and nuts are used in lieu of all-thread, which can stretch when subjected to tempera-ture cycling. FLANGELESS BODY: See FLANGELESS for a definition. This type of valve is very economical from a manufacturing and stocking standpoint because a valve that is rated as a 600# ANSI valve can also be used between 150# and 300# ANSI flanges thus eliminating the need to manufacture three different valve bodies or stock three different valve bodies. The down side is that valves with flangeless bodies are not acceptable in certain applications - particularly in refinery processes. FLASHING: Is the boiling or vaporizing of a liquid. See the definition of CAVITATION. When the vapor pressure downstream of a control valve is less than the upsteam vapor pressure, part of the liquid changes to a vapor and remains as a vapor unless the downstream pressure recovers significantly, in which case CAVITATION occurs. Flashing will normally cause a CHOKED FLOW condition to occur. In addition the vapor bubbles can also cause mechanical damage to the valve and piping system. FLOW CHARACTERISTIC: The relationship between valve capacity and valve travel. It is usually expressed graphically in the form of a curve. CONTROL VALVES have two types of characteristics INHERENT and INSTALLED. The INHERENT characteristic is derived from testing the valve with water as the fluid and a constant pressure drop across the valve. When valves are installed into a system with pumps, pipes, and fittings, the pressure dropped across the valve will vary with the travel. When the actual flow in a system is plotted against valve opening, the curve is known as the INSTALLED flow characteristic. Valves can be characterized by shaping the plugs, orifices, or cages to produce a particular curve. Valves are characterized in order to try to alter the valve gain. Valve gain is the flow change divided by the control signal change. This is done in an effort to compensate for nonlinearities in the control loop. FLOW COEFFICIENT: See the definition for Cv . GAIN: The relationship of input to output. If the full range of the input is equal to the full range of the output, then the gain is 1. Gain is another way to describe the sensitivity of a device. GLOBE VALVE: A valve with a linear motion, push-pull stem, whose one or more ports and body are distinguished by a globular shaped cavity around the port region. This type of valve is characterized by a torturous flow path and is also referred to as a LOW RECOVERY VALVE because some of the energy in the flow stream is dissipated; and the inlet pressure will not recover to the extent that it would in a more streamlined HIGH RECOVERY VALVE. HANDWHEEL: A manual override device used to stroke a valve or limit its travel. The handwheel is sometimes referred to as a hand jack. It may be top mounted, side mounted, in-yoke mounted or shaft mounted and declutchable. HARD FACING: A material that is harder than the surface to which it is applied. It is normally used to resist fluid erosion or to reduce the chance of galling between moving parts. Hard facing may be applied by fusion welding, diffusion, or spray coating the material. Alloy #6 or Stellite is a common material used for this purpose. HARDNESS: A property of metals that is discussed frequently when speaking of various component parts used in valve construction, particularly valve trim. There are two hardness scales which are commonly used, Rockwell & Brinell.


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HARDNESS COMPARISON 316 SST 17-4 PH Hardened Inconel #6 Stellite (Alloy 6) Chrome Plating

ROCKWELL 76B 34-38C X-750 38-42C 40-44C 59-67C

BRINELL 137 352 401 415 725

Note that 316 SST is on the Rockwell B scale which means it is a much softer material than the others shown. HIGH RECOVERY VALVE: A valve design that dissipates relatively little flow stream energy due to streamlined internal contours and minimal flow turbulence. Therefore, pressure down stream of the valve VENA CONTRACTA recovers to a high percentage of its inlet value. These types of valves are identifiable by their straight-th rough flow paths. Examples are most rotary control valves, such as the eccentric plug, butterfly, and ball valve. HYSTERESIS: The difference between up-scale and down-scale results in instrument response when subjected to the same input approached from the opposite direction. Example: A control valve has a stroke of 1.0 inch and we give the valve a 9 psig signal. The valve travels 0.500 of an inch. We then give the valve a 12 psig signal, and the valve travels to 0.750 of an inch. When the valve is then given a 9 psig signal, the stroke is measured at 0.501. That represents hysteresis. Hysteresis can be caused by a multitude of variables, packing friction, loose linkage, pressure drop, etc. If someone asks you what the hysteresis of your control valve is, it is a bum question because hysteresis is more aptly applied to an instrument than to a control valve. There are simply too many variables in the valve and the system to answer the question properly. The control valve only responds to the controller signal and will move to a position to satisfy the controller - thus negating the effects of hysteresis. INCIPIENT CAVITATION: Is a term used to describe the early stages of CAVITATION. At this point the bubbles are small, and the noise is more of a hiss, like the sound of frying bacon. There is normally no mechanical damage associated with incipient cavitation although it could have an effect on the corrosive properties of some fluids. INHERENT DIAPHRAGM PRESSURE: The high and low values of pressure applied to the diaphragm to produce rated valve plug travel with atmospheric pressure in the valve body. This is more commonly referred to as BENCH SET. INHERENT FLOW CHARACTERISTIC: It is the relationship between valve capacity and valve travel and is usually expressed graphically. It is derived from testing a valve with water as the fluid and with a constant pressure drop across the valve. The most common types of inherent flow characteristics are LINEAR, EQUAL PERCENTAGE, MODIFIED PARABOLIC, and QUICK OPENING. INSTALLED DIAPHRAGM PRESSURE: The high and low values of pressure applied to the diaphragm to produce rated travel with stated conditions in the valve body. The "stated conditions" referred to here mean the actual pressure drops at operating conditions. Example: A control valve may have an INHERENT DIAPHRAGM PRESSURE or BENCH SET of 8 to 15 psig. But when subjected to a 600 psig. inlet pressure, it may start to open at 3 psig. and be full open at 15 psig. It is because of the forces acting on the valve plug and the direction of flow through the valve (FLOW-TO-OPEN or FLOW-TO-CLOSE) that the installed diaphragm pressure will differ from the inherent diaphragm pressure. INSTALLED FLOW CHARACTERISTIC: The flow characteristic when the pressure drop across the valve varies with flow and related conditions in the system in which the valve is installed. The purpose of characterizing a control valve is to help compensate for nonlinearities in the control loop. INSTRUMENT PRESSURE: The output pressure from an automatic controller that is used to operate a control valve. It is the input signal to the valve. INTEGRAL SEAT: The flow control orifice and seat that is an integral part of the valve body or cage. The seat is machined directly out of the valve body and is normally not replaceable without replacing the body itself although some can be repaired by welding and remachining.


INTEGRAL FLANGE: A valve body whose flange connection is an integral or cast part of the body. Valves with integral flanges were traditionally known to have the ANSI short FACE-TO-FACE dimension ANSI/ISA S75.03. However many manufacturers now produce valve bodies with both integral and SEPARABLE FLANGES that will meet both the ANSI short and long face-to-face dimensions. I/P: An abbreviation for current-to-pneumatic signal conversion. This term is commonly used to describe a type of transducer that converts an electric (4-20 m.a) input signal to a pneumatic (3-15 psig.) output signal. LANTERN RING: A rigid spacer used in the packing with packing above and below it. The lantern ring is used to allow lubrication to the packing or allow access to a leak off connection. On some of the new fugitive emission packing systems, it also acts as a stem guide. LAPPED-IN: A term that describes a procedure for reducing the leakage rate on metal-to-metal seated valves and regulators. The plug and seat are lapped together with the aid of an abrasive compound in an effort to establish a better seating surface than would normally be achieved by means of machining. LEAKAGE CLASSIFICATION: A term used to describe certain standardized testing procedures for CONTROL VALVES with a FLOW COEFFICIENT greater then 0. 1 (Cv ). These procedures are outlined in ANSI Standard d B16.104-1976, which gives specific tests and tolerances for six seat leakage classifications. It should be remembered that these tests are used to establish uniform acceptance standards for manufacturing quality and are not meant to be used to estimate leakage under actual working conditions. Nor should anyone expect these leakage rates to be maintained after a valve is placed in service. There is no standard test for SELFCONTAINED REGULATORS at this time. Note! You will see many instances where regulators are specified using the above criteria. LEAK-OFF: A term used to describe a threaded connection located on the BONNET of a valve that allows for the detection of leakage of the process fluid past the packing area. LINEAR FLOW CHARACTERISTIC: A characteristic where flow capacity or (Cv ) increases linearly with valve travel. Flow is directly proportional to valve travel. This is the preferred valve characteristic for a control valve that is being used with a distributive control system (DCS) or programmable logic controller (PLC). LINEAR VALVE: Another name for a GLOBE VALVE. It refers to the linear or straight-line movement of the plug and stem. LIQUID PRESSURE RECOVERY: See (F1 ). LOADING PRESSURE: The pressure used to position a pneumatic actuator. It is the pressure that is actually applied to the actuator diaphragm or piston. It can be the INSTRUMENT PRESSURE if a valve positioner is not used or is bypassed. LOCK-UP VALVE: A special type of regulator that is installed between the valve POSITIONER and the valve ACTUATOR, where it senses the supply air pressure. If that pressure falls below a certain level, it locks or traps the air loaded into the actuator causing the valve to FAIL-IN-PLACE. LOW RECOVERY VALVE: A valve design that dissipates a considerable amount of flow stream energy due to turbulence created by the contours of the flow path. Consequently, pressure downstream of the valve VENA CONTRACTA recovers to a lesser percentage of its inlet value than a valve with a more streamlined flow path. The conventional GLOBE STYLE control valve is in this category. MODIFIED PARABOLIC: A FLOW CHARACTERISTIC that lies somewhere between LINEAR and EQUAL PERCENTAGE. It provides fine throttling at low flow capacity and an approximately linear characteristic at higher flow capacities. NORMALLY CLOSED: See AIR-TO-OPEN. NORMALLY OPEN: See AIR-TO-CLOSE.

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P1: Is used to designate Inlet Pressure. P2: Is used to designate Outlet Pressure. PACKING: A sealing system that normally consists of a deformable material such as TFE, graphite, asbestos, etc. It is usually in the form of solid or split rings contained in a PACKING BOX that are compressed so as to provide an effective pressure seal. PACKING BOX: The chamber located in the BONNET which surrounds the stem and contains the PACKING and other stem-sealing components. PACKING FOLLOWER: A part that transfers a mechanical load to the PACKING from the packing flange or nut. PISTON ACTUATOR: A fluid-powered, normally pneumatic device in which the fluid acts upon a movable cylindrical member, the piston, to provide linear motion to the actuator stem. These units are spring or air opposed and operate at higher supply pressures than a SPRING RETURN ACTUATOR. PLUG: See CLOSURE MEMBER. PORT-GUIDED: A valve plug that fits inside the seat ring, which acts as a guide bushing. Examples: Splined Plug, Hollow Skirt, and the Feather-Guide Plug. POSITION SWITCH: A switch that is linked to the valve stem to detect a single, preset valve stem position. Example: Full open or full closed. The switch may be pneumatic, hydraulic, or electric. POSITION TRANSMITTER: A device that is mechanically connected to the valve stem and will generate and transmit either a pneumatic or electric signal that represents the valve stem position. POSITIONER: A device used to position a valve with regard to a signal. The positioner compares the input signal with a mechanical feed back link from the actuator. It then produces the force necessary to move the actuator output until the mechanical output position feedback corresponds with the pneumatic signal value. Positioners can also be used to modify the action of the valve (reverse acting positioner), alter the stroke or controller input signal (split range positioner), increase the pressure to the valve actuator (amplifying positioner), or alter the control valve FLOW CHARACTERISTIC (characterized positioner). POST GUIDE: A guiding system where the valve stem is larger in the area that comes into contact with the guide busings than in the adjacent stem area. PUSH-DOWN-TO-C LOSE: A term used to describe a LINEAR or GLOBE STYLE valve that uses a DIRECT ACTING plug and stem arrangement. The plug is located above the seat ring. When the plug is pushed down, the plug contacts the seat, and the valve closes. Note! Most control valves are of this type. PUSH-DOWN-TO-OPEN: A term used to describe a LINEAR or GLOBE STYLE valve that uses a REVERSE ACTION plug and stem arrangement. The plug is located below the seat ring. When the plug is pushed down, the plug moves away from the seat, and the valve opens. PRESSURE RECOVERY FACTOR: See (F1 ). QUICK OPENING: A FLOW CHARACTERISTIC that provides maximum change in flow rate at low travels. The curve is basically linear through the first 40% of travel. It then flattens out indicating little increase in flow rate as travel approaches the wide open position. This decrease occurs when the valve plug travel equals the flow area of the port. This normally happens when the valve characteristics is used for on/off control.


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RANGEABILITY: The range over which a control valve can control. It is the ratio of the maximum to minimum controllable FLOW COEFFICIENTS. This is also called TURNDOWN although technically it is not the same thing. There are two types of rangeability - inherent and installed. Inherent rangeability is a property of the valve alone and may be defined as the range of flow coefficients between which the gain of the valve does not deviate from a specified gain by some stated tolerance limit. Installed rangeability is the range within which the deviation from a desired INSTALLED FLOW CHARACTERISTIC does not exceed some stated tolerance limit. REDUCED TRIM: Is an undersized orifice. Reduced or restricted capacity trim is used for several reasons. (1) It adapts a valve large enough to handle increased future flow requirement with trim capacity properly sized for present needs. (2) A valve with adequate structural strength can be selected and still retain reasonable travel vs. capacity relationships. (3) A valve with a large body using restricted trim can be used to reduce inlet and outlet fluid velocities. (4) It can eliminate the need for pipe reducers. (5) Errors in over sizing can be corrected by use of restricted capacity trim. REVERSE ACTING: This term has several deferent meanings depending upon the device it is describing. A REVERSE-ACTING ACTUATOR is one in which the actuator stem retracts with an increase in diaphragm pressure. A REVERSE-ACTING VALVE is one with a PUSH-DOWN-TO-OPEN plug and seat orientation. A REVERSE-ACTING POSITIONER or a REVERSE-ACTING CONTROLLER outputs a decrease in signal in response to an increase in set point. REVERSE FLOW: Flow of fluid in the opposite direction from that normally considered the standard direction. Some ROTARY VALVES are considered to be bi-directional although working pressure drop capabilities may be lower and leakage rates may be higher in reverse flow. ROTARY VALVE: A valve style in which the FLOW CLOSURE MEMBER is rotated in the flow stream to modify the amount of fluid passing through the valve. SEAT LOAD: The contact force between the seat and the valve plug. When an actuator is selected for a given control valve, it must be able to generate enough force to overcome static, stem, and dynamic unbalance with an allowance made for seat load. SEAT RING: A part of the flow passageway that is used in conjuction with the CLOSURE MEMBER to modify the rate of flow through the valve. SELF-CONTAINED REGULATOR: A valve with a positioning actuator using a self-generated power signal for moving the closure member relative to the valve port or ports in response and in proportion to the changes in energy of the controlled variable. The force necessary to position the CLOSURE MEMBER is derived from the fluid flowing through the valve. SEPARABLE FLANGE: Also known as a SLIP-ON FLANGE. A flange that fits over a valve body flow connection. It is generally held in place by means of a retaining ring. This style of flange connection conforms to ANSI/ISA 275.20 and allows for the use of different body and flange materials. Example: A valve with a stainless steel construction could use carbon steel flanges. This type of valve is very popular in the chemical and petro-chemical plants because it allows the use of exotic body materials and low cost flanges. SOFT SEATED: A term used to describe valve trim with an elastomeric or plastic material used either in the VALVE PLUG or SEAT RING to provide tight shutoff with a minimal amount of actuator force. A soft seated valve will usually provide CLASS VI seat leakage capability. SPLIT BODY: A valve whose body is split. This design allows for easy plug and seat removal. Split-bodied valves are made in both the straight-through and angle versions. The Masoneilan 2600 or ANNIN is an example of a split body valve. SPRING RATE: A term usually applied to SELF-CONTAINED REGULATORS describing the range of set point adjustment available for a particular range spring.


