SYNOPSIS by Wambeck

OIL PALM PROCESS SYNOPSIS
By Noel Wambeck. - June, 1999
Volume I OIL PALM MILL, SYSTEMS AND PROCESS

By Noel Wambeck - June 1999
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
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.
* Oil Palm Tree Matrix - Oil Palm Components, Biomass and analysis
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
Continue next page >
CONTENTS
13.0 OIL PALM MILL DESIGN BASIS
* Specific Gravities and Densities of Oil Palm Components & Substance.
14.0 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.
15.0 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.
16.0 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

Volume 2. TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL
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
APPENDICES
Master list of machinery
Checklist of oil palm mill.
Electric motor list
5.0
SPECIFICATION FOR MACHINERY
6.0
MECHANICAL & ELECTRICAL DRAWINGS

Vol.1 - OIL PALM MILL, SYSTEMS & PROCESS
Vol.3 - OIL PALM MILL MAINTENANCE MANUAL
Noel Wambeck June 1999.

Volume 3. - OIL PALM MILL MAINTENANCE MANUAL
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
GEARBOX & GEARMOTOR USE AND MAINTENANCE
15
MAINTENANCE GLOSSARY & TERMINOLOGY
16
GLOSSARY OF BEARINGS
17
COMPRESSED AIR TERMINOLOGY AND SYSTEMS
18
PIPE FITTING AND VALVE GLOSSARY & TERMINOLOGY
19
PUMP MAINTENANCE
Pump maintenance programs pay.
Pump maintenance.
Why Seals Fail.
Pump performance checklist.
Pump seal maintenance.
Troubleshooting Electro-Hydraulic Pumps.
20
ROLLER CHAIN DRIVES

Roller chain drives installation.
Roller chain maintenance.
Roller chain drives maintenance.
Roller chain drives lubrication.
Roller chain drives - Troubleshooting Guide.
21
V-BELT INSTALLATION AND MAINTENANCE.
22
USEFUL TABLES.
Page 2.
Vol.1 - OIL PALM MILL, SYSTEMS & PROCESS.
Vol.2 - TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL.
Noel Wambeck June 1999.
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 writers experience.

Noel Wambeck @ Nurehsan born in Penang during the Japanese occupation to James
Godfry Wambeck and Dorothy Symons of Dutch descendents.
Educated at St. Xaviers 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 Pharaohs 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.
Hallets 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 90s.
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 Barlows 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 1900s 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 1900s and not until 1960s 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 1950s 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
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.
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.
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.
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.
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.
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.
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.
&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.
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.
&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 harvesters 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.
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.
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
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
The fruit mash then passes to the screw presses (capacities of 1016Mt 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.
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 60C 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 260C 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
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
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
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
Milling capacity
MT FFB / hr
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
Organic loading Rate ( 0.3 kg BOD/m3/Day )
kg
7.2
216
324
432
648
864
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
45
5.625
67.5
8.4375
90
11.25
135
16.875
180
22.5
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
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.
Selection of the Oil Palm Mill complex location.
Provide detail design and specification, supervision, commissioning, training of

personnel and guarantee performance for the proposed project.
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.
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
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 :
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
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.
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.
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
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.
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.
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.
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 TREE MATRIX
OIL PALM COMPONENTS, BIOMASS AND ANALYSIS
by Noel Wambeck
6/12/00 11:46
UNIT MEASURE
WEIGHT
PERCENTAGE
BASIC DATA
Type of Palm tree
Planting density
Growth of fronds per year
Tree growth rate per year
Inflorescence
Production of FFB per year
Weight of Fresh fruit bunch (FFB)
Fruitlets in each bunch
Weight of each fruitlet
FFB yield per year
Crude oil yield per year
Palm Kernel yield per year
Tenera ( D x P )
Number of trees per hectare
New leaves per year
Vertical trunk height
full production at every
number of fruit bunch
average weight
Individual fruitlet
Individual fruitlet
average weight per hectare in a year
Trees per hectare

Nr. Of Fronds
mm / year
days per cycle
Nr / year
kg
Nr
grammes
mt / year
mt / year
mt / year
13
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10
13.11
13.12
13.13
13.14
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 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
14
14.1
ENERGY
Energy value for Oil palm products
Annual energy values - INPUT

Annual energy values - OUTPUT
Energy values
GJ / ha / year
GJ / ha / year
Ratio
19.2
182.1
9.5
14.2
Energy consumption in oil palm plantation
INPUT
Fertilizers
Pesticides, herbicides, rat baits
Machinery
other
average yield of methane is litres per kg dry matter
GJ / ha / year
GJ / ha / year
GJ / ha / year
GJ / ha / year
l / kg
11.2
0.8
5.14
2.06
230
methane percentage 60%

carbon dioxide percntage 35%
other gas percentage 5%
l / kg
l / kg
l / kg
230
135
19
1
2
3
4
5
6
7
8
9
10
11
12
143
21 - 25
1000
15
300
20
1500
8 to 10
25
6
1.1
14.3
Methane yield of kg mill effluent dry matter
14.4
Gas liberated by anaerobic digester contain
15
15.1
15.2
15.3
15.4
15.5
15.6
15.7
15.8
15.9
15.10
15.11
15.12
15.13
15.14
15.15
15.16
15.17
15.18
15.19
15.20
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
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
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
16
16.1
16.2
16.3
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

displacement of fossal fuel / tons carbon dioxide per kw
tonnes of oxygen per hectare
tonnes
tonnes
tonnes
17
17.1
Soil enrichment contribution

Carbon contribution of root biomass at replanting
contributes carbon per hectare at replanting
mt / ha
17.2
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
17.3
POME application
3 rounds a year or equivalent to twice rate of Nitrogen
kg N/ ha/ year
17.4
Properties of raw effluent (POME)
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
17.5
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 %
650
4.1
25,000
53,630
43,635
19,020
36,515
35
770
8,370
B
20 ppm
Cu 20-50 ppm
Fe 3000-5000 ppm
Mn 50-70 ppm
Zn 20-100 ppm
9%
19%
21%
48%
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.
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.
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.
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.
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.
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 95C
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.
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.
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
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.
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.

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.
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.

Manual operation.
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 - 40C
Humidity
99%
Power
230 / 415 volts 50 Hz
Power Interruption
Operate through a total loss of power for 17.6 msec.
ITEM
DESCRIPTION
TYPE
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
Printer - Colour graphic type
600x1200 pdi
1 unit
Modem ( Data / Fax/ Voice )
56 K bps
1 unit
Uninterrupted Power Supply (UPS)
2000 VA
1 unit
Custom built PMC system software
Microsoft Windows
NT Pro
1 lot
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.
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.
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 1970s to
diversify Malaysias 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 1980s.
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 1990s 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 1990s 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 oils 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
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.
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 organisations 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
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.
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
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
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 (Bolaos, 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.
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
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. Bolaos
(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.
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
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
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.
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 Sarra, 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).
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
Sarra (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).
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
10
20
30
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.
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 Sarra (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 Sarra (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).
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 Sarra 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
(Beltrn, 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
Nitrogen free extract
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
Nitrogen free extract
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.
Bolaos, 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.
Beltrn, 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.
16
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 Coordinacin Nacional Tcnica 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. Situacin actual de la palma aceitera en Mxico. 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 ecolgicos 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 Trpico" y IV Seminario
Nacional "Alternativas de Produccin 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. Utilizacin de la cachaza de palma africana como
fuente de energa en el levante, desarrollo y ceba de cerdos. Livest. Res. Rur. Dev. 2(1): 43-50.
17
Ocampo, A., Castro, C. and Alfonso, L. 1990b Determination del nivel ptimo de protena al utilizar
cachaza de palma africana como fuente de energa 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.
Sarra, P., Solano, A. and Preston, T.R. 1990. Utilizacin de jugo de caa y cachaza panelera en la
alimentacin 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
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Jos, 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.
STAGE 1. PROPOSED SITE SELECTION AND FEASIBILITY STUDY REPORT
The essential elements in Stage 1 are as follows :1.1
Discussions with the Clients 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.
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 Clients 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.
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 Clients 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.
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
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 tenderers 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.
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
Review and Approve Contractors 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 Contractors 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
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 Contractors submittals will be prepared in writing
for approval of the Client prior to presentation to the Contractor.
Copies of Contractors 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
Contractors 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 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, vendors 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 :
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
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
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
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
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
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
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
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
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

PROPOSED CONSTRUCTION OF .
FOR ( Client )
(For the month of November 1998)
Prepared by :
The Contract
The Employer:
The Employers
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.
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 Managers 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 :
SPECIFIC GRAVITIES AND DENSITIES OF OIL PALM CONPONENTS & SUBSTANCE