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STATIC UNBALANCE: The net force produced on the valve stem by the fluid pressure acting on the CLOSURE MEMBER and STEM within the pressure retaining boundary. The closure member is at a stated opening with a stated flow condition. This is one of the forces an actuator must overcome. STELLITE: Also called #6 Stellite or Alloy 6. A material used in valve trim known for its hardness, wear and corrosion resistance. Stellite is available as a casting, barstock material and may be applied to a softer material such as 316 stainless steel by means of spray coating or welding. STEM: The VALVE PLUG STEM is a rod extending through the bonnet assembly to permit positioning of the plug or CLOSURE MEMBER. The ACTUATOR STEM is a rod or shaft which connects to the valve stem and transmits motion or force from the actuator to the valve. STEM GUIDE: A guide bushing closely fitted to the valve stem and aligned with the seat. Good stem guiding is essential to minimizing packing leakage. SUPPLY PRESSURE: The pressure at the supply port of a device such as a controller, positioner, or transducer. Common values of control valve supply pressures are 20 psig. for a 3-15 psig. output and 35 psig. for a 6-30 psig. output. STROKE: See TRAVEL. THROTTLING: Modulating control as opposed to ON/OFF control. TRANSDUCER: An element or device which receives information in the form of one quantity and coverts it to information in the form of the same or another quantity. (See I/P) TRAVEL: The distance the plug or stem moves in order to go from a full-closed to a full-open position. Also called STROKE. TRIM: Includes all the parts that are in flowing contact with the process fluid except the body, BONNET, and body flanges and gaskets. The plug, seats, stem, guides, bushings, and cage are some of the parts included in the term trim. TRUNNION MOUNTING: A style of mounting the disc or ball on the valve shaft or stub shaft with two bushings diametrically opposed. TURNDOWN: A term used to describe the ratio between the minimum and maximum flow conditions seen in a particular system. Example: If the minimum flow were 10 G.P.M. and the maximum flow were 100 G.P.M. the turndown would be 10:1. This term is sometimes incorrectly applied to valves. See RANGEABILITY. VALVE: A device which dispenses, dissipates, or distributes energy in a system. VALVE BODY: See BODY. VALVE FLOW COEFFICIENT: See Cv . VALVE PLUG: See CLOSURE MEMBER. VENA CONTRACTA: The location where cross-sectional area of the flow stream is at its minimum size, where fluid velocity is at its highest level, and where fluid pressure is at its lowest level. The vena contracta normally occurs just downstream of the actual physical restriction in a control valve.

MAINTAINING COMPRESSED AIR SYSTEMS

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Maintaining compressed air systems. Predictive maintenance and controls in the information age Unanticipated compressor outages can be one of the most frustrating things to happen in the plant. Similar to electrical power failures, compressor outages disrupt production, require extensive repairs, and lead to the many associated costs of unscheduled downtime. However, many of us know that these outages can be identified and avoided by using statistical trends based on daily maintenance data readings. Unfortunately, as many companies expand operations faster than they expand their maintenance staff, time is pressed and daily data collection becomes less of a priority compared to other maintenance duties. Additionally, the practice of having back-up compressors is more of the exception than the rule. This has led more and more plant operators to seek alternatives to the time-consuming, but necessary, practice of data collection and monitoring. This article reviews where predictive maintenance programs originated and present options that companies may utilize to streamline the data collection process.

The importance of daily data collection. Generally, the operation of a compressor, like other equipment, is constant and usually predictable. Compressor applications and subsequent performance are based on specific physical conditions. Over time, the physical and mechanical demands of operation adversely affect the general performance efficiencies of the compression process and operating temperatures. For example, a condensate trap on a two-stage unit that fails allows the intercooler to fill with liquid. Consequently, the velocity of the compressed air sweeps any foreign liquid into the next compression chamber. These result in premature compressor wear and air system contamination. To avoid this and other similar scenarios, most companies typically perform periodic observation maintenance programs for compressors and other rotating equipment. These programs require that readings of temperatures, pressures, and functions be recorded. Then, by analyzing this data, operators can schedule downtime to address maintenance issues.

Control systems. Technology has played a significant role in improving predictive maintenance practices. Let's begin with the first step in the process, the data collection source. Typically, operators used to be required to manually record all gauge readings from the compressor on a daily basis. For instance, compressors that have electro-pneumatic systems gauges monitor several functions on the compressor.


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These gauges sometimes are unlabeled and occasionally require operators to gather multiple readings to ascertain compressor functions. Now, electronic, or microprocessor controls, offer detailed text information on compressor functions on one control panel. By incorporating the controls operators obtain actual operating values. Often operators perform this function from one central location at the touch of a button. In addition, the information available from the microprocessor controls is more accurate. Instead of common pressure and metering devices, the microprocessor control system relies on electrical transducers and sensors. These devices sense air pressure and temperature values, which are then transmitted to a central microprocessor. In turn, the microprocessor interprets the information and adjusts the compressor's output through an integrated control system. The microprocessor also measures and stores compressor-operating data for future maintenance reports and needs. For instance, monitoring the airend discharge temperature of rotary screw compressors can be a critical element in reducing downtime. In this case, the microprocessor control system alerts operators to any changes in these values to allow for preventive maintenance. The microprocessor control system also allows operators to adjust shutdown setpoints automatically and respond to alerts. The task of mechanically resetting each protective switch is no longer necessary. The microprocessor allows resetting from the control panel. When compressor units experience shutdowns, it is sometimes difficult to pinpoint the root cause because several alarms may have been activated. However, microprocessor control systems can monitor multiple alarms, and if shutdowns occur, they can recall the alarms to help identify the various problems and points of origin. Further, the microprocessor control system provides troubleshooting assistance through its monitoring alarm system. Even if a warning alarm is activated when the compressor is unattended and the system corrects itself, the alarm remains on the microprocessor panel along with the various operating parameters that were present at the moment of the alarm. This enables operators to reconstruct and evaluate the conditions when the warning alarm was activated. Effectively, predictive maintenance technology is or can be built in to the equipment by manufacturers.

Data logs Once the data is collected, the next step is logging and trending the information to plan preventive or corrective maintenance practices. Historically, companies typically performed these daily data collection and routine maintenance programs for compressors and recorded them in sequential log sheets. Unfortunately, log sheets provide only a limited area for recording system performance. When filled, the log sheets usually are filed and only reviewed after an unscheduled failure occurs. Currently however, log sheet data no longer needs to be collected and viewed from a historical perspective.


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Operators or maintenance staff can load the data to computer spreadsheets and trend analysis programs that offers operators the option of viewing visual charts. The charts allow tracking compressor performance and help identify needs for servic ing. However, even with microprocessor control systems, log sheets still remain a key component in preventive maintenance. To determine sources of problems, log sheets can be examined with computer trend analysis data, such as intercooling functions within the compressor process. Intercooling is critical to both a centrifugal compressor's performance and the life of internal parts. Larger compressors use water-cooled heat exchangers to achieve efficient heat transfer. Often, minerals and solids suspended in the cooling water collect in the cooler and reduce the heat transfer capability and efficiency of the compressor. While a trend of increasing temperatures may not be noticeable on the log sheet, computer-generated analysis and graphics identify the need to revise cleaning and back flushing schedules. Analyzing maintenance observations and statistical data, supported by trend graphics, enables plant operators to relegate unscheduled system outages to the routine maintenance program. Another example of the benefits gained through computer-based trend analysis involves the universal measurement of cooler performance. Commonly known as cold temperature difference, engineers determine this measurement by calculating the inlet temperature of the cooling media and the discharge temperature of the air at each cooler. The temperature measurements that are required to calculate cold temperature differences are routinely noted in log sheet records, but the calculations are often postponed or overlooked until a problem occurs. However if operators plot the two temperatures, the data quickly reveals the trend in cooler performance that is useful for future planning purposes. Generally, log sheet data and observations for any rotating piece of equipment can be classified as qualitative and quantitative. The qualitative observations are quite simple. For example, either a condensate trap operates or it doesn't. Yet, quantitative observations that illustrate trends used for planning future service and general maintenance schedules are sometimes more difficult to see. These days, savvy plant operators harness the power of computer programs to identify and analyze these quantitative observations. The combination of daily log sheet entries and compressor control data provides operators with sound and predictable maintenance programs.

Remote access and outsourcing services There is a new breed of services available to the plant and asset care manager that takes the computerized performance observations to the next level by adding remote access. Communications protocols, such as MODBUS, allow many facilities to download data onto analysis tools to help predict maintenance schedules.


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Compressor original equipment manufacturers and other third-party vendors are working to expand the parameters of microprocessor controls, multiple compressor control systems and predictive maintenance data collection tools to allow plant operators to monitor compressor functions remotely, adjust settings, and collect and trend data. This process allows operators to use one or two tools to monitor the complete compressed air system performance and predict its required maintenance. Shrewd observers will notice that this concept is consistent with Deming's thoughts regarding increased productivity through elevation of the level of technology. Beyond monitoring the compressed air system, companies also have the option of tying the compressed air system control systems into facility-wide monitoring systems that allow for trending and remote access. Predictive maintenance and control system vendors will be able to evaluate a company's facility and maintenance needs, collect the appropriate technical data, and develop the communications protocol that ties in all the systems into one data collection and trending device. While the system can be extremely efficient in terms of monitoring equipment, it can be costly to develop. Also, this requires the expertise of a supplier who is intimately familiar with the nature of the equipment in the plant. The demands of the language or protocol are such that they must allow the computers to speak to the compressor's control systems and this may require some custom programming before any predictive maintenance can occur. The other concern with on-board predictive maintenance technology and custom software packages is that suppliers need to understand the compressed air equipment design in sufficient depth to determine the proper equipment set points to make the predic tive maintenance system effective. The other option that will soon be available for companies is the ability to completely outsource their compressed air system predictive maintenance programs. Similar to outsourcing janitorial services or other maintenance functions, companies will have the option of outsourcing daily data collection, trending, troubleshooting, routine maintenance and scheduled repairs to a vendor who collects the data daily through a modem line. By utilizing the advancements that have been made to microprocessor controls, industry leaders are working to develop programs that supply the communications hardware to transmit the compressor data to an outside service vendor. The service vendor not only will collect and trend the data, but also will handle the routine maintenance tasks from filter changeouts to more extensive maintenance needs, including cooler cleaning. Ideally, this service would be offered as an incentive for predictive maintenance packages, eliminating the need to incorporate compressor control systems into facility-wide controllers and trending tools.

As technology improves so do the options companies have for automating these routine but critical predictive maintenance processes. Who knows, maybe technology will prom pt the invention of a self-fixing air compressor.

COMPRESSED AIR TERMINOLOGY

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COMPRESSED AIR TERMINOLOGY. Absolute Pressure. Total pressure measured from absolute zero. ACFM or acfm. Actual cubic feet per minute. Flow rate of air measured at some reference point and based on Conditions at that reference point. Aftercooler. Heat exchanger for cooling air discharged from air compressors. ATM or atm. Atmospheres. Atmosphere(s). Pounds-force per square inch (lbf/in 2 ) (psi). 14.696 psi. Atmospheric Pressure. Pressure above absolute zero at a specific location and altitude. See PSIA. Auto-Dual Control. Combination of Dual (Two-Step) with Modulating Control. Bar. Pounds-force per square inch (lbf/in 2 ) (psi). 14.504 psi. BARG or barg. Bar gauge (similar to the acronym "psig"). 14.504 psig. Barometric Pressure (see Atmospheric Pressure). Must be referenced when rating air compressors for altitude at which they will be operated. See PSIA. BHP or bhp. Brake horsepower. Horsepower delivered to the output shaft of the drive motor. Unit of comparison between motors. Total package bhp is the sum of all motor shaft outputs, including compressor and cooling fans. Blow-Off Valve. Valve assembly mounted "tee'ed" from the air compressor discharge line or from a port adjacent to the air discharge port of the air compressor casing. High-performance wafer style butterfly valve or stainless-steel ball valve. Consists of positioner, actuator, and valve. May be referred to as "bleed" valve or "anti-surge" valve. Provides for reduced demand modulating and for "Surge" relief to atmosphere. May be used as a "re -circulation" valve with nitrogen and other service applications or compressor packages. Constant blow-off modulating may signal a need to "down-size" your air compressor capacity to eliminate wasted energy dollars. Capacity. The amount of air flow delivered or required under some specific conditions. May be in acfm, scfm, etc. CFM or cfm. Cubic feet of air per minute. Volume rate of air flow. CFM, Free Air. Cubic feet of air per minute, free air. Cfm of air delivered to some specific point and converted back to ambient (free air) conditions. Check Valve. During un-load or shut-down, prevents reversal of air flow from an air system (and loss of system pressure!) through a centrifugal air compressor. See Surge. Cold Start. Starting a comp ressor from a state of total shutdown. Usually done with "local" control.at the compressor. May be done with "remote" control, but only advised with "heavy" instrumentation and monitoring accessories. Computer Control. Just as it say's. May be "local" using a micro-processor or "remote" using a PC (Personal Computer) or "larger" computer. Only recommended where large "swings" in system (process) demand amplitude may occur. Very effective where "load shaping" is an important consideration. "Heavy" monitoring and instrumentation accessories required for it to be efficient and effective. Usually not necessary where system demand is predominantly constant. CTD. Approach temperature. Usually the difference between cooling water temperature in to compressed air temperature out of an inter-cooler or after-cooler. Sometimes used to define oil cooler efficiency (cooling water temperature in to oil temperature out). DELTA (∆ ∆ ) P. Pressure drop. Loss of pressure in a compressed air system due to friction or restriction. Also, the water pressure drop across coolers.


DELTA (∆ ∆ ) T. Temperature drop. Rise (or decrease) of temperature between two points. Demand. Flow of air under specific conditions required at a particular point. Discharge Pressure. Rated air pressure produced at a rated reference point. At the discharge flange of an air compressor. Discharge Pressure, Required. Air pressure required at point of entry to the system. Displacement. Amount of air (cfm) displaced by a reciprocating compressor piston under no load, discharging directly to the atmosphere. Dual Control. Load/unload control system that tries to maximize compressor efficiency by matching air delivery and air demand. Compressor is operated at full load or idle. See Two-Step Control. FAD. Free Air Delivered. Free Air (an oxymoron?). Air at ambient conditions of temperature, humidity, and atmospheric pressure at any specific location. Fouling. Accumulation of foreign matter, such as mud or debris, in a cooler, pipe, or valve. In a cooler, H2 O ∆P and ∆T will be seen to increase, as well as CTD. Hot Start. The compressor is started automatically, depending on demand. Control panel is energized with no "prestart" cycle required, as pre-lubrication pump and buffer (seal) air are always "on". A state of pre-start exists. Steam turbine compressors are "slow-rolling" to maintain "pre-start" turbine temperatures at an adequate, recommended level. "Heavy" instrumentation and monitoring accessories are recommended. ICFM or icfm. Inlet cubic feet per minute. Cfm flowing through the compressor inlet filter or inlet valve under rated conditions. Inlet Conditions. The combination of temperature, pressure, and humidity at the inlet to the compressor after inlet filtration. At sea level, inlet pressure is usually 14.4 psia, after filtration. Inlet Pressure. The total pressure at the inlet flange of the compressor. Inlet Valve. Valve assembly at the air inlet to an air compressor. Butterfly (wafer style, a.k.a. damper) or IGV (inlet guide-vane valve). Consists of positioner, actuator, and valve. IGV. Inlet guide-vane valve. Valve assembly at the air inlet of a "blower" (single stage, low pressure, centrifugal air compressor). Usually advised to be mounted in very close proximity to the "blower" impeller. Provides "pre-swirl" of air flow in same rotational direction as "blower" impeller. Proven to improve efficiency (reduced bhp) during throttled-down modulation of "blowers". Effectiveness, when used with multi-stage centrifugal air compressors, degrades rapidly. Application with multi-stage centrifugal air compressors is paradoxical, i.e., "Centrifugals are most efficient (bhp per cfm) when fully loaded". Not recommended for multi-stage I-R Centac* "standard" or Centac II centrifugal air compressors (unlike Joy, Elliott, and others, ihherent casing design of Centac* does not allow mounting an IGV in close proximity to the first stage of compression. Beware of offers for IGV "improved efficiency" if it is offered for sale alone or in combination with a "re-rate" of impeller(s) to lower discharge pressure of your compressor. IGV valves are expensive. Kick Back. A common term for what may be legally known as "embezzlement". In the compressor industry it has been known to occur between vendor and customer as well as between vendor and sub-contractor. Usually financed through overcharges directly to the customer or indirectly through overcharges from a sub-contractor to the vendor, which are then passed along to the customer -- at a mark-up! Should be treated with the same severity as armed robbery, but isn't. Load Factor. Ratio of the average compressor load to the maximum rated compressor load during a given period of time.

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Modulating Control. Compressor controls will run the compressor at varying loads to accommodate demand variations. Running a compressor at less than full load results in a drop in compressor efficiency and thus an increase in operating costs. Off-Site. Not at your facility. CAUTION: An unscrupulous compressor repair company will use removal of parts and, especially, rotor assemblies or complete units to an off-site repair shop as an opportunity to charge for parts not actually "replaced" and/or for "repairs" not actually performed. In the middle 1980's a multi-million dollar compressor parts "scam" occurred at a U.S. Air Force base in Texas, which resulted in the conviction and sentencing to five years in federal prison of an unscrupulous compressor repair company president. Several other individuals were also either fined or imprisoned. Convictions and prison terms have also been obtained for individuals and companies involved in "kick back" schemes. See Kick Back. Pressure. Force per unit area. PSI or psi. Pounds per square inch. Force per unit area exerted by compressed air. PSIA or psia. Pounds per square inch absolute. Pressure above absolute vacuum. Atmospheric pressure is stated in psia. PSIG or psig. Pounds per square inch gauge. Pressure at some reference point as measured with a gauge and dependent on atmospheric pressure. PSID. Pounds per square inch differential. Pressure difference between two points. PDP. Pressure dew point. Temperature at which water will begin to condense out of air at a given pressure. Receiver. Tank used for storage of air discharged from a comp ressor. Scaling. Build-up of foreign matter on the interior (H2 O) surface of coolers and pipe. Often caused by the precipitating-out of calcium carbonates due to high temperatures at the "hot" end of a cooler. With a cooler, seen as an increase of CTD (high air temperature) and lower ∆T. Unfiltered, untreated, and oxygenated water are the most frequent causes in pipe. SCFM or scfm. Standard cubic feet per minute (scfm). Flow of free air measured at some reference point and converted to a standard set of reference conditions (e.g., 14.4 psia, 80o F, and 60% relative humidity.) Sea Level. Where absolute air pressure is 14.7 psia, before inlet air filtration. SPC. Specific Power Consumption. Surge. The rapid reversal of air flow through a centrifugal air compressor. High temperatures are generated and gross instability occurs in the air compressor! If it continues unabated; the compressor "buys the farm"! Surge may be preceeded by fouling, scaling, or by-passing of inter-coolers, thus allowing high temperatures (reduction in air mass density). Surge may occur due to lack of adequate cooling water flow. Surge may also occur because of high air intake DELTA P (fouled/clogged air intake filter elements, under-sized air intake pipe, malfunctioning or poorly "stroked" inlet valve, and/or poorly calibrated LLR). Two-Step Control. Load/unload control system that tries to maximizes compressor efficiency by matching air delivery and air demand. Compressor is operated at full load or idle See Dual Control.

PUMP MAINTENANCE PROGRAM

Pump maintenance programs pay Use these suggested inspection tips for every pump in your plant

No matter what types of pumps are in your charge, the key to a successful maintenance program is regularity. Regular observations detect unusual wear in the early stages and minimize pump repair costs. They also guard against costly downtime. Your investment in a regular maintenance program pays big dividends. Without wear, of course, machinery would be virtually maintenance-free except for normal lubrication. Detecting wear in the early stages lets you repair your pump at minimum cost and get it back into operation at the earliest date. Regular lubrication and a simple look -feel inspection of your pump are good operating procedures that help detect signs of trouble at an early stage. They require only a few minutes and may save you an appreciable amount of money.

In-house pump knowledge Equipment maintenance problems vary from simple to complex. The type of service for which the pump is intended, the general construction of the pump, the relative complexity of the required repairs, the facilities available at the site, and other factors enter into the decision on who repairs the pump --plant personnel, your local equipment distributor, or manufacturers' personnel. The extent of knowledge in-house maintenance personnel should have about the pumps depends upon the demands and complexities of the system in which the pumps are installed. In most cases, information on mechanical construction found in the manufacturer's maintenance manual is sufficient. Generally, the maintenance personnel should know the required conditions of service. This information is usually recorded on the pump nameplate. If these conditions have changed, then review them with the manufacturer. Your staff may, on occasion, need more complete information about the pump than what's included in the maintenance manual to provide adequate inspection and maintenance. Operating parameters may change during the life of the pump. Changes in materials of construction, packing, or seals may be required. In some cases, a different size or type of pump may be warranted.

An abrupt change in bearing temperature is much more indicative of trouble than a constant high temperature. Ultimately, when wear causes excessive clearances, contact the manufacturer for recommended repair procedures. In cases of extreme wear, the manufacturer may suggest reconditioning or remanufacturing the pump.

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Study the manufacturer's instruction book carefully before making any attempt to service a pump. Even though there is a wide variation in types, sizes, parts, and design of pumps, the basic maintenance program is the same for each. In general, a pump maintenance program can be divided into three levels: daily, as required by manufacturer, and annual inspections. Review your maintenance manual and check with the manufacturer of your particular pump for recommended maintenance intervals before annual inspections and overhauls.

Daily inspection Inspect pump installations daily. A card record system is unnecessary for these inspections, but the operator should immediately report any irregularity in pump operation.

Be sure to make this communication a clear objective of job performance for personnel. Investigate immediately any change in the sound of a running pump. Pump noise often gives an experienced maintenance person a definite indication of the source of trouble. If a pump produces a crackling noise, for example, the source of trouble is probably at the pump suction. This type of noise is usually associated with cavitation. This is a direct result of insufficient net positive suction head (NPSH). Cavitation can result in damage to the inside of the pump or, at a minimum, will reduce the life of your seals and bearings. Next on the check list are bearings. An abrupt change in bearing temperature is much more indicative of trouble than a constant high temperature. Observe stuffing box operation daily. Stuffing box leakage is normal with packing but should be reported if it is greater than that required for lubrication and cooling. If mechanical seals are installed, report any leakage immediately to prevent a complete failure of the seals. Check the pressure gauges and flow indicator, if installed, daily for proper operation. Check recording instruments, if available, daily to ensure that the capacity output, pressure, or power consumption do not indicate that something needs attention.

Maintenance intervals required by manufacturer Check the alignment of the pump and driver and correct it if necessary. Oil-lubricated bearings and gears should be drained and refilled with fresh oil. Check grease-lubricated bearings to see if the correct amount of grease is being provided.

Over-greasing can be as harmful as under-greasing. Review the lubrication required for your pumps, drivers, and couplings.

Annual inspection Thoroughly inspect pumps once a year. Remove, clean, and examine the bearings for wear. Carefully clean the bearing housings. The cost of completely replacing bearings during annual inspections may be justified since this cost is a minimal part of the overall inspection budget. Immediately after cleaning and inspecting, coat the bearings with oil or grease, as appropriate, and then cover them to prevent dirt or moisture from getting into them.


Remove the packing or seals and examine the shaft sleeves--or shaft, if sleeves are not used--for wear. Check and flush pump drain connections, sealing, and cooling water piping, as well as other piping. Inspect mechanical seals and elastomers and replace parts as necessary. Recheck alignment after reconnecting the couplings. Recalibrate and test the instruments and metering devices to confirm proper performance.

Test the pump again after completion of any internal repairs. Record of inspection and repairs Record the normal maintenance intervals required by the manufacturer on maintenance cards. There should be a card for each pump in the installation. Be sure to leave space for comments and observations of the inspecting personnel. These cards should contain the following:

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pump identification number, the date of the scheduled inspection, and a complete record of items requiring individual inspection

Adequate maintenance doesn't stop with repair work on worn or damaged parts. A written record of the condition of the parts to be repaired or replaced, of the rate and appearance of the wear, and of the method by which the repair was carried out is as important as the repair job itself. These records form the basis of preventive measures that reduce both the frequency and cost of maintenance work. The type of inspection records and the extent of detail they contain vary with the type of pump and availability of personnel. Photograph badly worn parts before repairing them. Photographs provide a more accurate and graphic record of the damage than a written description.

Always keep complete records of maintenance and repair costs for each individual pump. These records, together with a record of operating hours, may reveal whether a change in materials or design will be the most economical plan to follow.

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PUMPS MAINTENANCE

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Pumps Maintenance. The initial purchase price of a centrifugal pump is minuscule when compared with the cost of ownership over the life of the equipment. Consequently, the current practice of buying the cheapest pump available can haunt you with inflated operation and maintenance costs throughout the life of the pump. Unfortunately, the purchase of the most expensive pump does not necessarily protect you from high maintenance costs. To ensure efficient and reliable operation throughout the life of the pump, consider a number of factors when purchasing a pump. If it is already too late for that, the good news is that these same factors can be revisited and considered any time. Identify the pumping conditions This may seem a little basic, yet there are certain applications in which identifying the required pump performance is not as straightforward as we might think. The major problem is a system head that keeps changing, thus causing fluctuating pump capacity. One example is the automated system that provides a consistent temperature or pressure in a process that may require frequent changes in operating conditions to balance the system. In fact, the pump simply is varying its flow rate in response to the back pressure created at the pump discharge nozzle by the valves in the system. A similar situation occurs when a pump is required to deliver a liquid to three destinations. These are often at different distances from the pump, involving varying pipe lengths

Tell your supplies. While the awareness of these variations is important, it is essential to discuss them with your pump suppliers when selecting the pump. For example, it is common practice in some areas to size the pump based on the values that the system designer considers the worst or maximum condition. This assumes that if the pump can handle the worst condition, it can handle all conditions. The problem is that selecting on the basis of the worst condition may be completely erroneous. Using the example of emptying a tank, we may decide the worst condition is when the tank is nearly empty. Under these conditions, the total static head to be developed is at its maximum. By selecting a pump on this basis alone, it follows that the pump starts out--when the tank is full-operating at a much lower head. The pump starts out running at a higher flow rate and slowly works back toward the selected flow and head condition.

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This results in the system operating with a higher liquid velocity than was planned and with the tank being emptied much faster than anticipated. Conversely, if the pump is designed for the minimum head condition at start-up, the system operates with a lower liquid velocity and a slower transfer time. As the normal pump selection process involves matching the operating point with the best efficiency point, either of the above condition involves operating the pump a way from the best efficiency point most of the time. The optimum solution is to identify the extreme conditions under which the pump may operate and to review them with the pump supplier so that when you select a pump, the extremes bracket the best efficiency point. This results in a higher overall operating efficiency within the most stable hydraulic range of the pump. However, the efficiency of pump operation can only be identified if we know what the pump is actually doing. This can only be achieved by installing pressure gauges on the suction and discharge of the pump and maintaining the gauges properly.

Consider potential failure modes Any number of medical conditions can cause a headache, yet we rarely conduct a root cause analysis. Instead, we simply take two aspirin. While this does nothing for the basic condition, it does take away the pain. The same is often true in industry. While we often cannot--or will not--eliminate the root cause, usually we can minimize the effect of the symptoms. If we use the earlier example, it is obvious that inevitably this pump will cavitate at the end of the cycle when the tank is almost empty and the suction head is drastically reduced. In addition, reduced submergence over the tank outlet also creates a vortex and air entrainment. These conditions have identical effects. The pump rattles as though it is pumping gravel. It vibrates excessively and the impeller suffers pitting damage. As these symptoms are inevitable and cannot be eliminated under the existing operating conditions, we have to focus on minimizing the impeller damage and the vibration. Preventing impeller damage Impeller damage is caused by the energy level developed by a series of implosions that exceed the tensile strength of the impeller material. This causes pieces of the impeller to break off. Selecting an impeller material with a higher tensile strength reduces the damage caused by the implosions. For example, while a bronze impeller may be totally destroyed by cavitation within six months, a stainless steel impeller may last two years under the same conditions. If a change in impeller material is not feasible, many coatings are now available that increase the resistance to cavitation damage and permit longer operating life of the pump.

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You may also wish to consider similar coatings in a unit that is pumping abrasive materials.

Piping should be one size larger than the pump nozzles on both sides of the pump.

Minimizing vibration Pump vibration causes premature failure of mechanical seals and bearings. Reducing the shaft slenderness ratio. ("Causes of centrifugal pump failure," Plant Services, July 1996) by either increasing the shaft diameter or reducing the overhung length from the nearest bearing reduces failures. This reduces the frequency and the amplitude of the vibration and minimizes damage. You may also wish to consider installing larger bearings in a heavier bearing housing to reduce the effects of vibration. System conditions System conditions also cause pump problems. Appropriate piping and system design avoids many of these. For example, if a pump is supplying an intermittent filling platform in which the system is turned on and off on a regular basis, these fluctuations prove fatal for any pump. Creating a continuous recirculation system from which the platform draws its filling requirements avoids this damage. By identifying the possible causes of pump failure in either the pump or the system, frequently problems can be avoided through design modifications even before the pump is installed. In other cases the pump may be purchased with these upgrades already in place. The optimum solution is to identify the extreme conditions under which the pump may operate and to review them with the pump supplier so that when you select a pump, the extremes bracket the best efficiency point.