ITEM / CONPONENT / MATERIAL OR SUBSTANCE
Bulk Density
Specific Gravity
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
0.55
0.62
0.535
0.8927
0.890
0.257
0.480
0.640
0.892
0.653
0.9015
0.8865
0.550
0.994
0.650
0.899
0.640
0.945
1
Average weight
mt / m3
0.437
0.6
0.53
0.89
0.89
0.26
0.48
0.64
0.89
0.65
0.90
0.89
0.55
0.99
0.65
0.90
0.64
0.94
1
REFINING PROCESS
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
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
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
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
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
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
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
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
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)
PORLA GUIDELINES.
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.
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.
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.
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.
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.
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.
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
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
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
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:
FFB GRADING MANUAL
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
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
FFB GRADING MANUAL
Only one copy of this form is to be filled for record and retention by the mill.
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.
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.
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.
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 clients 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.
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 Manufacturers 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.
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.
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.
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.
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.
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
manufacturers 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 manufacturers
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 manufacturers 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 manufacturers 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
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%)
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.
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.
FRUIT RECEPTION
1.1
Weighbridge
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
Nr
7.5
15
1.4
Cage Transfer Carriage No.1
Nr.
5.5
5.5
1.5
FFB Cages
42
Nr.
1.6
Rail Tracks
Lines
STERILISING STATION
2.1
Mobile Rail piece
Nr
2.2
Sterilisers - 2 DOOR TYPE
Nr.
2.3
Steriliser Auto Program Control
Nr
2.2
6.6
2.4
Steriliser Catwalk
Lot
2.5
Blow off Silencer
Nr.
2.6
Winches
Nr.
11
66
2.7
Idler Bollard
Nr.
2.8
Condensate Blow-down Chamber
Nr.
2.9
Steriliser condensate sump pump
Nr.
2.10
Steriliser Condensate Recovery Tank
Nr.
2.11
Clarification waste water sump pump
Nr.
2.12
Clarification waste water sludge tank
Nr.
2.13
Skimmed oil - collection tank
Nr.
2.14
Skimmed oil - pumps
Nr.
2.2
2.2
2.15
Acid oil collection Tank
Nr.
2.16
Acid oil drumming pump
Nr
2.2
2.2
2.17
Transfer carriage system at Loading Ramp
Nr.
7.5
7.5
Page 1 of 18
25
1460
1460
1460
1460
Perunding AME Sdn Bhd / 25 Jan. 99 / NW.
ITEM
DESCRIPTIONS
QTY
UNIT
POWER / KW
Unit
Total
SPEED
RPM
THRESHING STATION
3.1
Cage Tippler machine
Nr.
7.5
7.5
3.2
FFB conveyor cum auto feeder for tippler
Nr.
7.5
7.5
3.3
FFB cross conveyor to Thresher No.2
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
Nr.
18
18
25
46
3.5
Recycled Bunch Elevator
Nr.
5.5
5.5
56
3.6
Bunch crasher with feed chute
Nr
22
22
3.7
Thresher No.2 for recycle bunches with bottom

screw conveyor with platform, handrail & walkway
Drum drive
Bottom screw conveyor
Nr.
3.8
a
b
c
Empty bunch conveyor ( 3 sections ) with support

Horizontal section No.1
Inclined section
Horizontal section No.2
3.9
E.B. Hopper c/w Hydraulic system
a
b
a
b
2 to 10
18
18
25
3.75
3.75
46
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
Nr.
5.5
11
46
4.2
Fruit distribution conveyor c/w chutes and doors
Nr.
3.75
3.75
46
4.3
Fruit Return Conveyor complete with chute
Nr.
3.75
3.75
46
4.4
Press station structure complete with platform

handrails and walkways.
lot
4.5
Hot water tank for press station
Nr.
4.6
Digester - type 3500 kg cap.
Nr.
22
66
28
4.7
Twin Screw Presses - type P15 complete hydraulics
Nr.
30
90
16
4.8
Crude oil collection gutter in SS
Lot
4.9
Desanding tank ( sand trap )
Nr.
4.10
Sand removal conveyor for sand trap
Nr.
3.75
3.75
46
4.12
Sand removal elevator with screen buckets
Nr.
3.75
3.75
56
4.13
Hopper with support for sand waste
Nr.
4.14
Vibrating screen - 60" Circular - double deck type

complete with ms structure, platform & walkway
Nr.
3.75
7.5
4.15
Screen Waste Conveyor
Nr.
2.2
2.2
4.16
Crude Oil Tank with auto steam heating, insulation etc.
Nr.
4.17
Crude Oil Transfer Pumps with auto level switch
Nr.
3.75
7.5
4.18
Crude Oil diluation control system
Nr.
Page 2 of 18
56
1460
ITEM
DESCRIPTIONS
QTY
UNIT
POWER / KW
Unit
Total
SPEED
RPM
5.1
Vertical Clarifier with stirrer, insulation & cladding
Nr.
3.75
3.75
25
5.2
Heating tank with pumps
lot
2 x 2.2kw
4.4
1460
5.3
Sludge settling tank with SS liner
Nr
5.4
Crude oil tank with SS liner
Nr.
5.5
Pumps for sludge tank
Nr.
2.2
4.4
5.6
Steel structure for decanter & Vacuum dryer platform

complete with handrails, supports & walkways
lot
5.7
Desanding multi-cyclone unit & pumpset
Set
2.2
2.2
5.8
Sludge balance tank of SS
Nr.
5.9
3 Phase Decanter
Nr.
30
30
5.10
Solid waste Conveyor for Decanter sludge
Nr
2.2
2.2
5.11
Hopper for solid waste
Nr
5.12
Light Phase Tank with pumpset
Nr.
2.2
2.2
1460
5.13
Heavy Phase Tank with pumpsets
Nr.
2.2
2.2
1460
5.14
Balance tank with SS liner
Nr.
5.15
Steel Structure for Clarification Station

with 1 ton maintenance chain block
lot
5.16
Sludge Separator complete unit
Nr.
15
15
5.17
Oil Heater Tank with Pumpset c/w Level switch
Nr.
3.75
3.75
5.18
Oil Purifier
Nr.
7.5
15
5.19
Vacuum Oil Dryer with vacuum & transfer pumps
Nr.
2x 7.5
15
5.20
Hot Water Tank with auto steam heating
Nr.
5.21
Sludge Fat pit pumpsets
Nr
3.75
11.25
5.22
Sludge oil recovery tank
Nr
5.23
Pumpsets for sludge oil & Effluent waste
Nr
3.75
7.5
5.24
Acid oil tank
Nr
Nr.
11
11
Lot
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
POWER / KW
Unit
Total
SPEED
RPM
b)
Ducting To Cyclones And Fan
Lot
c)
Fibre Cyclone
Nr.
d)
Air lock c/w Drive and mounting

rollers for easy removal
Nr.
2.2
2.2
e)
Fan complete with Motor
Nr.
56
56
6.3
Depericarper Damper Control System
Nr.
6.4
Nut Polishing Drum
Nr.
5.5
5.5
30
6.5
Nut conveyor No.1
Nr
3.75
3.75
56
6.6
Nut Elevator No.1
Nr.
3.75
3.75
56
6.7
Destoning System Consists Of:-
a)
Separating & Expansion column with

Supporting Structures
Lot
b)
Ducting From Column To Cyclone and

Fan
Lot
c)
Cyclone
Nr.
d)
Air lock ( Inlet feed ) c/w drive
Nr.
2.2
2.2
30
e)
Airlock ( Nuts ) c/w drive
Nr.
2.2
2.2
30
f)
Cyclone
Nr.
g)
Air Lock ( Cyclone ) c/w Drive
Nr.
2.2
2.2
h)
Fan complete with motor
Nr.
25
25
6.8
Destoner Damper Control System
Nr.
6.9
Nut conveyor No.2
Nr
3.75
3.75
56
56
30
0
30
KERNEL RECOVERY STATION
7.1
Nut Conveyor No.3
Nr.
2.2
2.2
7.2
Nut Silos
Nr.
7.3
Nut feed conveyor to elevator
Nr.
3.75
3.75
7.4
Nut Elevator
Nr.
5.5
5.5
7.5
Nut grading drum
Nr.
2.2
2.2
56
7.6
Nut feed conveyor to ripple mills
Nr.
2.2
2.2
56
7.7
Nut cracking rippler mills
Nr.
5.5
22
30
7.8
Cracked mixture conveyor
Nr.
2.2
2.2
56
7.9
Cracked mixture elevator
Nr
3.75
3.75
46
Page 4 of 18
ITEM
7.10
DESCRIPTIONS
QTY
UNIT
POWER / KW
Unit
Total
SPEED
RPM
Cracked mixture dry separation system

consist of :
a)
Air lock c/w Drive
Nr.
2.2
4.4
b)
Winnowing Column c/w Adjustable

Damper
Lot
c)

Fan
Lot
d)
Cyclone 1st stage
Nr.
e)
Airlock ( cyclone ) c/w Drive
Nr.
2.2
2.2
f)
Fan c/w Motor
Nr.
11
11
g)
Winnowing Column Damper Control System
Nr.
h)
2nd stage Winnowing Column c/w Adjustable

Damper
Nr.
30
30
I)

Fan
Nr.
j)
Cyclone 2nd stage
Nr.
k)
Airlock ( cyclone ) c/w Drive
Nr.
2.2
2.2
l)
Fan c/w Motor
Nr.
11
11
m)
Winnowing Column Damper Control
7.11
Cracked Mixture Conveyor
Nr.
2.2
2.2
56
7.12
Kernel conveyor
Nr.
2.2
2.2
56
7.13
Hydrocyclone 3 stage type c/w pumps
Nr.
2 x 15
60
7.14
Wet Shell Pneumatic Transport System
30
a)
Airlock c/w Drive
Nr.
2.2
2.2
b)
Fan c/w Motor
Nr.
7.5
7.5
c)
Ducting From Fan to Cyclone
Nr.
d)
Cyclone
Nr.
7.15
Wet Kernel Elevator
Nr.
5.5
5.5
46
7.16
Wet Kernel Conveyor
Nr.
5.5
5.5
56
7.17
Kernel Silo c/w Fan and Feeder
Nr.
11
22
7.18
Dry Kernel Conveyor
Nr.
3.75
3.75
56
7.19
Kernel Winnowing System Consist Of:30
a)
Airlock c/w Drive
Nr.
2.2
4.4
b)
Column, air duct and cyclone
lot
c)
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
Nr
b)
Air duct & cyclone
lot
c)
7.21
Distribution conveyor on top of bulk silos
7.22
Kernel Bulk Silo c/w discharge Doors & Vent Fan
POWER / KW
Unit
Total
2.2
4.4
Nr
11
11
Nr
3.75
3.75
Nr
3 x 18
54
BOILER HOUSE
8.1
Shell Bunker with steel structure
Nr.
8.2
Boiler fuel distribution conveying system
lot
Fuel conveyor I
Fuel conveyor II ( double deck )
Nr
7.5
7.5
56
Nr
7.5
7.5
56
8.3
Ground Feed Tank
Nr.
8.4
Boiler feed water treatment plant, consist of :