Installation procedures and protection On many occasions a root cause analysis of repetitive pump failure identifies the manner in which the pump was installed as being the root cause. To alleviate this, three areas require particular consideration: the support, the coupling, and the piping.

Support arrangement. The pump support must be designed to accommodate all the physical loads and be able to absorb the destructive forces of vibration. Recognize that current baseplate designs are considered flexible and are intended to be grouted into place. Consequently, to ensure a strong installation, the pump support must be viewed as a combination of the baseplate and the foundation.

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Occasionally the use of non-grouted baseplates attempts to solve the effects of poor piping procedures with a high penalty being paid in premature failure of seals and bearings. Current practice requires an epoxy grout on a concrete base having a combined mass at least three times the weight of the full centrifugal pump, the motor, and the baseplate. It has been clearly established that the amount of time and money spent on the pump support will be saved in reduced maintenance costs during the first few years of operation.

Shaft coupling. It is essential to recognize that the pump shaft and the motor shaft must rotate on a common axis or the increased radial loads cause more frequent bearing failures. Straightedge shaft alignments once considered adequate for packed pumps are not acceptable for pumps with mechanical seals. As a consequence, align shafts with the more accurate methods of the reverse dial indicator or using laser alignment equipment. Most pump manufacturers still promote an acceptable limit of shaft alignment tolerance of 0.002 inch. However, if we realize that new seal faces are lapped flat to within tolerances of 1 to 3 helium light bands--approximately 0.00001 to 0.00003 inch--it is evident that improvement in shaft alignment increases seal life. Flexible couplings do not eliminate the axial and radial loads that misaligned shafts create. Consequently, bring your shaft alignment to the same level of accuracy regardless of the type of coupling. Flexible couplings are valuable in high temperature applications while the pump heats up to operating temperature. At both extremes, establish accurate shaft alignment. Pipe support and arrangement. Pump piping should be fully self-supported and aligned to the pump flanges and impose no pipe strain on the pump. Piping should be one size larger than the pump nozzles on both sides of the pump. The discharge side should have a concentric increaser before the check valve with any isolating valves being located further downstream. Any flexible pipe joints should be anchored independently of the pump base on the side closest to the pump. It is interesting to note that any errors in discharge piping design are often automatically corrected by the pump running at the higher head needed and a correspondingly lower flow. Piping errors on the suction side normally are not traced to the correct source and cause continuing problems that prove expensive for many years.

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Two simple rules ensure a smooth running unit, are: 1. Locate the pump far enough away from the suction source or closest elbow to allow a straight run of suction piping that is five to ten times the diameter of the line. 2. Position the eccentric reducer with the flat side on top to eliminate air pockets in the suction piping.

Parting words If you implement these precautions at the design stage of a new system, the pump and system achieve the optimum efficiency and reliability. However they should not be written off just because your system has been up and running for years. These recommendations can be put in place at any time and although they may then be more expensive than implementing them initially, they are still likely to save thousands of dollars over the life of the pump.

It is essential to recognize that the pump shaft and the motor shaft must rotate on a common axis or the increased radial loads cause more frequent bearing failures.

PUMP PERFORMANCE CHECKLIST

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Pump Performance Checklist

Whether you use your pumps for agricultural, construction, industrial or sewage applications, keeping them in shape can help reduce costs and boost profits by cutting fuel consumption, reducing parts replacement costs and minimizing pumping time on every project. A pump that lets you down when you need it most causes obvious losses of time and money. Not so obvious, but every bit as costly, are losses you can incur with pumps that operate at less-than-peak efficiency. A pump laboring under the handicap of a suction line air leak, a corroded discharge line or a clogged impeller gulps excessive amounts of energy, takes longer than necessary to do the job, and subjects parts to undue stress, causing premature wear-out.

How High Can The Losses Run? A 6-inch gasoline-driven, self-priming centrifugal pump operating at 25% less than peak efficiency through an 8 hour day uses approximately 40 litres more fuel than a pump which is operating efficiently. At RM1.10 per litre x 40 litres per day x 300 days, that's RM 13,200 per year LOST! and that figure doesn't include added personnel costs. Multiply the possible hidden losses by the number of pumps you have in operation and you see why it pays to keep your pump in top working order. We want to keep your pump efficient. There's really no reason to let them deliver less than their best.

A 9-Point Helpful Checklist We prepared it because today every dollar of profit counts, and we want your pumps to work for all they're worth.

Centrifugal Pumps Look for these signs of inefficiency. Indications that your pump is costing you more to operate than it should may not be dramatic but they're easily recognized. You know you're being short-changed if...

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THERE'S A NOTICEABLE DIFFERENCE IN PUMP FLOW. Has the discharge flow visibly decreased? Is it taking your pump longer than it used to to do the same job? The slow-up might be caused by a collapsed suction hose lining, a leaking gasket, plugged suction line, a damaged or worn impeller or wear plate.

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YOUR PUMP ISN'T REPRIMING AS RAPIDLY AS IT ONCE DID. Is the seal leaking, is all hardware at gaskets tight, is the suction check valve sealing properly, is the cut water section of volute badly worn or recirculating port clogged?


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YOUR PUMP IS MAKING EXCESSIVE NOISE. Does it sound like a bunch of marbles rattling in a can? This may be cavitation and could be caused by too high of a suction lift, too long a suction hose, a clogged strainer or collapsed suction hose lining, plugged suction line or combination of all these. Maybe the bearings are going out.

YOUR PUMP IS CLOGGING FREQUENTLY. The suction check valve may be clogged, and improper strainer may be too large or small, or the strainer may be in mud plugging the suction side.

YOUR PUMP IS OVERHEATING Very likely the flow of liquid into or out of the pump is being restricted. Improper impeller clearance could be slowing repriming or the suction strainer may be clogged.

Use this Checklist to Improve Pump Performance . . . and Profits Although this list is not a complete guide to pump inspection and service, it does cover the more common conditions that can impair pump efficiency.

SUCTION LINE 1.

Check for air leaks. Using a vacuum gauge, make sure that the suction line, fittings and pipe plugs are airtight. Most pumps have a tapped hole for easy connection of a vacuum gauge. Use pipe dope to seal gauge threads and pipe plugs. Replace leaky seals and badly worn hoses.

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Check the suction hose lining. The rubber lining in a suction hose can pull away from the fabric, causing partial blockage of the line. If the pump develops a high vacuum but low discharge, the hose lining may be blocking suction flow. Replace hose.

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Check the suction strainer. Frequent inspection and cleaning of the suction strainer is particularly important when pumping liquids containing solids. Proper size strainer should prevent pump from clogging.

PUMP 1.

Check impeller vanes, wear plate or wear rings. The removable cover plate on many pumps permits quick, easy inspection of the impeller and wear plate. These components should be inspected every six months or sooner, depending on pump application. They're subject to faster wear when pumping abrasive liquids and slurries. Wear plates and wear rings can be replaced without replacing expensive castings.

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Check impeller clearance. If the clearance between impeller and wear plate or wear rings is beyond recommended limits, pumping efficiency will be reduced. If the clearance is less than that recommended, components will wear excessively. If tolerances are too close, rubbing could cause an overload on the engine or motor. Check the impeller clearance against pump manual specifications and adjust if necessary.

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Check the seal. Most pumps are equipped with a double seal lubricated under pressure - with a springloaded grease cup or an oil lubricated tungsten titanium carbide seal for long, trouble-free service. If your pump has a single seal and it is lubricated with the water being pumped, sand and other solids can cause rapid wear. Check and replace the seal if worn. Replace seal liner or shaft sleeve if it has scratches.


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Check bearings. Worn bearings can cause the shaft to wobble. Eventually the pump will overheat and sooner or later it win freeze up and stop. Replace bearings at the first sign of wear.

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Check the engine or motor. The pump may not be getting the power it needs to operate efficiently. The engine may need a tune-up or the motor may need service.

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DISCHARGE LINE Check operating condition. Check air release devices, valves, check valves and shock control devices for proper operation. Old discharge lines are subject to internal rusting and pitting, which cause friction loss and reduce flow by as much as 15%. Replace badly deteriorated line.

A Word about Submersible and Diaphragm Pumps If your submersible pump operates but at a reduced capacity it could be caused by a worn impeller, excessive impeller clearance, low or incorrect voltage or it could be running backwards. Too high of a discharge head, a clogged or kinked hose or a clogged strainer could also be responsible for reduced flow. Use an amp meter and volt meter to determine if the pump is getting the proper power it needs to operate efficiently. Amp readings are in the operation manual. If your diaphragm pump isn't pumping as it should check diaphragm, suction and discharge check valve flappers and seats; replace if worn. Check suction hose and fittings for leaks. Check plunger rod for proper adjustment.

PUMP SEAL MAINTENANCE

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PUMP SEAL MAINTENANCE. Sooner or later, every pump wears out. Before repairing or replacing a pump, consider the options. Knowing the advantages and disadvantages of each option before pump performance deteriorates could save you direct costs and downtime losses. Typical repair options include factory remanufacturing or reconditioning, out-of-plant repairs by a factory-trained distributor or local repair shop, and in-plant repairs. Some pump styles are easier to repair and remanufacture than others. This discussion focuses on the repair and remanufacturing options for rotary positive displacement pumps.

Remanufacturing Remanufacturing options are important considerations even before purchasing a pump. The major components of a rotary positive displacement pump--the body, cover, and rotors--are the most expensive to replace. The cost of replacing these parts rivals that of a new pump. However, remanufacturing results in a like-new unit that is often fully warranted and is about two-thirds the cost of a new pump. The efficiency of the pump begins to suffer when wear increases the clearance between the pump rotors and body. The remanufacturing process involves replacing or machining critical wearing parts of the pump. Body and cover wear can be machined away. Replacing the original rotors with standard over sized rotors to match the re-machined body produces new pump clearances. The pump body, cover and gear case are completely remanufactured. Other parts, including shafts, bearings, gears and oil/grease seals, are replaced. Each remanufactured pump gets a new serial number. Most factory remanufactured pumps are fully warranted after successful performance testing. Manufacturers differ in the number of times a pump can be remanufactured. Most allow two times to ensure that standard dimensioned replacement rotors are available.


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Turnaround time for remanufacturing ranges from six to eight weeks. A pump exchange program is often available to minimize downtime. Order a remanufactured pump matching the model number of the original pump when a pump begins to show signs of excessive wear. This move minimizes downtime because the newly remanufactured pump is installed before the old pump goes down. Repair shops are launching into the remanufacturing business. Their cost is slightly less and turnaround time can be faster than going through the manufacturer. On the other hand, this approach loses part standardization. Warranties that repair shops offer are usually more limited than those from the manufacturer. Be sure to know the provisions of the warranty and get references before work begins. Seals deemed "not reconditionable" can be replaced with comparable cost savings and quality benefits. Unreconditionable seals can be replaced with equivalent reconditioned seals when available.


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Factory trained distributors If reconditioning or remanufacturing isn't needed, distributors often offer repair services by factory trained technicians. In addition to having qualified personnel, the distributor stocks genuine factory parts that decreases turnaround time. Some distributors are trained to do regular maintenance such as replacing seals, bearings, or shafts, as well as special repairs. A few are qualified to remachine or recondition parts to factory specifications. If your distributor is not factory authorized, be sure to investigate the warranty options offered and the potential impact on the factory warranty.

Repair shops General repair shops provide only simple pump maintenance or repair. Shops specializing in a particular manufacturers' pumps are also becoming more common. Independent repair shops usually charge less for labor than factory-trained distributors. However, parts may cost more because the independent shop may not have a direct relationship with the manufacturer. Additionally, they may use non-standard parts. Warranty provisions are also critical considerations.

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PUMPS MAINTENANCE – WHY SEALS FAIL

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PUMPS MAINTENANCE - Why Seals Fail Mechanical face seals should last until the carbon face wears away. If the seal starts leaking before that happens to the point where the pump must be shut down and the seal replaced, then the seal has failed.

Examine the faces Chipped edges on either or both faces Chipping is caused by a large separation of the faces and consequent breaking when they slam back into each other. It is most often associated with FLASHING. It is most common in hot water systems or in fluids that may have water condense in them. Water when it changes from a liquid to a gas expands thousands of times in volume and can cause a large face separation. Severe cavitation of the pump coupled with a hung up seal may also cause the problem. Usually small vibrations, misalignments and the like cannot cause the breakage, because they do not separate the faces enough. The cure in the case of flashing is to reduce the face heat. This is done by using carbon versus tungsten carbide or other cool combinations, by using pressure balanced seals, by cooling the stuffing box ensuring that the seal spring tension was not excessive due to installing it wrong double seal or an outside quenching fluid to keep the faces running in a cooling cannot occur.

running face fluid area, by or by using a fluid so that it

A cooling flush to the stationary ring by the use of a special gland can also be used for this problem.

Flaking or peeling of the hard facing Hard facing of stellite, ceramic, and a variety of other materials are often used in seal designs with a rotary hard face. Flaking or peeling is generally a sign of either a defective coating or a chemical attack at the bond. The attack was probably caused by the intense heat that is often found at the face of a seal. It should be noted that when materials are plated you usually retain the chemical properties of the substrate due to the fact that most facings have some degree of porosity. This type of problem is solved by using solid face materials.


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Pitting, blistering, corrosion of the carbon face The carbon used in mechanical seals is selected for the particular application and should not be subject to these problems. This occurs when the wrong carbon is being used or where carbon faces are machined locally. Most seal carbons use an impregnated face and this is not obtainable when a carbon is machined from tube stock. Hot oil service carbon has been formulated especially to prevent blistering and pitting and this is easily cured in oil by using these carbons. Corrosive attack of carbon can be stopped by selecting carbons which are relatively binder free. In the few fluids which attack a pure carbon or carbon graphite such as nitric acid, oleum, chlorosulphonic acid and some exotic highly oxidizing acids, the alternative to use is a TFE or filled TFE face. Faces made from PTFE, TFE are a poor substitute for carbon but are appropriate for the few fluids where a pure carbon will not withstand the fluid.

Check the springs Spring(s) or bellows breakage (metal) Springs and bellows break usually because of chemical attack at the same time the device is being stressed. The phenomena of stress corrosion cracking is explained by many different theoretical methods. It is commonly seen in seals when stainless steel springs and bellows are used in certain fluids. When the fluid being sealed contains chlorine, bromine, iodine, fluorine and irons or compounds of these elements, they often will attack the chrome oxide layer that protects most grades of stainless steel. While the oxide layer is being attacked. the flexing will open up small cracks. If the oxide particles wedge into these cracks, a sudden failure can occur. For this reason, spring materials and bellows plate materials should be chosen from alloys, such as Hastelloy, Carpenter 20, Monel and the like, in the presence of the elements listed. One common fluid which also causes spring breakage is caustic soda. Stainless steel springs and bellows should be avoided in the presence of caustic. Spring breakage and bellows breakage accompanies flexing of the device, but repeated axial compression of a bellows or spring will not cause fatigue failure. This happens when a portion of the spring or bellows is extended too much or flexed in torsion.


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Clogged springs Springs usually clog when the product is dirty and the seal is not moving axially. Some multispring designs clog very easily and should not run in a dirty fluid without some type of clean flushing fluid. On bellows designs and single spring type seals, clogging usually can only take place when the pump is not rotating. If this symptom is seen, it is not very important. It is only if the fluids lock up the two faces or cause the body to stick to the stuffing box that a problem is likely to develop.

Bellows clogged at the inside A metal bellows seal will only clog up and fail if the fluid hardens or particles become stuck at the inside of the bellows. This occurs when there is excessive leakage past the face or past the static shaft seal (usually an "O" ring). The normal leakage from a seal, installed and operating properly, will not cause clogging for years. The most important thing to investigate with this problem is: 1. Is the seal clogged at the proper operating length? If installed with no compression, or too little compression, the seal will start leaking and soon clog. This can be easily determined by measuring its length. 2. Is the wear track significant? If there are signs of excessive motion, this could be the cause of the leakage. If none, then the leakage came by the shaft seal. 3. Shaft seal damage. This can be caused by installation or by shaft deflection, causing a metal-to-metal contact in the region of the pump throat. This will leave a telltale ring around the shaft. This excessive heat will melt a TFE seal long enough to let it leak, but it may heal when the heat source is removed. If this is the problem, then the throat must be machined open, so the shaft deflects substantially.

Deep wear in the hard face This often accompanies outside seals, seals in misaligned pumps and seals in severe abrasive service. It is caused by face separation letting large particles between the faces. These particles then embed in the carbon face and grind the hard face. This can occur in crystallizing products also, where high face heat causes some products to change to abrasive crystals. The problem is often compounded by reuse of the carbon face because it shows little wear.


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When lapping compounds are used to lap carbon, the same problems can occur. The compounds embed and then grind the hard face. The problem is solved in the ways recommended for sealing abrasive products and products which crystallize. Briefly: keep the product at the O.D. of the faces so centrifugal action helps exclude the particles, reduce misalignment and vibration to prevent face separation. Use a seal with low shaft drag, such as the metal bellows or rubber bellows design, which have none. If possible, try to flush the fluid away from the seal with a clean external flush. For abrasive service, a very hard stationary face, such as Tungsten Carbide or Ceramic, can retard the problem and a hard face combination such as Tungsten Carbide against Tungsten Carbide, can drastically reduce abrasive face wear. The hard face combination is most effective because it eliminates the grinding mechanism. The particles cannot embed in either face, so usually get ground up and pass through the faces and leak out.

Worn drive lugs or worn drive slots This is caused by "slip stick". If the two faces stick together, the pin drive will load up with a high stress. This is then transferred back to the face, causing it to accelerate and then stick again. Instead of a smooth rotary motion, the face is being beaten around in its circular path. Slip stick is caused by a lack of face lubrication. This can be caused by a variety of problems. You must look at the other clues to determine the most likely. Lack of face lubrication can be caused by: 1. Installing the seal with too much compression on the springs. 2. Too much pressure acting on the face, i.e. using an unbalanced seal where a balanced seal should be used. 3. The fluid being sealed has poor lubricating properties. 4. The face combination is bad. Using faces for their chemical resistance without regard for their ability to run as a seal face. 5. Pump cavitation. 6. On vertical pumps, air trapped in the stuffing box. Also, on these pumps recirculation lines, from the pump discharge, rather than the suction, causing trapped gases. This is a very important clue because it tells you about the nature of your product. Double seal arrangements are necessary when a product is not a good lubricant.


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This clue will tell you about your product's lubricating properties.

Check the elastomer Swollen, sticky, or disintegrating elastomer This is a sign of chemical incompatibility. It is solved by using a different material. Charts should be consulted or if none are available for the product, immersion tests can be run. If the product is a mixed solvent and no elastomer is suitable, then a TFE sealing device should be selected. This can be in a V-ring seal, a wedge seal, a U-cup seal, an all PTFE seal, or in a metal bellows seal, with a static TFE "O" ring.

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Hardening of the elastomer

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Charring of the elastomer, cracking, burned appearance

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Elastomer has changed shape, "O" rings square, etc..

These are all signs of excessive heat. Usually the source of heat is the face or a metal-tometal contact of two parts. Excessive face heat is caused by lack of lubrication and that is caused by the items listed under drive lug wear. Look for signs of metal-to-metal contact. This is very common, yet often overlooked, because the marks look like they may have been machined onto the seal originally. In the case of heat transfer fluids, such as Downtherm, Humbletherm, etc., the hardening can be caused by heat transferred through the shaft or by the loss of the cooling system to the pump. When pumps use jacketed cooling, it is quite common to see it clog up and block the cooling.

Check for accidental rubbing In a troubleshooting approach, it is important to carefully inspect the shaft, the seal, gland and stuffing box, if possible. Look for signs of rubbing. In high temperature pumps, rubbing of parts may take place only when the pump is hot. When cooled, the worn mark may get covered over and not be as noticeable.


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Some easily overlooked causes for rubbing are:

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Flushing lines coming into a lantern connection and extending into the stuffing box. Glands that do not pivot slip down enough to hit the seal. Gaskets slip into the seal cavity. Stationary rings that do not pivot and come in contact with the rotating shaft. Built-in restricting bushings in pumps that are supposed to be removed for high temperature but are not. Build-up of scale in the stuffing box. Stuffing box not concentric with the shaft. Excessive shaft deflection caused by throttling the discharge or otherwise operating the pump at its wrong capacity. Set screws back out and hit the stuffing box.

Widened wear track A widened wear track indicates that there is serious misalignment of the pump. This can be caused by bad bearings, shaft whip, shaft deflection, a bent shaft, or severe vibrations from a cavitating pump, bad coupling alignment, severe pipe strain, or a stationary seal ring which is tilted. The widened wear track is usually associated with leakage and seal hangup. If the seal is forced to move both radially and axially on each revolution, there is a tendency for the seal faces to separate slightly on each move. This leads to leakage which can gum up the sliding elastomer. This is especially true when the seal has a TFE sliding shaft seal. These are more likely to get hung up then resilient elastomers which can often flex. The options to cure it include: alignment of items mentioned, reducing vibration through better couplings, reducing or eliminating pipe strain, operating the pump at the designed capacity, or by reducing the sliding friction on the shaft caused by the secondary seal. Though reducing the friction will not reduce the width of the wear track, it will extend the life of the seal. If the seal can follow the vibrations and motions with little drag, many of the problems caused by face separation can be eliminated.


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Broken ceramic Ceramics are sometimes subject to heat shock or cold shock. This most often occurs when the ceramic is heated unevenly and then subject to a rapid change in temperature. In many industries the pumps are cleaned by hosing them down. If a stream of water hits a ceramic that is running hot, it will cause it to fracture. Tests run by the ceramic companies indicate that breakage is a function of several things. The more pure and smaller grain size ceramics are less likely to break. Also breakage depends on the shape of the ceramic piece. The more corners and sharp-edges (called stress raisers) the more likely to break and if there is a temperature gradient across the face, that is, the face is hot but the back is cool, the more likely it is to break. What this all means is that a square block pure ceramic raised evenly to a high temperature and suddenly cooled will probably not break. A "T" shaped stationary ceramic running with a hot face which suddenly is cooled is most likely to break. As a general rule the cure for breaking ceramics is a material change if the problem is from heat shock. In initially selecting faces ceramic is often avoided When the fluids are in excess of 300o F(149o C) because there is always the possibility of rapid cooling. Ceramic is often an economical hard face which has exceptional corrosion resistance and if selected for these reasons, a block type shape would be the best around. The other cause of broken ceramic is from mechanical shock or tension. Ceramics are strong in compression but when put into tension by clamping them against an uneven surface or attempting to press them into a shell they often shatter. In seals that use rotating hard faces that are driven by pins ceramic should be avoided. The chance of fracture when the faces stick is very high. This is because the pins start hitting the ceramic.

Worn spot in the stationary ring In some seals the stationary ring is carbon and there circulation from the pump discharge impinges on it. When this happens, it can cause erosion. Some seal companies direct the seal flush at the faces without regard for this problem. It usually will accompany face abrasive damage and other signs of face separation. The flush line should be directed not directly at the seal, but tangent to it. That is, the flush should come in at an angle causing the fluid in the stuffing box to circulate.


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Heat Many problems associated with seal failure such as pump cavitation, dry running, loss of flush and accidental rubbing of metal to metal cause seal destruction because of the heat which may be generated. Heat generated by the faces cause problems only for those materials which are heat sensitive. The most heat sensitive element in any seal is the elastomer. In a rubber bellows seal, for example, the elastomer is in close contact with the face and even a short dry run will cause immediate damage. Other factors that contribute to excessive heat include the following. The face combination determines how fast and under how much pressure the seal can last. The best face combinations for chemical and refinery use are carbon against solid Tungsten Carbide (certain grades), carbon against ceramic and carbon against stellite. Some new silicon carbide face materials are exceptional in their ability to run dry without failure. The fluid being sealed of course is important. Viscous fluids at higher speeds and with very flat faces can cause excessive heat through shear of face film between the stationary and rotary face.

Seal balance is an important determinant of face heat. Balanced seals usually run with a lubricating film while unbalanced seals can quite often become over pressurized squeezing out the film and thus increasing the friction dramatically. The amount of face load plays an important part in determining how the face will be lubricated. The same holds true for the face width. Wide faces have a problem establishing a film across the face. Heat causes several problems that are not always obvious. When the seal contains a sliding elastomer in the face and the face is running hot, the elastomer will be hardened over a period of time . The hardening then reaches the point where leakage starts. Once leakage starts past the elastomer, there is a tendency to gum up or hang up the elastomer. This gumming up then stops the seal from following motions caused by misalignments at which time the seal starts increasing its leakage rate through face wear. When the leakage is too high to be tolerated, the seal is then changed.


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The underlying reason for the failure was the heat, but unless a close check is made of the elastomer, it will not appear to be the cause. Inspect the seal drive Seal designs all use some way to transmit torque from the shaft to the rotary face. Quite often, it is done with pins, set screws and lugs. In a few cases it is done with the single spring. To check for this clue you must first determine for your particular seal where the drive junction is located. Seals are usually loose in torsion, that is, outside the pump you can twist them slightly before they engage. You are looking for signs of wear at the pin, drive lug, dent or spring. In bellows seals the signs are not present because they are usually a solid drive.

Hysterisis When a stationary ring is not square with the shaft, the sliding elastomer in the face of the seal must move back and forth on each revolution in an axial direction. The amount of motion depends directly on how much misalignment from a perfect 90 degree angle. Misalignment can also be caused by pipe strain, bad bearings, a bent shaft or shaft deflection caused by improper system operation. The seal is alternately pushed away from the stationary ring by the immovable face and back towards it by the spring pressure and by the fluid hydraulic pressure. The spring force must be high enough to overcome the resistance to motion caused by the drag of the elastomer. Hysteresis is sometimes used to describe the amount of drag caused by the elastomer as measured in lbs., oz., etc. Hysteresis is also used to describe a delay or lag between two events. The rate of motion of the seal face axially must be the same in both directions or the seal faces will separate in not returning as fast as it was thrust away from the stationary ring. This minute separation caused by motion, drag and hysteresis depends then on not only the amount of drag, but the size of the seal and the speed. Hysteresis is the underlying reason for face separation, leakage, premature life, abrasive face damage and a variety of other ills in pumps that are not in perfect alignment.


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Face separation The faces of a seal are normally flat to less than 20 millionths of an inch and are lubricated with a thin film of the sealed fluid. Because this leaves something less than a micron between them, they would normally act as a natural excluder of abrasive particles. When the faces are moved axially on each rotation, there is a tendency for them to separate much greater distances than millionths of an inch. .005" to .030" misalignment is not uncommon. The number of times that the seal has to move axially is over 10 million times a day on a 3600 rpm pump. The separation of the stationary and rotating face by a few thousands of an inch causes two problems: It allows large abrasive particles to get between the faces and it allows the fluid being sealed to leak out. The leakage out can carry away wear particles causing rapid face wear and it will gum up or hang up the sliding elastomer from the outside where no self-cleaning takes place.

Proper size wear track This is an important sign because it tells you that the pump is in good alignment and face leakage is probably not the cause of any seal problem you might have. In a clogged metal bellows seal, for example, this is the clue that tells you the seal leaked by the static secondary seal.

Narrow wear track When the wear track is narrower than the thinnest face, this means that the seal has been over pressurized and has bowed away from the pressure. This bowing causes the seal to seal only on a portion of the face width. This is from improper design and the seal must be changed to a higher pressure, more rugged design if this occurs.

No wear track If there is no apparent wear on the faces of the seal after they have been in operation for some time and the seal is a rubber bellows type you should examine the springs and stuffing box. This means the faces may have been pressed together with the shaft rotating under the rubber. The springs will be worn and shiny if this has happened.


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This is because the spring remains stationary and rubs against some rotary part of the pump. This is caused by using the wrong lubricant on the rubber during installation and could be also due to an underside shaft and too good a shaft finish. In several conventional seals we have seen this symptom where the seal had run against the gland rather than the pressed-in stationary face. This had been caused by the gland slipping in one case and in another case by the gland bore being smaller than the OD of the seal.

No wear track - shiny spots on the face This is caused by a warping of the face with the spots. Warping is caused by too much pressure, improper bolting or clamping or a bad face on the pump where the face is clamped. This can happen easily on two bolt glands that are not thick enough; it also can happen when the face is severely out of flat before it has been installed. Cures for the problem include checking to see if the hard face is flat prior to installation, facing off the pump so that it is a clean smooth surface, using four bolt glands or glands that are strong enough to spread the bolt force evenly, and taking pains to draw up the bolts evenly. This is an important symptom because it indicates the seal probably was leaking from startup. The constant leakage usually causes the elastomer to hang up and the seal is no longer able to clean- itself. This can then lead to clogged springs which might have appeared to be the cause of the failure, but was really a result of the leakage.

Collect the entire seal Do not try to troubleshoot a seal by using only the parts that look important. You must have both the rotating part and the stationary part. If possible, you should also be able to inspect the gaskets, O-rings or other secondary seals, the shaft sleeve and the inside of the stuffing box. It is a good idea to have someone troubleshoot all the seals that are removed whether there appears to be a problem or not. The best way to do this is to use a procedure that is very successful in several chemical plants. When a seal is removed the stationary and rotating parts are tied together and tagged with any information that may be useful. Then they are stored in the shop until they are ready to be rebuilt or discarded. In the meantime they are available for troubleshooting and failure analysis.


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Though the troubleshooting may be of little help for the pump that contained the seal, quite often this type of troubleshooting turns up common problems that can be corrected. When the two parts of the seal are separated after removal, it sometimes becomes difficult, if not impossible, to determine the actual cause of seal failure.