2
Nr.
3.75
7.5
Nr.
a
b
Softener Booster Pump
Deaerator Feed Tank c/w Insulation

and supporting Structure
Deaerator Tank Pump c/w low level alarm
Nr.
15
30
Duplex Water Softener
Nr.
Chemical Dosing Pump c/w dosing tank
Nr.
0.33
0.66
Vacuum Deaerator
Nr.
Deaerator Extraction Pump
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
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
Nr.
7.5
7.5
56
8.7
Fuel Return Elevator
Nr.
5.5
5.5
46
8.8
Boiler Blowdown Chamber
Nr.
8.9
Ash Removal Conveyor
Nr.
3.75
3.75
8.5
a
b
c
d.
e
f
g
Page 6 of 18
46
ITEM
DESCRIPTIONS
QTY
UNIT
POWER / KW
Unit
Total
POWER PLANT
9.1
Turbo Alternator. 1200 kw
Nr.
9.2
BPR Pressure Controller
set
9.3
Back Pressure Receiver c/w Insulation,

Operating Platform
Nr.
9.4
Exhaust silencer
Nr
9.5
Diesel skid tank with pumpset
Nr.
3.75
3.75
9.6
Diesel day tank
Nr
9.7
Diesel genset 150 kw
Nr.
0.33
0.33
9.9
Diesel genset 350 kw
Nr.
0.33
0.66
9.10
Air compressor for pneumatic system
Nr
15
15
15
15
10
0.5
0.5
PALM OIL STORAGE & CPO LOADING SHED
10.1
CPO Storage Tanks - 2000mt cap.
Nr
10.2
CPO transfer pumps
Nr
10.3
CPO inspection bridge structure
Nr
11
N - RAW WATER TREATMENT PLANT
11.1
Raw Water Clarifier
Nr.
11.2
Clarified water concretesettling tank
Nr.
11.3
Clear Water Pump c/w Level Switch
Nr.
11
22
11.4
Chemical dosing pumps & mixing tanks
Nr
0.33
11.5
Pressure Sand Filters
Nr.
11.6
Water transfer pumps
Nr
15
30
11.7
Water Storage Tank with structure
Nr.
11.8
Chlorination System with dosing pumps
Nr.
12
0
0.33
0.33
FIRE PROTECTION EQUIPMENT & SYSTEM
12.1
Hose reel points
Nr
12.2
Fire Hydrant
Nr
12.3
Emergency Diesel Pump
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
POWER / KW
Unit
Total
SPEED
RPM
MISCELLANEOUS
13.1
Central Monitoring, Alarm & Control System
13.2
Coupling, belt & pulley guards
Lot
13.3
Maintenance Platform for Conveyor &

Elevator Drives
Lot
13.4
Effluent Recycling Pumps c/w Float switch
Nr.
15
30
1460
13.5
Surface Aerators
Nr.
7.5
30
1460
Lot
14
Lot
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
Lot
b)
Ring Main within Factory Building with

50mm as main and 25mm as down comer
installed @ 18m c/c c/w valves
Lot
c)
To Factory Office
Lot
d)
To Workshop
Lot
e)
To Canteen/Toilet/Locker Room
Lot
14.3
Steam Piping:-
a)
High Pressure From Boiler to Engine Room
Lot
b)
High Pressure From Boiler to Vacuum

Ejectors, Turbine Feed Water Pump
Lot
c)
Low Pressure From Turbine to Back

Pressure Receiver
Lot
d)
Low Pressure to and Within Sterilisation

Station
Lot
e)
Low Pressure to and Within Steam Plant
Lot
f)
Low Pressure to and Within Main Process

Building
Lot
g)
Low Pressure to and Within Clarification

Station
Lot
h)
Low Pressure to and Within CPO Storage

Tanks
Lot
Page 8 of 18
ITEM
DESCRIPTIONS
QTY
UNIT
Lot
14.4
Steam Condensate Piping
14.5
Sludge Oil Piping:-
a)
Within Press Station
Lot
b)
Within Clarification Station
Lot
14.6
SPEED
RPM
Crude Oil Piping:-
a)
Press station within & to Clarification station
Lot
b)
Within Clarification Station
Lot
c)
Clarification To CPO Tanks
Lot
d)
CPO Tanks To Unloading Shed
Lot
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
14.10
Effluent piping from sump to recycle

pumps to Acidification Ponds
1
Approx. 200
Lot
M
Total power installed for operating machinery
Allowing a load diversity factor of 65 %

to operate the mill at 45 mt FFB per hour.
Complex street lighting and domestic use
POWER / KW
Unit
Total
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 :
Appendix B
Sheet 2 of 2
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 :
Appendix B
Sheet 3 of 3
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.
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 :
Appendix B
Sheet 4 of 4
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 :
Appendix B
Sheet 5 of 5
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 :
Appendix B
Sheet 6 of 6
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 :
Appendix B
Sheet 7 of 7
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 :
Appendix B
Sheet 8 of 8

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 :
Appendix B
Sheet 9 of 9

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
Appendix B
Sheet 10 of 10
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
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
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
RAIL TRACKS & SLEEPERS
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
RECEPTION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
FFB LOADING RAMP &

HOPPERS
DELIVERY
DRAWING NO.
PREPARED BY
NW
REVISION No.
LOCATION
RECEPTION
ITEM No.
QUANTITY / UNITS
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
HORIZONTAL CONVEYOR
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
DRAWING NO.
RECEPTION
ITEM No.
QUANTITY / UNITS
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
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
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
HORIZONTAL CONVEYOR
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
DRAWING NO.
RECEPTION
ITEM No.
QUANTITY / UNITS
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
PREPARED BY
NW
MACHINE NAME
PROJECT CODE
OIL PALM MILL
CAGE FEED CONVEYOR
DELIVERY
REVISION No.
LOCATION
RECEPTION
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:
Capacity:
90mt FFB per hour
General Arrangment:
As per drawing
Chain:
Drag Plate:
Frame:
Sprocket:
Wear Plate:

breaking load
Basic Dimension:
Width:
Length:
Inclination:
Conveying Section:
Shaft Speed:
Drive:
Speed Reducer:
Input speed:
Output speed:
Output torque:
1200
mm
30
m
Horizontal
Top
25
rpm
1.00
chain & sprocket
1450
25
2865
<
rpm
rpm
Nm (min)
1.5
Page 1 of 2
CAGE FEED CONVEYOR
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
PREPARED BY
NW
MACHINE NAME
PROJECT CODE
OIL PALM MILL
CAGE FEED CONVEYOR
DELIVERY
REVISION No.
LOCATION
RECEPTION
DRAWING NO.
ITEM No.
A5
QUANTITY / UNITS
1 unit
Sheet 2.
Motor:Power:
Type:
7.5
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
chain, sprocket
Bearing:
Crompton Parkinson, ABB Brook, Brush, ELEKTRIM

Renold, Tsubaki, PC
SKF, FAG, NTN
Page 2 of 2
CAGE TRANSFER CARRIAGE No. 1
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
PREPARED BY
NW
MACHINE NAME
PROJECT CODE
OIL PALM MILL
TRANSFER CARRIAGE
MACHINE No.1
DELIVERY
DRAWING NO.
GENERAL
REVISION No.
LOCATION
RECEPTION
ITEM No.
A6
QUANTITY / UNITS
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
WINCH & BOLLARDS
DELIVERY
NW
REVISION No.
LOCATION
RECEPTION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
A7
4
Scope of works include the manfacture, erection & installation

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:
Vertical drum motor driven steel rope winch

60 mt load ( 7 x 7 tonnes fully loaded FFB cages)
As per drawing
As per drawing
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:
1450 rpm
25
rpm
5730 Nm (min)
>
1.5
Motor:Power:
Type:
15
KW
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
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:
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

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 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
PREPARED
BY:
Mobile Rail Piece
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
MOBILE RAIL PIECE
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
DRAWING NO.
STERILISER STATION
ITEM No.
QUANTITY / UNITS
B 1.
2
GENERAL
Scope of works include the manufacture,delivery, erection & installation

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:
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
12-Aug-98
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
STERILISERS
DELIVERY
NW
REVISION No.
LOCATION
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
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
STERILISER
SPECIFICATION SHEET
PROJECT NAME
DATE:
12-Aug-98
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
STERILISERS
DELIVERY
NW
REVISION No.
LOCATION
STERILISER STATION
DRAWING NO.
ITEM No.
B2
QUANTITY / UNITS
Sheet 2.
Steriliser Doors
Type:
Safety device:
Qty:
Working Pressure:
Quick opening/closing, rotating ring

To be provided against accidental opening when under
pressure
2
for each steriliser
3.5
O.D:
o
150
C
2,700 mm
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
STERILISER AUTO PROGRAM

CONTROL SYSTEM
DELIVERY
PREPARED BY
REVISION No.
LOCATION
STERILISER STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
STERILISER AUTO PROGRAM