Guides for the installation of successful mechanical seals Preparation of the pump (a) Be sure seal chamber is clean and free of all foreign matter. (b) Shaft of shaft sleeve on which the seal is to operate must be to size, must be smooth, straight, and free of all burrs, sharp corners, nicks, or excessively deep scratches. (c) Plug all holes in the stuffing box which are not to be used in the operation of the seal. (d) Face of stuffing boxes must be smooth, clean, and square with the axis of the shaft. (e) Halves of boxes on horizontal split case pumps must match perfectly, with the gasket between the halves extending flush with the surface on which the mechanical seal glandgasket is to seal. Remove all sharp corners and burrs from stuffing box face. (f) Check the shaft for alignment with a dial Indicator. The maximum allowable runout for optimum seal performance Is .005" TIR. Excessive misalignment may mean faulty bearings or bent shafts. (g) Keep shaft end-play at a minimum Recommended maximum end-play is .005 inches. (h) Check pump wear rings and impeller for proper clearances. Shaft must turn freely. Vibrations caused by rubbing and improper clearances can cause seal failure. (i) Wherever shaft sleeves are used, make certain the sleeve is properly gasketed to the shaft to prevent leakage under the sleeve.

Installation of the Seal (a) Always handle mechanical seals with extreme care. Cleanliness is imperative. Never place faces face down on bench or floor. Keep seal in shipping containers until ready to install. (b) Follow seal Installations Instructions carefully, (See Installation Instructions). (c) Be sure all seal set screws are tight. (d) Where set screws are used as a drive between seal and shaft, shaft should be counter-sunk to receive cup point.


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(e) Care should be exercised In tightening gland bolts. Tighten evenly and do not spring gland. (f) Use four equal-spaced gland bolts wherever possible; API-ASME Code for Unfired Pressure Vessels should be followed wherever possible when selecting gland bolt size and spacing. (g) When tightening gland bolts, check clearances between shaft and gland with feeler gauges. This is particularly important when the gland is not piloted on the stuffing box as glands must be accurately centered. (h) Test seals statically under pressure before starting pump. Make slight adjustments in gland nuts as necessary to stop any leakage which may occur through gland-gasket. (i) Never operate mechanical seals dry. Carefully follow instructions for flushing and cooling connections where specified. Be sure suction and discharge of pump is open and a positive head of fluid is present before starting pump. This applies even to that period when checking for proper direction of rotation and adjustment of motor electrical connections.

Troubleshooting 1. Seal spits and sputters in Operation Product is flashing across the seal faces due to vaporization. Keep in mind a definite liquid condition between the faces is required and take steps to maintain this. Check to determine if pressure, perhaps, requires balanced design rather than unbalanced and, if the seal is already balanced, it may be that pressures are more severe than indicated on the specification sheet. Determine the correct actual stuffing box pressure and temperature and also the specific gravity and vapor pressure at these conditions for the product being handled as this data may provide the clue to the trouble.

2. Seal leaks and icing appears around the gland Product is flashing across the seal faces due to vaporization. If icing has occurred, undoubtedly some damage has been inflicted on the stationary seat and the carbon seal ring. These faces should be inspected and repaired, if possible, or replaced, if necessary, after the vaporizing condition has been corrected.


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3. Seal drips steadily Check to see that the gland gasket is under proper compression against the face of the stuffing box. With horizontally split case pumps, be sure to check at interface of joint and gland. Faces may be deflected or not truly flat. Improper gland-bolting or overstressing of the bolts may have caused a deflection of the stationary seat under compression. This will occur, primarily, with clamped type seats. Shaft packing on the rotary unit or on the stationary seat may have been damaged in installation. The waring faces may have been scored by abrasives or other fine particles. If a unitary assembly or mounted on a pump sleeve, it is possible that leakage is coming under the sleeve itself.

4. Squealing seal This indicates dry operation which may be due to lack of liquid at the sealing faces. It is possible that a circulating flush line from discharge or an external source of fluid may be necessary. Furthermore, if one is already installed, it is possible that the orifice in it is too small and it may be necessary to enlarge the orifice.

5. Carbon rotating face dusting and this wear showing up outside the seal on gland and along the shaft Insufficient liquid at the sealing faces. Liquid is flashing due to vapor pressure built up between the seal faces leaving a fine crystallized particle residue or is creating dry contact thus grinding the carbon away. The stuffing box pressure is too high for the seal design and, undoubtedly, some correction has to be made. A balanced seal may be the answer.

6. Seal leaks and there is nothing apparently wrong The faces may not be flat. This can best be determined by removing the faces and examining the wear pattern as discussed previously. The stationary seat may have been distorted due to excessive gland bolting stressing the clamped stationary seat and distorting same.


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This can also be determined from the wear pattern on examination. Improper piping to the suction and discharge gland of a pump can actually stress that pump, distorting the seal faces in the alignment with the shaft. If this problem is encountered, it is most common on vertical end suction overhung type impeller centrifugal pumps. Many of these pumps are not of sufficient strength in design, etc. to tolerate the excessive weight which results in misalignment due to same and this will affect the seal. Pipe hangers are the only solution to this problem. Possible shaft vibration can be caused by misalignment, impeller unbalance, cavitation, and bad bearings.

7. Short Seal Life The greatest major cause of short seal life is excessive abrasives getting between the faces and causing rapid wear. The source of these abrasives may either come from slurry condition or they may come from the super cooling of a supersaturated solution or it may occur due to flashing across the seal faces, causing the dissolved solids to crystallize out between said faces and, again, causing wear. Cooling or heating, as the situation might occur, and/or most assuredly circulation of pump from discharge to the stuffing box or external clear flushing will alleviate these conditions. Misalignment of equipment. Pipe strain distortions as mentioned above. Seal shows signs of running too hot when a by-pass flush or recirculation may be necessary. Check for the possible rubbing of seal components along the shaft. Throttle bushings and poorly piloted glands can often cause this condition. Attempt more effective cooling of the seal area by connecting all cooling lines, checking to ascertain that all cross drilling of flush lines, etc., are clear and unobstructed (remove all scale, etc., that may accumulate in these lines), and by increasing the capacity of cooling lines or open the orifice clearances on circulation lines.

Possible improper choice of type of seal may have been selected.

TROUBLESHOOTING ELECTRO-HYDRAULIC PUMPS.

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Troubleshooting Electro-Hydraulic Pumps The art of troubleshooting is not really an art at all. Instead, it is more of a science. When a system malfunctions, you gather information and evidence, form a hypothesis about what caused the problem, test the hypothesis, fix the problem, then continuously verify the repair. Modern industry demands tremendous control of pressure and flow during very complicated, dynamic processes. Many hydraulic pump manufacturers meet this demand by integrating advanced electronic technology with the latest hydraulic technology. As a result, manufacturers enjoy shorter response times, precise pump control, and increased pump efficiency. However, when something goes wrong, troubleshooting the pump can be a challenge. There are few maintenance people with the experience and training in both electronics and hydraulics to diagnose and repair electro-hydraulic pumps. The following twelve steps provide a foundation for your troubleshooting.

Make safety your first priority Hydraulic pressure and electricity are inherently dangerous. I personally saw a mechanic maim a finger as he was running his hand along a high pressure pipe looking for a pinhole leak. He found it. Use common sense. Unless you are absolutely positive the system is "dead", locked out, and tagged, assume the system is under pressure and electrical components are live. Do not take shortcuts if it means sacrificing safety.

Understand the system The electro-hydraulic pump is only one component in a larger system. It is important to know how the pump and every other component interact with each other. Review and understand the system schematics, read manufacturer specifications, know the capabilities of every component; understand the purpose of each component and how it contributes to the function of the entire system. Your system is only as good as its weakest component. For example, if you use a pressure transducer with a tolerance 5 percent, the best tolerance you can expect your system pressure to have is 5 percent. Five percent of hydraulic pressure means a lot of psi in the deadband.


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Talk to the operator If the system has been in operation, talk to the operator. Ask what the symptoms are, when the problem occurs, where the problem manifests itself, and the magnitude of the problem in the system. In addition to describing symptoms, the operator can often give you some history. It is not unusual for the operator to remember how a previous maintenance crew fixed the same problem before.

Test the system Run the system yourself to get the full experience of the malfunction. If you are not familiar enough with it to safely operate it yourself, observe as someone else runs the system. It is usually a good idea to have the operator show you the problem. By doing this step, you do not have to rely on other people's opinions.

Verify that the components are properly connected Spread out the system schematic and compare the drawing to the actual system. Follow the flow path through the circuit. Ensure that the electrical connections are correct. Look for discrepancies between the schematic and the actual system. Focus on those discrepancies. As just one example, contamination caused two pump shaft seal failures during a distributor's pump test. Initially, we thought the shaft seal was overly sensitive to contamination and we asked for a redesign of the seal. However, after asking some very pointed questions, the distributor discovered the operator used a thirty micron filter instead of the three micron filter specified for the system.

Compare the problem machine with one that is working If you have the luxury of another machine with a similar pump, look for differences between the machine that works and the one that doesn't. Look for differences in components, location of transducers, the age of the system, temperatures, the size of the pump, pressure and flow differences, and anything else that helps to answer the question, "Why does one system work while the other one doesn't?"


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For example, we had a valve test stand experiencing severe flow oscillations. We were sure the pump was broken. After ordering a replacement pump, an alert maintenance mechanic pointed out that this system had about seven gallons less fluid in the reservoir than systems with similar sized reservoirs. Before changing the pump, he added fluid to the reservoir. The problem went away as soon as the pump saw a flooded suction

Causes of the malfunction Consider everything that could cause the malfunction. Use maintenance manuals and textbooks. Ask co-workers who previously used or maintained the machine. Pump vendors have troubleshooting guides; use them. A little time spent during this step can save a lot of time later. You may want to consider forming an impromptu team to try to determine what went wrong. If you want to see a good, effective team in action, watch the movie Apollo 13.

Test the pump electronics By now you should be reasonably sure that the pump is causing or contributing to the problem. It's time to focus on finding out what's wrong with it. Use a multimeter to check the continuity of the pump leads. Check the wiring diagram and make sure the pump is wired correctly. Check the voltage from the transducers to ensure the transducers are working. If your pump has dual inline pin (DIP) or dual inline (DIL) switches, double check the position of each switch. Measure the voltage output of the electronics portion of the pump. Electricity flowing through a solenoid creates a magnetic field. Hold a magnetic compass or ferrous metal object near the solenoid to verify the solenoid is energized when it is supposed to be energized. Don't get anywhere near the electrical feed to the solenoid and use properly insulated tools to hold the compass or piece of metal. If a computer or programmable login controller controls your system, there are several more things to check. Verify the programming, make sure the parameters are correct, look for error messages from the computer, and check that the software is loaded correctly. Debugging computer systems is tedious and time consuming and worthy of its own article.

Test the pump mechanically Once you are reasonably confident that the pump's electronics are working, check the mechanical functioning of the pump. Look at the suction pipe and check for restrictions or air leaks. Measure the flow and pressure coming at the pump's pressure port.


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Check for excessive flow from the case drain on the pump. Check the pump's speed and direction of rotation. Verify that the operating temperature is normal. If possible, check the pilot pressure to make sure there is pressure when there's supposed to be pressure. Equally important is to make sure there is no pressure when there should be none.

Replace suspected problem components Based on what you learned in the above steps, you should now have an idea what is causing the problem. You may want to take a little time to brainstorm again, this time focusing on the pump. If you think a transducer is bad, replace it and retest the system. If you suspect contamination in the pilot system, open the system, look for evidence of contamination damage, clean the pieces, then retest the system. It is important that you do only one corrective action at a time. Fixing the pump by simultaneously replacing a transducer, spool, and electronic card gives you no way of determining what exactly caused the failure. These components are expensive and few companies can afford to waste money replacing parts that are still good.

Call for help Most distributors and vendors have experts who are ready to help. While you may be dealing with only one pump, they have experience with hundreds of pumps. After you have given the troubleshooting your best shot, call the distributor who sold you the pump. If the distributor is unable to help, ask for the telephone number to the factory. Be prepared to describe the application and symptoms in detail. You may want to fax a schematic of the system to the technician helping you. The more information you can give, the better will be the help you receive.

Verify the system works This is the final step. Monitor the system and make sure it is operating correctly. Make sure the operator knows how to monitor the system. Also, describe and show others what the problem was and how you fixed it. Another set of eyes increases confidence in the repair. As a former maintenance test pilot, I never flew an aircraft until a technical inspector and I inspected the work of a repairman. Ten thousand feet off the ground is not the safest place to discover a faulty repair job. Another advantage to showing others the repairs is the training value. A breakdown is a chance for several people to learn.


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This makes the company stronger because it does not rely on only a few people to fix similar breakdowns in the future. This helps avoid the painful situation where the one person who knows how to fix a breakdown is on vacation and can't be reached.

Troubleshooting improves with practice. Every breakdown is an opportunity to hone your skills. Soon the troubleshooting process will be second nature.

Y ou w i l l see your effi ci ency and ski l l i ncrease. Som eday, after a tri cky but successful repai r, you m ay even say to yoursel f, "It w as beauti ful ."

ROLLER CHAIN DRIVES INSTALLATION

Roller Chain Drives Installation. To obtain maximum service-life and efficiency from a chain drive, it is necessary that certain precautions in installation be taken. Chain drive installation is relatively simple and good results may be obtained when the following conditions are met: 1. 2. 3. 4.

The roller chain, sprockets, and other components are in good condition. The sprockets are properly aligned. Provision is made for adequate lubrication. The chain is correctly tensioned.

Condition of Components Shafting, bearings, and foundations should be supported rigidly to maintain the initial alignment. Roller chain should be free of grit and dirt. Wash chain in kerosene when required. Relubricate!

Drive Alignment Misalignment results in uneven loading across the width of the chain and may cause roller linkplate and sprocket tooth wear. Drive alignment involves two things: parallel shaft alignment and axial sprocket alignment. Shafts should be parallel and level. This condition may be readily checked by the use of a feeler bar, and a machinist's level. It there is axial movement of the shaft (as in the case of an electric motor), lock the shaft in the normal running position before aligning the sprockets. Sprocket axial alignment can be checked with a straight edge which will extend across the finished sides of the two sprockets. Normally, it is good practice to align the sprockets as close to the shaft bearing as possible. For long center distances, use a taut cord, or wire long enough to extend beyond each of the sprockets.

Installing the Chain Recheck all preceding adjustments for alignment and make certain all setscrews, bolts and nuts are tight. Fit chain around both sprockets and bring the free ends together on one sprocket for connection, The sprocket teeth will locate the chain end links. Install the connecting link, and connecting link coverplate, and the spring clip or coffer pins. On larger pitch chains or heavy multiple strand, it may be necessary to lock the sprockets for this operation.

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ROLLER CHAIN DRIVES INSTALLATION

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When press fit cover plates are used, be careful not to drive the plate on so far as to grip the roller links. Stiff joints can result if this is done. On drives with long spans, it may be necessary to support the chain with a plank or bar as the connection is made.

Chain Tension Check chain tension to be certain the slack span has 4-6% mid-span movement in horizontal drives and 2-3% in vertical drives.