CONTROL SYSTEM
DELIVERY
DRAWING NO.
PREPARED BY
NW
REVISION No.
LOCATION
STERILISER STATION
ITEM No.
QUANTITY / UNITS
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
12-Aug-98
MACHINE NAME
PROJECT CODE
BLOW OFF CHAMBER

and SILENCER
OIL PALM MILL
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
STERILISER STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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
As per drawing
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
BLOW DOWN CHAMBER
DELIVERY
NW
REVISION No.
LOCATION
STERILISER STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

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
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
MACHINE NAME
PROJECT CODE
OIL PALM MILL
CONDENSATE TANK
DELIVERY
PREPARED BY
REVISION No.
LOCATION
STERILISER STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To recover oil from steriliser condensate
SPECIFICATIONS
Quantity
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:
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
OIL PALM MILL
PROJECT CODE
PREPARED BY
CONDENSATE PIT PUMP
DELIVERY
NW
REVISION No.
LOCATION
STERILISER STATION
DRAWING NO.
ITEM No.
B7
QUANTITY / UNITS
GENERAL
Scope

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
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
ACID OIL TANK
SPECIFICATION SHEET
DATE: ######
PROJECT NAME
MACHINE NAME
PROJECT CODE
OIL PALM MILL
ACID OIL TANK
DELIVERY
PREPARED BY
REVISION No.
LOCATION
STERILISER STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To receive skimmed oil from Steriliser condensate recovery tank
SPECIFICATIONS
Quantity
Capacity:
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
mm
Raised face to DIN 2526
Page 1 of 1
B8
1
ACID OIL PUMP
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
ACID OIL DRUMMING PUMP

SET
PREPARED BY
DELIVERY
DRAWING NO.
REVISION No.
LOCATION
STERILISER STATION
ITEM No.
QUANTITY / UNITS
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 )
Magnetic type with stainless steel float, stainless steel rod
and counter weight
SIHI, KSB, Warman, Southern Cross
Crompton Parkinson, Brush, ABB Brooks, Elektrim
Fenner (Fenaflex)
SKF, FAG
Mobrey, BESTA
OTHER REQUIREMENTS
Page 1 of 1
B9
2
TRANSFER CARRIAGE
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
CAGE TRANSFER CARRIAGE No.2
DELIVERY
DRAWING NO.
REVISION No.
LOCATION
FRUIT HANDLING
ITEM No.
QUANTITY / UNITS
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
SPECIFICATION
Quantity
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
CAGE TRANSFER CARRIAGE No.2
DELIVERY
DRAWING NO.
REVISION No.
LOCATION
FRUIT HANDLING
ITEM No.
QUANTITY / UNITS
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 )

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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OILPALM MILL
WINCH & BOLLARDS
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
FRUIT HANDLING
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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:
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
Gear box:
Input speed:
Output speed:
Output torque:
1450 rpm
25 rpm
5730 Nm (min)
>
1.5
Motor:Power:
Type:
15
KW
( Vendor to advise )
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
OIL PALM MILL
PROJECT CODE
FFB CAGE TIPPLER
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
FRUIT HANDLING
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To rotate FFB cage and discharge into hopper than to

FRUIT FEEDING CONVEYOR
SPECIFICATIONS
Quantity
Type:
Capacity:
General Arrangement:
One (1) unit Tippler complete with drive as follows :

Rotating
To handle 7MT FFB Cage
As per drawing
As per drawing
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.
Gear box:
Input speed:
Output speed:
Output torque:
# rpm
20 rpm
# Nm (min)
<
1.5
Motor:Power:
Type:
Hydraulic System:
8
KW
Vendor to advise
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
FFB CAGE TIPPLER
DELIVERY
DRAWING NO.
PREPARED BY
NW
REVISION No.
LOCATION
FRUIT HANDLING
ITEM No.
QUANTITY / UNITS
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
OIL PALM MILL
PROJECT CODE
FRUIT FEED CONVEYOR
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
FRUIT HANDLING
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey sterilised fruit bunches from TIPPLER to Thresher
SPECIFICATIONS
Quantity
One (1) unit Fruit Feed Conveyor with drive as follows :
Type:
Capacity:
S - type conveyor with scrapper plate on twin flanged roller chain

45 MT FFB PER HOUR.
As per drawings
Chain:
Drag Plate:
Frame:
Sprocket:
Wear Plate:
Steel c/w hardened steel flanged rollers, 150 mm pitch, 15,000 kg

breaking load
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)
<
1.5
Motor:Power:
Type:
7.5
KW
Page 1 of 2
C4
1
FRUIT FEED CONVEYOR
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
FRUIT FEED CONVEYOR
DELIVERY
NW
REVISION No.
LOCATION
FRUIT HANDLING
DRAWING NO.
ITEM No.
QUANTITY / UNITS
C4
1
Sheet 2.
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Crompton Parkinson, ABB Brook, Brush, Elektrim


chain, sprocket
Bearing:
Renold, Tsubaki
SKF, FAG, NTN
OTHER REQUIREMENTS
4. Vendor to provide full specification, drawings and catalogues of components.
Page 2 of 2
TOIP FEED CONVEYOR
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
OIL PALM MILL
PROJECT CODE
PREPARED BY
TOP FEED CONVEYOR
DELIVERY
NW
REVISION No.
LOCATION
THRESHING STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
D1
1

Function:
To convey empty bunches from Tippler fruit feed conveyor to any of the
Thresher
SPECIFICATIONS
Quantity
Type:
Capacity:
General Arrangment:
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
Basic Dimension:
Width:
Length:
Inclination:
Conveying Section:
Shaft Speed:
Drive:
760
mm
mm
Horizontal
Top
25
rpm
1.00
chain & sprocket
Speed Reducer:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
7.5
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:

chain, sprocket
Bearing:
Renold, Tsubaki, PC
1450
25
2865
<
rpm
rpm
Nm (min)
1.5
SKF, FAG, NTN
Page 1 of 2
THRESHER STRUCTURE
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
OIL PALM MILL
PROJECT CODE
THRESHER MACHINE
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
THRESHING STATION
DRAWING NO.
ITEM No.
QUANTITY
GENERAL
Scope

Function:
To thresh sterilised fruit bunches
SPECIFICATIONS
Quantity
Type:
Capacity:
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
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:
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
Page 1 of 2
D2
1
THRESHER STRUCTURE
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
THRESHER MACHINE
DELIVERY
DRAWING NO.
PREPARED BY
NW
REVISION No.
LOCATION
THRESHING STATION
ITEM No.
QUANTITY
D2
1
Sheet 2.
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
chain, sprocket
Bearing:

Sew, HANSEN, SEW, Renold, EPG ElectroPower
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
OIL PALM MILL
PROJECT CODE
PREPARED BY
BOTTOM SCREW CONVEYOR
DELIVERY
NW
REVISION No.
LOCATION
THRESHING STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey fruitlets from THRESHER to Fruit Elevator
SPECIFICATIONS
One (1) Bottom Screw Conveyor as follows :
Type:
Size:
Full flight screw

600 mm dia.
As per drawing
As per drawing
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
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
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
chain, sprocket
Bearing:
Crompton Parkinson, ABB Brook, Brush

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
SPECIFICATION SHEET
PROJECT NAME
DATE: 13-May-00
MACHINE NAME
HORIZONTAL EMPTY BUNCH
CONVEYOR
OIL PALM MILL
PROJECT CODE
PREPARED BY
DELIVERY
NW
REVISION No.
LOCATION
THRESHING STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey empty bunches from THRESHER to

EMPTY INCLINED BUNCH CONVEYOR
SPECIFICATIONS
Quantity
One (1) unit Horizontal Empty Bunch Conveyor

Type:
Capacity:
General Arrangment:

As per drawing
Chain:
Drag Plate:
Frame:
Sprocket:
Wear Plate:
Steel c/w hardened steel rollers, 100 mm pitch, 8,000 kg

breaking load
Basic Dimension:
Width:
Length:
Inclination:
Conveying Section:
Shaft Speed:
Drive:
760
mm
mm
Horizontal
Top
25
rpm
1.00
Geared motor coupled conveyor shaft by transmission
chain & sprocket
Speed Reducer:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
7.5
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Renold, Tsubaki, PC
chain, sprocket
Bearing:
SKF, FAG, NTN
1450
25
2865
<
rpm
rpm
Nm (min)
1.5
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
DELIVERY
DRAWING NO.
PREPARED BY
NW
REVISION No.
LOCATION
THRESHING STATION
ITEM No.
QUANTITY / UNITS
Page 2 of 2
D4
1
UNSTRIPPED BUNCH ELEVATOR
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
UNSTRIPPED BUNCH
ELEVATOR
OIL PALM MILL
PROJECT CODE
PREPARED BY
DELIVERY
NW
REVISION No.
LOCATION
THRESHING STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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
SPECIFICATIONS
Quantity
Type:
Capacity:
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
Casing:
Sprocket
Bucket:
Chain rail:
Wear plate:
Chain:
Drive:
Shaft Speed:
Mild steel with 6mm minimum thickness

Mild steel
Mild steel angle
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:
1450
25
2865
>
rpm
rpm
Nm (min)
1.5
Power:
Type:
7.5
KW
Motor:-
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:
Crompton Parkinson, ABB Brooks, Brush, Elektrim

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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
OIL PALM MILL
PROJECT CODE
PREPARED BY
THRESHER MACHINE No.2
DELIVERY
NW
REVISION No.
LOCATION
THRESHING STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
D6
1
Scope of works include the manufacture, delivery & installation, commissioning,