Recommended Possible Mid-span Movement AC Tangent Length Between Sprockets Drive Center-Line Horizontal to 45 degrees Vertical to 45 degrees

5" .25"

10" .5"

15" .75"

20" 1"

30" 1.5"

40" 2"

60" 80" 3" 4"

100" 5"

.12

.25

.38

.5

.75

1

1.5

2.5

2

Aligning Shafts Aligning Sprockets

AC = Total Possible Mid-Span Movement Depth of Free Sag = .866 AB, approximately.

ROLLER CHAIN MAINTENANCE.

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Roller chain Maintenance. These tips improve long term performance Steve Barbacki, Manager of Product Engineering, Roller Chain Division, U.S. Tsubaki, Inc., Holyoke, Massachusetts

Connected rings have been used for more than 2,000 years for such power transmission applications as raising buckets of water. Yet, as we know it, roller chain is a fairly recent invention. In fact, highly engineered roller chain reliable enough for use in timing luxury automobile engines--evolved substantially over the last 50 years. Roller chain is a complex mechanism designed to provide excellent tensile strength, fatigue strength, wear resistance, and reliable performance often under adverse conditions. Manufacturers produce roller chain in continuous strands on precise automated equipment. The chain can be cut to needed lengths and a special connecting link brings the ends together to form loops. Roller chain transmits power, as from a motor to a driven shaft, or conveys diverse products in a wide variety of ways. Power transmission applications for roller chain--ANSI Standard B 29.1M--exist in almost all industries in addition to the well-known uses in motorcycles and automobiles. The alternatives to chain are often gears or belts. Chain is used most frequently to transmit power smoothly at low speeds--below 150 feet per minute--with heavy loads, while softening shocks and suppressing vibration. High speed applications up to 9,000 feet per minute are possible, depending on chain size and with sufficient continuous lubrication. Chain or belting can often be used where shaft center distance precludes gearing, but under the same general conditions, chains and sprockets cost less than toothed belts and pulleys. Other roller chain characteristics include: • speed reduction--up to 7-to-1, • layout flexibility--chain can be used with multiple shafts or drives, • ease-of-assembly and adjustment • variable lengths • excellent synchronization. Chain sprocket diameter can be smaller than with belt pulleys while transmitting the same torque. Wear is inevitable due to the metal-to-metal contact and constant articulation of chain over sprockets. Regular lubrication reduces the wear rate and noise, yet wear eventually occurs, even with the best maintenance. As roller chain wears it becomes longer. This elongation can be measured, providing a means of predicting when a chain needs replacement. Maintenance personnel can reduce the elongation rate and extend the useful service life of a chain by lubricating effectively and maintaining the proper chain tension. With proper selection and care, high quality roller chain provides long-term value for users.


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Roller chain construction Roller chains consist of alternate connections of roller links and pin leaks (see Figure 1). Each pin link is made of a pair of pin-link plates connected by two press-fit pins. Each roller link has a pair of roller link side plates connected by press-fit bushings. This type of chain gets its name from the free-to-turn rollers placed over every bushing. The pin and roller links join together in alternating fashion, with pins fitting inside the bushings so that each link swings freely independent of the links on either side. The link plates form the sides of the roller chain, with pierced holes accurately placed to accommodate the press-fit pins and bushings. The plates bear the tension imposed on the chain. These chain plates withstand cyclic loading that is often accompanied by shock. Additionally, plates must meet environmental requirements such as resistance to corrosion and abrasion. The pins are subject to shearing and bending forces transmitted by the side plates. Pins, together with the bushings and rollers, bear the loads exerted during sprocket engagement. The pins must exhibit high tensile and shear strength, resistance to bending, and endurance against shock and wear. Bushings also experience bending, shear, and shock loads when the sprocket teeth engage the chain. Pins must have great tensile strength and shear strength, along with shock resistance. The bushings also provide bearing surfaces for pin articulation and must resist wear. The rollers reduce friction and wear as the chain engages the sprockets. During engagement, each roller presses against its bushing and the sprocket. The roller surface, must be wear resistant and still be strong enough to to resist shock, fatigue, and compression loads. Roller chain is made of high-grade carbon steel, although other materials such as stainless steels, alloys, and engineered plastics are used for various applications. Some chains are plated with special materials to resist corrosion in wet environments. Roller chain is sized by pitch (P), the distance from the centerline of one pin to the next (see Figure 2, Other key measurements are the roller diameter (R), pin diameter (D), width between roller link plates (W), and the height of the link plates (H). When multiple strands are connected side-by-side for greater strength, the distance between the centerline of each strand is known as the transverse pitch (C). An offset link is used when an odd number of chain links is required. Standard offset links have a fatigue strength 35 percent lower than the chain itself, but special, two-pitch offset links result in no loss of fatigue strength.

Wear is inevitable due to the metal-to-metal contact and constant articulation of chain over sprockets. Select with care No roller chain product can deliver optimum performance unless it is properly selected. Most roller chain manufacturers publish a selection procedure, including diagrams, charts, and tables. Figure 3 is a typical roller chain selection diagram. To use this chart, users should include the type of power source--normally an electric motor--the equipment being driven, horsepower to be transmitted, speed in revolutions per minute of drive and driven shafts at full load, shaft diameters, and the distance between the shafts. Other chain selection considerations include the service factor--the reduced transmission capability due to frequent or severe load fluctuations.


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One must also consider chain speed, available space, and environmental factors such as abrasive conditions, cleanliness requirements, and noise constraints. Design engineers use charts and calculations to determine the approximate chain size and number of teeth for each sprocket, but the final decision on size and type of chain often hinges on an environmental factor. For example, it may be desirable to select one of the recently developed lube-free chains to maintain clean manufacturing spaces and prevent contamination of nearby equipment or products. Some chain producers offer design engineering assistance so end-users can be certain that chain and sprockets are selected correctly with appropriate consideration of factors, including economy and longevity. Matching both sprockets to the roller chain is equally important. If the sprockets aren't made with the correct tooth profile, pitch, and proper hardness levels in the right places, the chain may wear prematurely. Excessive wear results in a substantial reduction of chain life and premature chain replacement.

Prolonging roller chain life Understanding how to reduce roller chain wear can provide maintenance at just the right time, prolonging chain life and extending replacement intervals. If the chain on a given application has to be replaced every six months and you can make that chain last a year by spending more on maintenance, you've saved the cost of one total replacement job, including the cost of the new chain plus all the labor involved. A number of steps increase chain life while actually reducing the total amount of maintenance devoted to roller chains in your plant. These steps include ensuring correct alignment, keeping the right chain tension, maintaining proper lubrication, and adjusting elongation. Accurate alignment of sprockets is necessary for smooth transmission of power and prolonged life of the roller chain. Roller chain, by its nature, must not be subjected to twisting forces. To prevent wear on the inside of the roller chain sidebars and the outside of the sprocket teeth, the shafts on which sprockets are mounted must be level and parallel with exactly the same distance between the ends of each shaft. One method to verify sprocket alignment requires laying a straightedge across the machined surfaces of the drive and driven sprockets. The straightedge must be flat against both surfaces to ensure they are rotating in the same plane and not trying to bend or twist the chain. Wear on the inside of sideplates and on the sides of sprocket teeth is a sign of misalignment. Verifying sprockets alignment contributes to the longevity of both chain and sprockets.

Sintered, oil-impregnated bushings and specially plated pins in these newer chains reduce the coefficient of friction and maintain effective long-term internal lubrication without the use of O-rings. The tension in the working strand of roller chain between the drive and driven sprockets is normally taut while some slack is desirable on the return strand. Generally, the slack strand should flex no more than 4 percent of the distance between sprocket shafts. For example, if the return span is 25 inches, you should be able to raise the center of that span only about one inch. When the distance between shafts is more than 36 inches, when loads are heavy with frequent starting and stopping, or when chain movement is reversible, the flex should be only about 2 percent.


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Chains that are too loose tend to whip and are difficult to control. Whip causes excessive chain wear and leads to premature replacement. Remember, chains elongate with wear, so this can happen periodically. Check chain tension occasionally, and look for chain riding high on the sprockets with polished sprocket teeth, indicating an adjustment is needed. If chain elongation exceeds manufacturers' limits, the chain should be replaced. Tension may affect horsepower limits and working loads and must be maintained according to manufacturers' instructions. The simplest method of adjusting tension is to move one shaft--commonly the drive motor shaft. An idler sprocket on the return strand can be used to maintain tension with fixed-center drives or long spans. Most chain users recognize the importance of chain lubrication. Yet, lack of lubricant is probably the greatest contributor to excessive chain wear leading to early replacement. Most chain manufacturers provide guidelines for SAE-rated lubricant viscosity. This depends on chain size, application method, and operating temperature. Determining the frequency of manual lubrication depends largely on its operation, including chain speed, and the environment. Each maintenance manager must decide how often to lubricate to prevent excessive chain wear. Without proper lubrication, most roller chains fail prematurely. To prevent unexpected chain failure, maintenance personnel should look for chain elongation. Normal chain wear occurs on the hard-to-see outside of the pins and insides of bushings. This results in in observable chain elongation. When a chain elongates beyond the manufacturer's specific elongation tolerance, it should be replaced to prevent unexpected breakage and damage to associated equipment. The allowable elongation for many standard roller chain products used with sprockets having 60 teeth or less is 2.0 percent. Elongation can be checked by measuring a six to ten link section of used chain and comparing that length with the same number of links of a new chain.

Generally, the slack strand should flex no more than 4 percent of the distance between sprocket shafts. New developments Leading chain manufacturers sponsor extensive research programs seeking ways to improve their products for longer service and greater economy for end-users. In recent years, these programs are concentrating on ways to reduce corrosion and eliminate the need for constant lubrication. Among the solutions to the problems of chain corrosion under demanding operating conditions are the use of stainless steel, nickel plating, and proprietary coatings.

Results have been mixed; stainless steel sacrifices strength and is expensive, while metal plating can flake off leaving the surface unprotected. One of the best developments is a process that results in a metallurgically bonded plating that can't flake or peel off. Component surfaces are coated prior to assembly so corrosion protection is significantly better than with postassembly plating or dipping processes.


If maintaining proper lubrication is difficult because of chain location or contamination potential from excess lubrication, a lube-free product may be a solution. Lube-free chain lowers maintenance costs by eliminating the need for lubrication and extending wear life. For example, an oil-impregnated, sintered bushing roller chain offers improved wear life--up to 40 times longer than standard ANSI roller chain. These newer chains operate without additional lubrication and last longer than older types of lube-free chain. Sintered, oil-impregnated bushings and specially plated pins in these newer chains reduce the coefficient of friction and maintain effective long-term internal lubrication without the use of O-rings. The special construction of these chains results in smooth articulation of the chain over each sprocket, reducing chain pull and yielding exceptional wear life.

Conclusion With proper installation, adjustment, and lubrication, the run time of chains can be extended with less unexpected downtime. By recognizing the causes of wear and taking the right precautions, you can make your roller chains last longer with less effort.

5

ROLLER CHAIN DRIVE MAINTENANCE

Roller Chain Drives Maintenance. WHEN DISASSEMBLING OR ASSEMBLING CHAINS:

WARNING - The components of a chain are hardened parts. Striking these parts may cause metal chips to break off from the chain or the tools used resulting in personal injury. During all stages of chain disassembly and assembly, wear safety glasses to prevent metal parts or chips from entering your eyes and have personnel in the immediate area do likewise.

A. Pin Removal 1. 2. 3.

If chain is of cotterpin-type construction, remove cotters. It chain is riveted-type construction, grind pin heads off so pin ends are flush with the linkplate. Drive pins out of linkplate using a Diamond pin extractor Model # 113 or 135. Some multiple strand chains or large pitch models will require a hammer and punch or a press to remove the pins.

B. Installation of Coversides Diamond coversides are manufactured three different ways: 1. 2. 3. 4.

Slip Fit Modified Press Fit Full Press Fit Modified and Full Press Fits require some patience and tools to assemb le and/or disassemble.

All chain drives should receive regular maintenance. Each drive should be inspected after the initial 100 hours of operation. Thereafter, most drives may be inspected at 500 hour intervals. However, drives subjected to shock loads or severe operating conditions should be inspected at 200 hour intervals. At each inspection, the following items should be checked and corrected, if necessary.

1. Check lubrication On slow speed drives, where manual lubrication is used, be sure the lubrication schedule is being followed. If the chain is covered with dirt and debris, clean the chain with kerosene and relubricate it. WARNING! NEVER USE GASOLINE OR OTHER FLAMMABLE SOLVENTS TO CLEAN A CHAIN. A FIRE MAY RESULT. If drip lubrication is used, check for adequate oil flow and proper application to the chain. With bath or pump lubrication, check oil level and add oil if needed. Check oil for contamination and change oil if needed. Change oil after the first 100 hours of operation and each 500 hours thereafter. If pump lubrication is used, check each orifice to be sure it is clear and is directing oil onto the chain properly.

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2. Check Chain Tension – Check chain tension and adjust as needed to maintain the proper sag in the slack span. If elongation exceeds the available adjustment, remove two pitches and reconnect the chain.

3. Check Chain Wear Measure the chain wear elongation and if elongation exceeds functional limits or is greater than 3% (.36 inches in one foot) replace the entire chain. Do not connect a new section of chain to a worn chain because it may run rough and damage the drive. Do not continue to run a chain worn beyond 3% elongation because the chain will not engage the sprockets properly and it may damage the sprockets.

C. Installation of Spring Locks and Cotterpins After coversides have been installed, install spring locks or cotters (depending on chain design). Avoid using bent or worn cotters or spring locks. After spring locks (or cotters) are installed, lightly tap pin ends to position these parts snug against the coverside for additional support. WHEN INSTALLING CHAIN DRIVES ON EQUIPMENT:

WARNING - You may be seriously injured if you attempt to install chain on equipment under power. Shut off power and lock out gears and sprockets before attempting installation. Once installed, the chain drive must be guarded to prevent personal injury or property damage in the event the chain separates during operation. If chain drive is not guarded, contact equipment manufacturer for recommendations on guarding before using equipment. Knowing more about how the chain is constructed may help in assembly and disassembly.

4. Check Sprocket Tooth Wear Check for roughness or binding when the chain engages or dis engages from the sprocket. Inspect the sprocket teeth for reduced tooth section and hooked tooth tips. If these conditions are present, the sprocket teeth are excessively worn and the sprocket should be replaced. Do not run new chain on worn sprockets as it will cause the new chain to wear rapidly. Conversely, do not run a worn chain on new sprockets as it will cause the new sprockets to wear rapidly.

5. Check Sprocket Alignment If there is noticeable wear on the inside surface of the chain roller linkplates, the sprockets may be misaligned. Realign the sprockets as outlined in the installation instructions to prevent further abnormal chain and sprocket wear.


6. Check for Drive Interference Check for interference between the drive and other parts of the equipment. If there is any, correct it immediately. Interference can cause abnormal and potentially destructive wear on the chain or the interfering part. If the edges of the chain linkplates impact against a rigid part, linkplate fatigue and chain failure can result. Check for and eliminate any buildup of debris or foreign material between the chain and sprockets. A RELATIVELY SMALL AMOUNT OF DEBRIS IN THE SPROCKET ROLL SEAT CAN CAUSE TENSILE LOADS GREAT ENOUGH TO BREAK THE CHAIN IF FORCED THROUGH THE DRIVE.

7. Check for Failure – Inspect the chain for cracked, broken or deformed parts. If any of these conditions are found, REPLACE THE ENTIRE CHAIN, even though portions of the chain appear to be in good condition.

Perunding AME / 6 th June 1999/ NW.

3

ROLLER CHAIN DRIVES LUBRICATION

Roller Chain Drives Lubrication. Lubrication - Part 1 Roller chain consists of a series of connecting traveling metallic bearings, which must be properly lubricated to obtain the maximum service life of the chain. Although many slow speed drives operate successfully with little or no lubrication beyond the initial factory lubrication, proper lubrication will greatly extend the useful life of every chain drive. The chain drive requires lubrication for six purposes. 1. 2. 3. 4. 5. 6.

To resist wear of the pin-bushing joint. To cushion impact loads. To dissipate any heat generated. To flush away foreign materials. To lubricate chain-sprocket contact surfaces. To retard rust or corrosion.

A good grade of clean petroleum oil without additives, free flowing at the prevailing temperatures, should be used. Some additives leave a varnish or gum deposit which prevents the oil from entering chain joints. Heavy oils and greases are generally too stiff to enter the chain joints and should not be used. With proper lubrication, a separating wedge of lubrication is formed between the pins and bushings in the chain joints much like that formed in journal bearings. The viscosity of the lubricant greatly affects its film strength, and its ability to separate moving parts. The highest viscosity oil which will flow between the chain link plates and fill the pin-bushing areas will provide the best wear life. This is essential to minimize metal to metal contact and, if supplied in sufficient volume, the lubricant also provides effective cooling and impact dampening at higher speeds.

Note: Rotating speeds beyond the maximum recommended for chain operation are indicated in the horsepower rating tables with zero horsepower. Operation at these or higher speeds will result in excess galling of the chain pins and bushings regardless of the volume of oil applied. Chain drives should be protected from abrasive and corrosive conditions, and the oil supply kept free of contamination. Periodic oil change is desirable.

Oil applied to rollers only cannot reach pin-bushing joints, and therefore, cannot retard chain elongation due to wear. The lengthening of chains in service results from wear on pin and bushing surfaces, not rollers. When lubricating multiple strand chain, it is important that lubricant be directed to each row of chain link plates.

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In conveyor applications oil should be directed between the rollers and bushings as well as between the chain link plates.

The following table indicates the lubricant viscosity recommended for various surrounding temperatures: Recommended Grade SAE 5 SAE 10 SAE 20 SAE 30 SAE 40 SAE 50

Temperature, oF -50 to + 50 -20 to + 80 +10 to +110 +20 to +130 +30 to +140 +40 to +150

Note: Oil should be applied to the lower span of chain on the upper edges of link plates since access of oil to pinbushing joints is possible only through the clearances between the roller chain link plates. There are three basic types of lubrication for roller chain drives. Close adherence to the recommended type of lubrication is essential to obtaining maximum service life of a chain drive. The recommended type of lubrication as shown in the horsepower rating tables is determined by the chain speed and the amount of power transmitted.

Manual or drip lubrication. (Type A) Oil should be applied periodically between the chain link plate edges with a brush, spout can, or drip lubrication.

Oil bath or oil slinger. (Type B) With bath lubrication the lower strand of chain runs through a sump of oil in the drive housing. The oil level should reach the pitch line of the chain at its lowest point while operating. Only a short length of chain should run through the oil. A typical drive arrangement for bath lubrication is shown in the illustration below.

Chain Cross-Section Showing Exaggerated Clearances Drive arrangements which permit long length of chain to travel through the oil should be avoided as overheating or foaming may result.


Lubrication - Part 2 With slinger disc lubrication, the chain operates above the oil level. The disc picks up oil from the sump and deposits it into the chain, usually by means of a trough. The diameter of the disc should produce rim speeds between 600 fpm minimum and 8000 fpm maximum. A collector plate is usually required to direct the oil to the chain link plates.

Oil Stream Lubrication. (Type C) This type of lubrication is required for large horsepower, high speed drives. An oil pump should be provided to spray the oil across the lower span of chain in a continuous stream. Orifices should be placed so that oil is sprayed across each strand of the chain. This type of lubrication may be used up to the maximum speeds shown in the horsepower rating tables for each size of chain, except where the rating is zero.

Perunding AME / 5th June 1999 / NW.

3

ROLLER CHAIN DRIVE TROUBLESHOOTING

1

Roller Chain Drives Troubleshooting Guide CONDITION / SYMPTOM

POSSIBLE CAUSE

WHAT TO DO

Dirt or foreign material in chain joints.

Clean and relubricate chain.

Tight Joints.

Inadequate lubrication. Misalignment.

Internal corrosion or rust. Overload bends pins or spreads roller. Rusted Chain

Exposed to moisture. Water in lubricant. Inadequate lubrication.

Turned Pins Enlarged Holes

Broken Pins

Replace chain. Re-establish proper lubrication. Replace sprockets and chain if needed. Realign sprockets.

Replace chain. Eliminate cause of corrosion or protect chain. Replace chain. Eliminate cause of overload. Replace chain. Protect from moisture. Change lubricant. Protect lubrication system from water. Replace chain. Provide or re-establish proper lubrication. Replace chain, if needed.

Inadequate lubrication.

Replace chain. Re-establish proper lubrication.

Overload.

Replace chain. Eliminate cause of overload.

Extreme overload.

Replace chain. Replace sprockets if indicated. Eliminate cause of overload or redesign drive for larger pitch chain. 1


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Broken Link Plates

Missing Parts

Missing at assembly. Broken and lost.

Broken, Cracked or Defromed Roller

Pin Galling

Chains Climbs Sprocket Teeth

Missing or Broken Cotters

Replace chain. Find and correct cause of damage. Replace chain.

Speed too high.

Replace chain. Reduce speed.

Sprockets too small.

Replace chain. Use larger sprockets, or possibly redesign drive for smaller pitch chain.

Chain riding too high on sprocket teeth.

Replace chain. Retension chain more often.

Inadequate lubrication.

Reduce speed or load. Possibly redesign drive for smaller pitch chain. Provide or re-establish proper lubrication.

Excess chain slack. Excessive chain wear.

Retension chain. Replace and retension chain.

Excessive sprocket wear.

Replace sprockets and chain.

Excessive overload.

Replace chain. Eliminate cause or overload.

Cotters installed improperly. Vibration. Excessively high speed.

Install new cotters per manufacturer's instructions. Replace chain. Reduce vibration. Use larger sprockets. Replace chain. Reduce speed. Redesign drive for smaller pitch chain.

Exposed Chain Surfaces Corroded or Pitted

Exposure to corrosive environment.

Replace chain. Protect from hostile environment.

Cracked Link Plates (Stress Corrosion)

Exposure to corrosive environment combined with stress from press fits.

Replace chain. Protect from hostile environment.

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Cracked Link Plates (Fatigue)

Battered Link Plate Edges

Worn Link Plate Contours

Excessive Noise

3 Loading greater than chain's dynamic capacity.

Replace chain. Reduce dynamic loading or redesign drive for larger chain.

Chain striking an obstruction.

Replace chain. Eliminate interference.

Chain rubbing on casing, guide, or obstruction.

Replace chain if 5% or more of height worn away. Retension chain. Eliminate interference.

Chain striking an obstruction. Loose casing or shaft mounts. Excess chain slack. Excessive chain wear. Excessive sprocket wear. Sprocket misalignment. Inadequate lubrication. Chain pitch too large. Too few sprocket teeth.

Wear on Inside of Roller Link Plates and one side of Sprockets.

Sprocket misalignment.

Chain Clings to Sprocket

Excessive sprocket wear. Sprocket misalignment.

Replace chain. Eliminate interference. Tighten fasteners. Retension chain.. Replace and retension chain. Replace sprockets and chain. Replace chain and sprockets, if needed. Realign sprockets. Replace chain if needed. Re-establish proper lubrication. Redesign drive for smaller pitch chain. Check to see if larger sprockets can be used. If not, redesign drive. Replace sprockets and chain Realign drive. Retension chain.. Replace sprockets and chain. Replace sprockets and chain if needed. Realign sprockets.

3 rd June 1999/ NW.

3

V-BELTS INSTALLATION AND MAINTENANCE

1

V-BELTS INSTALLATION AND MAINTENANCE Proper Installation and Maintenance Can Prolong the Life of V-Belts

V-belts run longer and perform better if they are given the proper care and attention during installation, and in particular, during the following 48-hour running-in period. This is a most critical time for V-belts, especially if they are to last for a few years. During this run-in period, the initial stretch is taken out of the belt. Also, the soft rubber surface of the belt's outer envelope is abraded away, and the belt settles deeper in the groove of the sheave. This causes the belt to run slack. At this point, the slack on the new belts must be taken up to avoid considerable slippage, frictional burning, and other irreparable damage. It is very important that the belts are checked often over the first few days of operation and are adjusted according to the correct tension until all signs of stretching have been eliminated. This practice will eliminate early damage and promote longer belt lives. This article is intended to provide maintenance personnel with a standardized procedure for correctly installing a V-belt and the sheaves in which they operate. This, in turn, improves the mechanical efficiency of the motor and the driven mechanical equipment by reducing wear on rotating mechanical components. This procedure provides general guidelines for the operation and maintenance of V-belt drives. It is intended to support any technical literature that may have been supplied by the belt manufacturer or their agents.

Step 1 Follow your company´s safety work practices during the installation of the V-belts, including personal protective equipment policies and lockout and tag-out policies.

Step 2 Remove the safety guard from the V-belt drive area.

Step 3 Adjust the moveable plate toward the fixed component by using the adjusting screws to reduce the center-tocenter distance of the driver-to driven sheaves. This reduces the tension on the belt and allows slack in the belt between the sheaves.

Step 4 Remove the old belts from the sheaves. Examine the operational surfaces to determine if any damage had forced the belts into an early demise. Look specifically for fabric wear on the sidewalls, reinforcing nylon cords, cracking caused by dry out, and oily surfaces. Note: If any of the above symptoms are apparent, do not install any new V-belts until the root cause of the problem has been identified and corrected. Step 5


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Clean the sheaves of all foreign matter with a stiff brush that has bristles softer than the sheave surface material. Heavy-duty wire brushes can scratch the surface of the groove walls. These scratches can, in turn, tear up the V-belt's outer skin and systematically destroy the belt.

Step 6 Using the "go-no-go" slip gauges that can be obtained from a belt manufacturer, determine the condition of the V-groove in the sheave. This will accurately determine if the walls of the V-groove have been subjected to excessive forces caused by improper tension causing slippage and poor alignment between the driver and the driven shafting.

Step 7 If the sheaves do not meet these criteria or are damaged in other ways (chipped or cracked sidewalls), discard these defective parts and install new ones.

Step 8 Verify that the replacement belts are the correct size. Check with the "go-no-go" gauge to ensure the crosssection of the V-belt is compatible with the V section in the groove. The belt must ride in the groove with its top flat surface level with the outer periphery of the sheave. Note: Never mix new and old belts regardless of the "new" look of the old one. Belts should always be installed in matched sets. This ensures that all of the replacement belts are exactly alike in all respects. Never mix belts from different manufacturers because they have different stretch characteristics, coefficients of friction, and cross-sectional areas. If the V-belts are not the same length, they will not carry the same amount of load. This will cause some of the belts to become overloaded and wear rapidly, shortening the life of the belt drive. Step 9 Before installing the new belts, the following checks must be made:

•

Check the TIR (Total Indicated Run-out) of both the driver and driven shafts. These should be within +/0.003". If the run-out reading exceeds this value, the shaft(s) must be straightened. This check must also be carried out on the outer rim of each sheave, as it is quite common to find the shaft hole in the hub drilled off-center causing damaging eccentricity. This eccentricity causes the belts to slacken off at the 3 o'clock position and to snap into tension at the 9 o'clock position during shaft rotation. This continual snapping action creates rapid belt and bearing deterioration.

• •

Check all of the hold-down bolts around the bedplate to determine if any soft-foot condition(s) exist. This reading should not be greater than 0.002". Check sheave alignment by placing a straightedge or a tightly drawn cord across the sheave faces so that it touches all four points of contact.

Note: This method of alignment is only effective when the sheaves are a matched pair.


3

If the sheaves are mismatched, there may be differences in the sidewalls' thickness, which will aggravate the misalignment. When this is the case, align the Vs with each other, as this is the perfect way to line up the belts. Misalignment causes uneven wear on one side of the belt, which causes it to roll over in the sheave, or it can throw the entire load on one side of the belt, stretching or breaking the cords. Therefore: • •

Parallel the position of the sheave shafts. Correctly align the grooves in the sheave.

Step 10 Install the new belts on the sheaves so that the slack sides of all belts are on the same side, either top or bottom, of the drive. Caution: Under no circumstances install the belts by prying them onto the sheaves with a screwdriver or any other forcible method. This will damage the internal cords of the belts and possibly break off the rim of the sheave's sidewalls, which would cause unbalance of the rotating components. The motor must always be detensioned enough to allow the belts to be removed or installed without forcing them.

Step 11 Adjust the tensioning screws to pull the motor away from the driven unit until the belts are correctly in tension. The following formula is used for determining the correct tension of the belts: Tension load = The distance in inches between the axes of the driver and driven shafts x 1/64" For example, if the distance between the centers of the driver shaft and the driven shaft is 64 inches, the belt deflection load will be: Deflection Load = 64 inches x 1/64 inch = 1 inch of deflection

Step 12 When the belts are correctly in tension, paint a thin, narrow line across the belts' top surfaces at 90 degrees to the length. (After the unit is started, a strobe light flashing on the belts at the operating frequency of the belts will show the painted line appearing as if it was stopped. Should there be any slippage, the belts that are slipping will be moving away from the line at various speeds according to their degree of looseness. This can be expected during the initial run-in period, but the belts must again be retensioned to allow the correct deflection. This may have to be repeated until all of the slack is taken out of the belts.)

Step 13 Replace the safety guard before removing all lockout and tag-outs. Note: The safety guard should be constructed from extruded open mesh steel as this permits free passage of air to circulate across the belt area in order to keep the belts cool and allow heat to escape.


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Step 14 Start the unit and allow the belts to seat themselves in the grooves of the sheaves.

Step 15 Stop the unit after a few hours to check the tension of all of the belts. (Refer to Step 12). Note: Before checking the belt tension, ensure all of the lockout procedure is in place.

Step 16 Restart the unit. Note: This is probably the most ignored task in belt installation, but it is a very important step in the operation and maintenance of V-belts. As such, it is worth repeating the following: After the machine has run for 48 hours, the tension on the new belts should be checked and retightened to the correct midspan deflection setpoint. This process must be repeated until all of the stretch has been eliminated. Belts that squeal during acceleration or when operating at full load usually have slippage. Never add a lubricant to the belts. Squealing merely indicates that the belts need to be tightened. This will extend the lifespan of the belts and bearings immensely. Avoid leaving old V-belts and other maintenance debris lying around after maintenance activities are completed. Collect waste products in an approved container and dispose of this waste according to established procedures.

June 99 / NW.

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