Function:
To thresh unstripped bunches
SPECIFICATIONS
Quantity
One ( 1 ) unit Thresher No.2 for Unstipped Bunches as follows:
Type:
Capacity:
Rotating Drum
90MT FFB per hour
As per drawing
As per drawing
Shaft:
Boss:
Rim:
Frame & Structure:
Drum Speed:
Drum Basic Dimension:
Drive System:
Gear box:
Input speed:
Output speed:
Output torque:
Overhung load:
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:
15
KW
Motor:-
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Crompton Parkinson, ABB Brook, Brush Elektrim
SEW, HANSEN, SEW, Renold, EPG ElectroPower.

chain, sprocket
Bearing:
Renold, Tsubaki
SKF, FAG, NTN
OTHER REQUIREMENTS:1. Vendor to furnish selection of gear reducers, fluid coupling, chain and sprockets
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
DELIVERY
DRAWING NO.
PREPARED BY
ITEM No.
GENERAL
Scope
Scope of works include the manufacture, delivery & installation,

Function:
To convey fruitlets from Unstripped Bunch Thresher to the fruit

Elevator Via Bottom cross conveyor.
SPECIFICATIONS
Quantity
One (1) Bottom Fruit Conveyor as follows :
Type:
Size:
Full flight screw

600 mm dia.
As per drawing
As per drawing
Screw
Shaft:
Hanger bearing:
Conveyor Speed:
Drive System:
NW
REVISION No.
LOCATION
THRESHING STATION
QUANTITY / UNITS
Casing:
Wear plate:
13-May-00

56 rpm
Geared motor directly coupled with flexible coupling
to the shaft.
Gear box:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
5.5
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Crompton Parkinson, Brook, Brush

SUMITOMO, HANSEN, Renold
Renold, Tsubaki
chain, sprocket
Bearing:
SKF, FAG, NTN
1450 rpm
56 rpm
938 Nm (min)
>
1.5
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
BOTTOM CROSS CONVEYOR
DELIVERY
NW
REVISION No.
LOCATION
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
SPECIFICATIONS
Quantity
One ( 1 ) unit Bottom Cross Fruit Conveyor as follows :
Type:
Size:
Full flight screw

600
mm dia.
As per drawing
As per drawing
Casing:
Wear plate:
Screw
Shaft:
Hanger bearing:
Conveyor Speed:
Drive System:
Gear box:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:

Mild steel with 6mm minimum thickness fitted thoughoutthe conveyor extended
a least 100mm above the centerline of the conveyor
56
rpm
Geared motor directly coupled with flexible coupling to the
shaft.
1450
56
938
<
rpm
rpm
Nm (min)
1.5
5.5
KW
APPROVED MAKES
Motor:
Gear reducer:

SEW, HANSEN, Renold, EPG ElectrolPower
Coupling:
Renold, Tsubaki
chain, sprocket
Bearing:
SKF, FAG, NTN
4. Conveyor shall be mounted on rollers and able to slide sideway for easy removal during maintainance
Page 1 of 1
INCLINED E.B.C
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
INCLINE EMPTY BUNCH CONVEYOR
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
EMPTY BUNCH DISPOSAL SYSTEM
DRAWING NO.
ITEM No.
QUANTITY / UNITS
E1
1
GENERAL
Scope

Function:
To convey empty bunches from the horizontal bunch conveyor to the empty bunch hoppers.
SPECIFICATIONS
Quantity
Type:
Capacity:
General Arrangment:
Chain:
Drag Plate:
Frame:
Sprocket:
Wear Plate:
Inclination:
Conveying Section:
Shaft Speed:
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.

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
chain & sprocket
Speed Reducer:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
11
KW
Vendor to advise
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
<
rpm
rpm
Nm (min)
1.5
Page 1 of 1
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
OIL PALM MILL
PROJECT CODE
PREPARED BY
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
E2
1
Scope of works include the manufacture, delivery & installation, commissioning

Function:
To convey unstripped bunches from H.E.B Conveyor to Thresher No.2
SPECIFICATIONS
Quantity
One ( 1 ) unit Unstripped Bunches Conveyor as follows :
Type:
Capacity:

90 MT FFB per hour.
As per drawing
As per drawing
Casing:
Sprocket
Bucket:
Chain rail:
Wear plate:
Chain:

Mild steel
Mild steel angle
Steel c/w hardened steel flanged rollers, 150mm pitch
Drive:
Shaft Speed:
25
rpm
1
Speed Reducer:
Input speed:
1450
rpm
Output speed:
25
rpm
Output torque:
2865
Nm (min)
1.5
Motor:Power:
Type:
7.5
KW
APPROVED MAKES
Motor:
Gear reducer:
SUMITOMO, HANSEN, Renold, EPG ElectroPower
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:

Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
OTHER REQUIREMENTS
Page 1 of 1
BUNCH CRUSHER
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
BUNCH CRUSHER
DELIVERY
DRAWING NO.
NW
REVISION No.
LOCATION
ITEM No.
E3
QUANTITY / UNITS
GENERAL
Scope
Scope of works include the manufacture, supply, installation, erection, testing

Function:
Crushing of the bunches for the removal of fruitlets and dewatering of bunches
SPECIFICATIONS
Quantity
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
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:
chain, sprocket
Bearing:
Sew, HANSEN, Renold, EPG ElectroPower
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
Page 1 of 1
TOP EMPTY BUNCH CONVEYOR
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
OIL PALM MILL
PROJECT CODE
PREPARED BY
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey empty bunches from Inclined EB Conveyor

to the EB Hoppers.
SPECIFICATIONS
Quantity
One (1) unit Top Empty Bunch Conveyor

Type:
Capacity:
General Arrangment:
Chain:
Drag Plate:
Frame:
Sprocket:
Wear Plate:
Basic Dimension:
Width:
Length:

### kg / hr of empty bunches
As per drawing

breaking load
Inclination:
mm
mm
Horizontal
Conveying Section:
Top
Shaft Speed:
25

Drive:
1.00
chain & sprocket
Speed Reducer:
Input speed:
Output speed:
Output torque:
760
rpm
1450 rpm
25
rpm
2865 Nm (min)
<
1.5
Motor:Power:
Type:
7.5
KW
Page 1 of 2
E4
1
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DELIVERY
DRAWING NO.
PREPARED BY
NW
REVISION No.
LOCATION
ITEM No.
QUANTITY / UNITS
E4
1
Sheet 2.
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
chain, sprocket
Bearing:

Renold, Tsubaki, PC
SKF, FAG, NTN
Page 2 of 2
Empty bunch Hoppers
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
EMPTY BUNCH HOPPERS

STRUCTURE
&
PREPARED BY
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
E5
QUANTITY / UNITS
16
GENERAL
Scope
Scope of works include the design, manufacture, delivery & installation

Function:
To receive, store and unload empty bunches into trucks.
SPECIFICATIONS
Quantity
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:
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
SPECIFICATION SHEET
PROJECT NAME
DATE: 13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
FRUIT ELEVATOR
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
PRESS STATION
ITEM No.
QUANTITY / UNITS
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
SPECIFICATIONS
Quantity
Two ( 2 ) unit Fruit Elevator.
Type:
Capacity:

45 MT FFB per hour.
As per drawing
As per drawing
Casing:
Sprocket
Bucket:
Chain rail:
Wear plate:
Chain:

Mild steel
Mild steel angle
Steel c/w hardened steel flanged rollers, 150mm pitch,
Drive:
Shaft Speed:

25
rpm
1
Speed Reducer:
Input speed:
Output speed:
Output torque:
1450
25
2865
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:
7.5
KW
Crompton Parkinson, Brush, ABB Brooks , Elektrim
Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
OTHER REQUIREMENTS
3. Take-up bearing with adjustable bolt and screw shall be provided at the bottom booth for chain
tightening
Page 1 of 1
F1
2
FRUIT FEED CONVEYOR
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
FRUIT FEED CONVEYOR
PREPARED BY
DELIVERY
DRAWING NO.
NW
REVISION No.
LOCATION
PRESS STATION
ITEM No.
QUANTITY / UNITS
F 2.
1
GENERAL
Scope

Function:
To convey loose fruit from FRUIT ELEVATOR to Digesters
SPECIFICATIONS
Quantity
Capacity:
Type:
Size:
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
Screw
Shaft:
Shaft joint:
Hanger bearing:

Seamless API 5L Gr B Sch 80 pipe
Solid carbon steel
Conveyor Speed:
Drive System:
56
rpm
Geared motor directly coupled to conveyor shaft by
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
5.5
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:

SEW, Renold,HANSEN, EPG ElectroPower
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
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
FRUIT FEED CONVEYOR
DELIVERY
DRAWING NO.
PREPARED BY
NW
REVISION No.
LOCATION
PRESS STATION
ITEM No.
QUANTITY / UNITS
5. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 2 of 2
F 2.
1
RETURN FRUIT CONVEYOR
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
DELIVERY
REVISION No.
LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
Scope of works include the Design, manufacture, delivery

Function:
To convey excess loose fruit from Fruit Feed Conveyor to

Fruit Elevator
SPECIFICATIONS
Quantity
Capacity:
Type:
Size:
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:
Gear box:
Input speed:
Output speed:
Output torque:
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

Solid carbon steel
56
rpm
flexible coupling
1450
56
640
>
rpm
rpm
Nm (min)
1.5
3.75
KW
APPROVED MAKES
Motor:
Gear reducer:

Coupling:
Bearing:

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.
Page 1 of 2
F 3.
1
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DELIVERY
DRAWING NO.
PREPARED BY
NW
REVISION No.
LOCATION
PRESS STATION
ITEM No.
QUANTITY / UNITS
5. Top of the conveyor shall be covered with 3mm thk m.s plate cover.
Page 2 of 2
F 3.
1
Recycle Chute
SPECIFICATION SHEET
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
RECYCLE CHUTE
DELIVERY
PREPARED BY
NW
REVISION No.
LOCATION
DRAWING NO.
PRESS STATION
ITEM No.
F 4.
QUANTITY / UNITS
GENERAL
Scope
Scope of works include the Design, manufacture, delivery, installation,

Function:
To convey excess loose fruit from Fruit Feed Conveyor to Fruit Elevator
SPECIFICATIONS
Quantity
One ( 1 ) unit Recycle Chute of mild steel
Casing:
Supports :
As per drawing
As per drawing
M. S. Channels & Angle iron
Page 1 of 1
DIGESTER
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DELIVERY
DRAWING NO.
PREPARED
DIGESTER ( 3500 m3 )
REVISION No.
PRESS STATION
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
Function:
SPECIFICATIONS
Quantity
Unit Capacity
Diamension
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
Motor:
Gear reducer:
Coupling:
Bearing:

FAG, SKF, NTN
Page 1 of 1
TWIN SCREW PRESS
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
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.
SPECIFICATIONS
Quantity
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
Construction
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
Motor:
Gear reducer:
Coupling:
Bearing:

FAG, SKF, NTN
Page 1 of 1
PRESS STRUCTURE
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PRESS STRUCTURE
DELIVERY
DRAWING NO.
PREPARED
REVISION No.
'PRESS STATION
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

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.
SPECIFICATIONS
Quantity
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:
Structures:
Plaform
Handrail:
As per drawing
As per drawing
Mild steel sections

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
PROJECT NAME
DATE:
2-Oct-98
MACHINE NAME
PROJECT CODE
OIL PALM MILL
CRUDE OIL GUTTER
DELIVERY
PREPARED NW
REVISION No.
LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
F 8.
QUANTITY / UNITS
GENERAL
Scope

Function:
To collect crude oil ex-SCREW PRESSES and channel it to Sand trap
SPECIFICATIONS
Quantity
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
PIPE S.S AISI 304
Thickness:
4.5 mm
Size:
200 mm Dia.
Page 1 of 1
SAND TRAP
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
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

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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OILPALM MILL
PREPARED
CIRCULAR VIBRO SIEVE SCREEN
DELIVERY
NW
REVISION No.
'PRESS STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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.
SPECIFICATIONS
Quantity
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
Motor:
Gear reducer:
Coupling:
Bearing:

FAG, SKF, NTN
Page 1 of 1
VIBRATING SCREEN STRUCTURE
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
VS STRUCTURE
DELIVERY
DRAWING NO.
REVISION No.
LOCATION
PRESS STATION
ITEM No.
QUANTITY / UNITS
GENERAL
Scope of works include the design, fabrication, delivery,

installation, testing, commissioning and guarantee.
Function:
To support 2 circular vibrating screens
SPECIFICATIONS
General Arrangment:
Structures:
Plaform
Handrail:
NW
As per drawing
As per drawing
Mild steel sections
40mm dia.black pipe
OTHER REQUIREMENTS
1. Handrail shall be of 40mm black pipe, 900mm high with intermediete poles at 2000 c/c
Page 1 of 1
F 11.
2
SCREEN WASTE CONVEYOR
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
SCREEN WASTE CONVEYOR
DELIVERY
NW
REVISION No.
LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
F 12
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey vibrating screen reject of solid waste to FRUIT ELEVATOR.
SPECIFICATIONS
Quantity
One ( 1 ) unit Screen Waste Conveyor as follows :
Type:
Size:
Full flight screw

300
As per drawing
As per drawing
Casing:
Wear plate:
Screw
Shaft:
Hanger bearing:
Conveyor Speed:
Drive System:
Gear box:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
mm dia.

Stainless steel 304 of 6mm minimum thickness
56
rpm
Motor directly coupled to speed reducer by flexible
coupling
1450
56
375
>
rpm
rpm
Nm (min)
1.5
2.2
KW
APPROVED MAKES
Motor:
Gear reducer:

SEW, Renold, HANSEN
Coupling:
Bearing:

FAG, SKF, NTN
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
CRUDE OIL TANK
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
CRUDE OIL TANK
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
PRESS STATION
ITEM No.
F 13.
QUANTITY / UNITS
GENERAL
Scope
Scope of works include the Design, manufacture, delivery, installation

Function:
To receive oil from VIBRATING SCREEN
SPECIFICATIONS
Quantity
One ( 1 ) unit Crude oil tank as follows :
Capacity:
Basic Dimensions:
Construction Details:-
7
m3
As per drawing
As per drawing
Close Steam Coil:
Live steam injection:
Insulation:
Nozzles:-
Stainless steel 4.5mm plate

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
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
SS 304 SCH10S
SS 304 SCH10S
CRUDE OIL PUMP
PROJECT NAME
DATE: 13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CRUDE OIL PUMP

DELIVERY
REVISION No.
LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function
To transfer the crude oil to the clarification station
SPECIFICATIONS
Quantity
Two ( 2 ) units Crude Oil Pump as follows :
Type
Connection
Centrifugal, End-suction
Raised face flange to BS 4504 PN 10
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Viscousity
Deleivery Head
Speed
NPSH available
45
Crude Oil
90
0.9
0.1425
35
1450
3
MT / hr
o
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
Drive:
Motor:Power:
Type:
approx. 3.75 kw Vendor to advice

OTHER REQUIREMENTS
Page 1 of 1
F 14
2
OVERHEAD HOT WATER TANK
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
HOT WATER TANK
DELIVERY
DRAWING NO.
NW
REVISION No.
LOCATION
PRESS STATION
ITEM No.
QUANTITY / UNITS
F 15
1
GENERAL
Scope

Function:
Heating tank of water for extracted crude oil dilution
SPECIFICATIONS
Quantity
One ( 1 ) unit Overhead Hot water tank as follows :
Capacity:
Basic Dimensions:
4
m3
As per drawing
As per drawing
Close Steam Coil:
Live steam injection:
Insulation:
Level switch
Control
Stainless steel 4.5mm plate

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
Flange
PN 10
PN 10
PN 10
PN 16
Protrusion
(mm)
150
150
150
150
Material
SS 304 SCH10S
SAND TRAP CONVEYOR
PROJECT NAME
DATE: 13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
SAND TRAP CONVEYOR
DELIVERY
REVISION No.
LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
TO convey trap sand for disposal
SPECIFICATIONS
Quantity
One ( 1 ) unit Sand trap Conveyor No. 1 as follows :
Capacity:
Type:
Size:
1,000 kg / hr of sand material

Full flight screw
200
mm dia.
As per drawing
As per drawing
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:
Gear box:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
NW

Solid carbon steel
56
rpm
flexible coupling
1450
56
375
>
rpm
rpm
Nm (min)
1.5
2.2
KW
APPROVED MAKES
Motor:
Gear reducer:

SEW, Renold, HANSEN, EPG ElectroPower
Coupling:
Bearing:

FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door
Page 1 of 2
F 16
1
STRAINER BUCKET ELEVATOR
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
BUCKET ELEVATOR
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
Function:
F 17.
1

Conveyor to drain the solid waste in buckets, while in motion and thereafer
unloading onto trailer or truck for field disposal.
SPECIFICATIONS
Quantity
One (1) Bucket Elevator ( strainer ) complete with drive as folows:
Type:
Capacity:

1,000 kg material per hour.
As per drawing
As per drawing
Casing:
Sprocket
Bucket:
Chain rail:
Wear plate:
Chain:
Drive:
Shaft Speed:
Speed Reducer:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:

12T, 100mm pitch, grey iron
Mild steel
Mild steel angle
Steel c/w hardened steel flanged rollers, 100mm pitch.
25
rpm
1
1450
25
1000
>
rpm
rpm
Nm (min)
1.5
3.75
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:

Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
OTHER REQUIREMENTS
Page 1 of 1
AUTO DILUTION SYSTEM
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
CRUDE OIL DILUTION SYSTEM
DELIVERY
NW
REVISION No.
LOCATION
PRESS STATION
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
SPECIFICATIONS
Quantity
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.
Microprocessor based controller with PID control and I/P conversion.
50mm dia. modulating control valve for hot water.
Crude Oil R.S.G. recorder.
Installation & Operating instructions, service manual and buffer tank drawing.
Testing and commissioning.
Page 1 of 1
WATER COLLECTION TANK
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
WATER COLLECTION TANK
DELIVERY
NW
REVISION No.
LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
F 19.
QUANTITY / UNITS
GENERAL
Scope

Function:
Tank to collect condensate water from all equipment and piping system
SPECIFICATIONS
Quantity
One ( 1 ) unit Water Collection tank as follows :
Capacity:
Basic Dimensions:
2.25
As per drawing
As per drawing
m3
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
PN 10
150 API 5L SEAMLESS SCH40
and outlet
50
PN 10
150 API 5L SEAMLESS SCH40
Flanges:
Page 1 of 1
PUMP SET - WATER COLLECTION TANK.
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PUMP FOR WATER

COLLECTION TANK
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
F 20
2
GENERAL
Scope
Scope of works include the Design, manufacture, delivery , installation

Function
To recycle the condensate water to the Hot water tank crude oil
dilution tank, vibrating screen and clarification station.
SPECIFICATIONS
Quantity
Two ( 2 ) Pump set with level switch for water collection tank as follows :
Note : One unit on standby.
Type
Connection
Control
Level switch
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Deleivery Head
Speed
NPSH available
15
WATER
100
1
30
1450
3
MT / hr
o
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
Drive:
Motor:Power:
Type:

OTHER REQUIREMENTS
Page 1 of 2
VERTICAL CLARIFIER
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
VERTICAL CLARIFIER
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
G 1.
1
GENERAL
Scope
Scope of works include the Design, Fabrication, delivery, installation, testing

Function:
Static separation of crude oil from sludge
SPECIFICATIONS
Quantity
One ( 1 ) unit Vertical Clarifier Tank as follows :
Capacity:
Basic Dimensions :
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

S.S 304
S.S 304 seamless sch 10S
S.S 304
S.S 304
Mild steel
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
PN 10
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
PURE OIL TANK
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
G 2.
1
GENERAL
Scope
Scope of works include the Design, Fabrication, delivery

Function:
To receive oil from VERTICAL CLARIFIER
SPECIFICATIONS
Quantity
Capacity:
Basic Dimensions:
One ( 1 ) Unit Pure Oil Tank as follows :

30
m3
As per drawing
As per drawing

Steam Coil:
Cover:
Insulation:
Mild steel
50mm dia. API 5L,Gr B seamless sch 40
Mild steel
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
150
150
150
150
80
80
Flanges:
Level Indicator:
Mechanical type with SS float and string
Page 1 of 1
SLUDGE TANK
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
SLUDGE OIL TANK
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL

installation, testing , commissioning and guarantee
Function:
To receive Sludge phase from VERTICAL CLARIFIER
SPECIFICATIONS
One ( 1 ) unit Sludge Tank as follows :
Capacity:
Basic Dimensions:
30
As per drawing
As per drawing

Steam Coil:
Cover:
Insulation:
Mild steel
SS AISI 304 seamless sch 10S
Mild steel
G 3.
1
m3
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
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 SS 304 seamless Sch 10S

Page 1 of 1
DESANDING CYCLONE
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
MULTI DESANDING CYCLONE
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
G 4.
QUANTITY / UNITS
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.
SPECIFICATIONS
Quantity
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
MULTI DESANDING CYCLONE
DELIVERY
DRAWING NO.
PREPARED
NW
REVISION No.
LOCATION
ITEM No.
G 4.
QUANTITY / UNITS
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
SLUDGE OIL TRANSFER PUMP
DELIVERY
DRAWING NO.
REVISION No.
LOCATION
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
Scope of works include the Purchase, delivery, installation

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:

BS 4504 PN 10
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Viscousity
Deleivery Head
Speed
NPSH available
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
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
TEFC 4-pole, S.C, IP 55, Class F Ins.,
415V/3-Ph/50 Hz
KSB, SIHI, Robuschi, Warman or equivalent
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
SLUDGE OIL TANK
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
G 6.
1
GENERAL
Scope
Scope of works include the Design, Fabrication, delivery, installation, testing

Function:
Buffer tank to feed the decanter or sludge separator
SPECIFICATIONS
Quantity
Capacity:
Basic Dimensions:
One ( 1 ) unit Sludge buffer tank as follows :

3
4
m
As per drawing
As per drawing

Steam Coil:
Cover:
Insulation:
Stainless steel 304, 3mm thick

SS AISI 304 seamless sch 10S
Mild steel
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
Flange
PN 10
PN 10
PN 10
PN 16
PN 16
PN 10

Page 1 of 1
Protrusion
(mm)
Material
80
80
SLUDGE SEPARATOR
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
SLUDGE SEPARATOR
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
G 7.
QUANTITY / UNITS
GENERAL
Scope
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:
SPECIFICATIONS
Quantity
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
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

Page 1 of 1
3 PHASE DECANTER
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DECANTER ( 3 PHASE )
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
G 8.
QUANTITY / UNITS
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
SPECIFICATIONS
Quantity
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:
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
CONVEYOR ( DECANTER SOLID )
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
G 9.
QUANTITY / UNITS
GENERAL
Scipe
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:
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
Casing:
Wear plate:
Screw
Shaft:
Hanger bearing:
Conveyor Speed:
Drive System:

Stainless steel 304 of 6mm minimum thickness
56
rpm
Motor directly coupled to speed reducer by flexible
coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
56
640
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:
3.75
KW
SEW, Renold, HANSEN, EGP ElectoPower
FAG, SKF, NTN
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
LIGHT PHASE TANK & PUMP

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
G 10.
QUANTITY / UNITS
GENERAL
Scope
Scope of work include the Design, Fabrication, delivery, installation,

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
Raised face flange toBS 4504 PN 10
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Viscousity
Deleivery Head
Speed
NPSH available
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:Power:
Type:
APPROVED MAKES
Pump:
Motor:
Coupling:
Bearing:
approx. 3.75kw Vendor to advice

KSB, SIHI, Robuschi, Warman
Crompton Parkinson, Brook
NTN, FAG, SKF
Page 1 of 1
DECANTER HEAVY PHASE TRANSFER PUMP
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DECANTER HP TRANSFER PUMP

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
G 11.
QUANTITY / UNITS
GENERAL
Scope
Scope of work include the Design, Fabrication, delivery

Function
To receive the heavy phase liquid from the decanter
SPECTIFICATION
Quantity
Type
Connection
Two ( 2 ) units Decanter Heavy Phase Transfer Pump

OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Viscousity
Deleivery Head
Speed
NPSH available
15
Sludge Oil
90
0.9
0.0798
20
1450
3
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
M3 per hour.
o
Ns/m2
m liquid
RPM (Max)
m liquid
Motor:Power:
Type:
APPROVED MAKES
Pump:
Motor:
Coupling:
Bearing:

Robuschi, Warman
NTN, FAG, SKF
Page 1 of 1
SLUDGE SETTLING TANK
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
SLUDGE SETTLING TANK

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
G 12.
1
GENERAL
Scope
Scope of works include the Design, fabrication, delivery

Function:
To receive sludge from various tank for recovery of Oil
SPECIFICATIONS
Quantity
Capacity:
Basic Dimensions:
One ( 1 ) unit Sludge / Oil recovery settling Tank as follows :

3
m
20
As per drawing
As per drawing

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
Flanges:
Raised face toBS 4504
Requirement
Contractor to provide full details for approval by consultant.
Page 1 of 1
SLUDGE SETTLING TANK PUMP
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
SETTLING TANK PUMP
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

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:

BS 4504 PN 10
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Viscousity
Deleivery Head
Speed
NPSH available
15
Crude Oil
90
0.86
0.1425
20
1450
3
mt/hr
o
Ns/m2
m liquid
RPM (Max)
m liquid
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
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

SKF, FAG, NTN
Crane, Burgman
Mobrey, BESTA
Page 1 of 2
G 13.
2
OIL HEATER TANK
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
OIL HEATER TANK
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
G 14.
1
GENERAL
Scope

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
Flange
PN 10
PN 16
PN 16
PN 10
Protrusion
(mm)
150
150
150
150
Page 1 of 1
Material
OIL PURIFIER
PROJECT NAME
DATE:
10-Oct-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
OIL PURIFIER
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
Clarification of the crude oil by removing dirt from oil.
SPECIFICATIONS
Quantity
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
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
CPO TRANSFER PUMP
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
Scope of work include the Design, Fabrication, delivery,

Function
To heat the Oil before Vacuum drying process
SPECIFICATION
Quantity
Two( 2 ) unit CPO Transfer Pump as follows :
Type
Connection
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Viscousity
Deleivery Head
Speed
NPSH available
15
Sludge Oil
90
0.9
0.0798
20
1450
3
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
M3 per hour.
o
Ns/m2
m liquid
RPM (Max)
m liquid
Motor:Power:
Type:
APPROVED MAKES
Pump:
Motor:
Coupling:
Bearing:

Robuschi, Warman
NTN, FAG, SKF
Page 1 of 1
G 16.
2
VACUUM OIL DRYER
PROJECT NAME
DATE:
10-Oct-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
VACUUM OIL DRYER

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
G 19.
QUANTITY / UNITS
GENERAL
Scope

Function:
Drying of Purified CPO by removing the moisture
SPECIFICATIONS
Quantity
One ( 1 ) Vacuum Oil Dryer as follows :
Capacity
15 metric ton per hour of Crude Palm Oil
Construction
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.
average and standard deviation
Page 1 of 1
HOT WATER TANK
PROJECT NAME
DATE:
10-Oct-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
HOT WATER TANK
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
G 20
1
GENERAL
Scope

Function:
To provide hot water for dilution purposes
SPECIFICATIONS
Quantity
One ( 1 ) unit Hot Water Tank as follows :
Capacity:
Basic Dimensions:
15
As per drawing
As per drawing
Steam Coil:
Insulation:
Mild steel
Carbon steel seamless Sch 40
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
Page 1 of 2
GI Class C to BS 1387
CLARIFICATION STRUCTURE
PROJECT NAME
DATE: 10-Oct-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CLARIFICATION STRUCTURE
DELIVERY
DRAWING NO.
REVISION No.
LOCATION
ITEM No.
QUANTITY / UNITS
G 21
1
GENERAL
Scope

Function:
To support equipment, tanks and vessels
SPECIFICATIONS
Quantity
General Arrangment:
Structures:
Plaform
Handrail:
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

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
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 NAME
DATE: 10-Oct-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
SLUDGE PIT PUMP

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
G 22
QUANTITY / UNITS
GENERAL
Scope
Scope of works include the purchase, delivery, installation

Function:
To pump Oil from Sludge pit to the Sludge recovery tank
SPECIFICATIONS
Quantity
Type
Connection
Two ( 2 ) units Sludge pit pump as follows :

Centrifugal, self-priming, Vertical mount
Raised face flange to BS 4504
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Viscousity
Deleivery Head
Speed
NPSH available
30
Crude Oil
100
0.9
0.0798
200
1500
3
CONSTRUCTION
Casing
Impeller
Shaft
Sealing
Wetted Parts
Coupling
DriveSystem:
Cast Iron GG-25

S.S AISI 304
S.S AISI 304
Mechanical seal
S.S AISI 304
Flexible
MT/hr
o
Ns/m2
Kpa
RPM (Max)
m liquid
Motor:Power:
Type:
APPROVED MAKES
Pump:
Motor:
Coupling:
Bearing:
approx. 3,75 kw Vendor to advice

Robuschi, Warman, CK Pump
NTN, SKF, FAG
OTHER REQUIREMENTS
Page 1 of 1
SLUDGE RECOVERY TANK
PROJECT NAME
DATE:
10-Oct-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
SLUDGE OIL RECOVERY TANK

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
G 23.
QUANTITY / UNITS
GENERAL
Scope

Function:
To recover oil from clarification and other process waste water
SPECIFICATIONS
Quantity
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:
150
As per drawings
As per drawings
m3
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
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CAKE BREAKER CONVEYOR

DELIVERY
REVISION No.
LOCATION
DEPARICARPER STATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

testing, commissioning, handing over and guarantee
Function:
To break up pressed cake from SCREW PRESSES and

convey to the DEPRICARPING COLUMN
SPECIFICATIONS
Quantity
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:
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:
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
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:
7.5
KW Vendor to advise.
SUMITOMO, HANSEN, Renold, SEW, EPG ElectroPower
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
PROJECT NAME
PROJECT CODE
DATE:
OIL PALM MILL
MACHINE NAME
DEPARICARPER WINNOWING
SYSTEM
PREPARED
DELIVERY
13-May-00
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To separate the nut and fibre using air separation method
SPECIFICATIONS
Quantity
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
As per drawing
As per drawing
Mild steel
Ducting
Basic Dimensions:
As per drawing
As per drawing
Mild steel
Diameter:
Thickness
600
6
mm
mm
Fibre Cyclone
As per drawing
As per drawing
Mild steel
Wear liner:
4.5mm thk to be provided at the inlet volute of the cyclone
Page 1 of 2
H 2.
1
DEPRICARPING SYSTEM
PROJECT NAME
DATE:
PROJECT CODE
OIL PALM MILL
MACHINE NAME
DEPARICARPER WINNOWING
SYSTEM
PREPARED
DELIVERY
13-May-00
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
H 2.
1
Sheet 2.
Airlock
Type:
Quantity:
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:
2.2
KW
Fan
Type:
Flowrate:
Static Pressure:
Cetrifugal
42,000
150
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

APPROVED MAKES
Motor:
Fan:
Coupling:
Bearing:

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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
DAMPER CONTROL SYSTEM
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
H 3.
QUANTITY / UNITS
GENERAL
Scope
Function
SPECIFICATIONS
Quantity
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
Equipment drawings, installation and operating instruction, spare parts list

and specification shall be provide upon commissioning.
General

Page 1 of 1
NUT POLISHING DRUM
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
NUT POLISHING DRUM

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
Scope of works include the design, fabrication, delivery

installation, testing and guarantee.
Function:
To polish nuts from DEPERICARPER COLUMN
SPECIFICATIONS
Quantity
One ( 1 ) unit Nut Polishing Drum complete as follows :
Type:
Capacity:
Rotating Drum
9,000 kg/hr of nuts
As per drawing
As per drawing
Shaft:
Hub:
Drum Casing:
Frame & Structure:
Basic Dimensions:
Drum Speed:
Drive System:
Gear box:
Input speed:
Output speed:
Output torque:
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:
5.5
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:

SUMITOMO, HANSEN, Renold, SEW, EPG ElectroPower
SKF, FAG, NTN
Page 1 of 1
H 4.
1
INCLINE NUT CONVEYOR
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
INCLINED NUT CONVEYOR
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
H5
1
GENERAL
Scope

Function:
To transfer nuts from NUT POLISHING DRUM to destoning system
SPECIFICATIONS
Quantity
One ( 1 ) unit Inclined Nut Conveyor as follows :
Type:
Full flight screw with round casing only at the end of the conveyor
Capacity
7,500
As per drawing
As per drawing
Diameter:
Conveyor Speed:
Drive System:
Mild steel
300
mm
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:
1450
56
375
<
kg nuts per hour.
rpm
rpm
Nm (min)
1.5 (min)
2.2
KW
SUMITOMO, HANSEN, SEW, Renold, Benzler SALA
NTN, SKF, FAG
OTHER REQUIREMENTS :
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DESTONING SYSTEM
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
H 6.
1
GENERAL
Scope

Function:
To separate the nut and stone using air separation method
SPECIFICATIONS
Quantity
One ( 1 ) Destoning System consisting of :

Expansion column, support, ducting, nut discharge chute,
cyclone, airlock and fan
Capacity:
Separation & Expansion Column
9,000 kg / hr of nut
As per drawing
As per drawing
Mild steel
Ducting
Basic dimensions:
Diameter:
Thickness:
450
6
Cyclone
Basic dimensions:
As per drawing
As per drawing
Mild steel
As per drawing
Airlock
Type:
Quantity:
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
Page 1 of 2
DESTONING SYSTEM
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
DESTONING SYSTEM
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
H 6.
1
Sheet 2.
Fan
Type:
Centrifugal
20,404 m3/hr
250 mm wg
Flowrate:
Static Pressure:
Casing:
Impeller:
Shaft:
Pulley:
Speed:
Drive System:
Mild steel
Carbon steel
Carbon steel
Cast steel
Motor coupled to fan shaft by fluid coupling then by
belt and pulley
To be provided
Belt guard:
Type of Mounting:
Baseframe:
Motor:-
Floor
Power:
Type:
Approx. 22 kw Vendor to advice

Supporting Structures
Construction details:
Material:
as per drawing
mild steel
APPROVED MAKES
Motor:
Gear reducer:

SUMITOMO, HANSEN, Renold, SEW, EPG Electropower
Fluid Coupling:
Bearing:
Fan:
Transmission Belt:
Fenner (Fenaflex), Renold, Transfluid

NTN, SKF, FAG
Fenner
Page 2 of 2
DESTONER DAMPER CONTROL SYSTEM
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DESTONER DAMPER CONTROL

SYSTEM
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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.
SPECIFICATIONS
Quantity
The control shall be based on the following process variables :

b. Predetermined separation air velocity in the Destoner column.

1. PLC unit system.
The PLC shall be linked to the Central control station via LAN networking.
3. Air flow meter.
Manuals

General

Page 1 of 1
NUT ELEVATOR
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NUT ELEVATOR
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
H 8.
QUANTITY / UNITS
GENERAL
Scope

Testing, commissioning, handing over and guarantee
Function:
To convey Nuts onto the NUT BIN
SPECIFICATIONS
Quantity
One ( 1 ) unit Nut Elevator as follows :
Type:
Capacity:
Conveyor chain c/w buckets

9,000 kg Nuts per hour
As per drawing
As per drawing
Casing:
Sprocket
Bucket:
Chain rail:
Chain:
Drive:
Shaft Speed:
Speed Reducer:
Input speed:
Output speed:
Output torque:

Mild steel
Mild steel angle
breaking load
30
rpm
1
1450
30
955
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
3
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:

SUMITOMO, HANSEN, Renold , EPG ElectroPower
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NUT CONVEYOR No.1
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey Nuts from the Nut Elevator to the Nut Silo.
SPECIFICATIONS
Quantity
Capacity:
Type:
Size:
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
Casing:
Wear plate:

Screw
Shaft:
Shaft joint:
Hanger bearing:

Solid carbon steel
Conveyor Speed:
Drive System:
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
56
375
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:
2.2
KW
SUMITOMO, Renold, HANSEN, EPG ElectroPower
FAG, SKF, NTN
Page 1 of 1
H 9.
1
PALM OIL STORAGE TANK
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CPO STORAGE TANK

DELIVERY
REVISION No.
LOCATION
CPO STORAGE
DRAWING NO.
ITEM No.
QUANTITY / UNITS
I 1.
2
GENERAL
Scope
Scope of works include the Design, fabrication, delivery, Installation

Function:
To store and heat palm oil prior to despatch
SPECIFICATIONS
Quantity
Capacity:
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
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
Flange
PN 10
PN 10
PN 10
PN 10
PN 16
PN 16
Material
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CPO DISPATCH PUMP

DELIVERY
REVISION No.
LOCATION
CPO STORAGE
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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.
SPECIFICATIONS
Quantity
Type
Connection
Two ( 2 ) units Palm Oil Despatch Pumps as follows:

Gear or screw positive displacement
BS 4504 PN 10 flange
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Viscousity
Deleivery Head
Speed
NPSH available
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
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:

TEFC 4-pole, S.C, IP 55, Class F Ins., 415 V / 3-Ph / 50 Hz
Tuthill, Viking, IMO, Leistritz
Crompton, Brook
SUMITOMO, Renold, HANSEN
SKF, FAG, NTN
OTHER REQUIREMENTS
Page 1 of 1
I 2.
2
NUT CONVEYOR No.2
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NUT CONVEYOR No.2
DELIVERY
NW
REVISION No.
LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey nuts from Destoner to Nut Buffer Silo
SPECIFICATIONS
Quantity
One ( 1 ) unit Nut Conveyor No.2 as follows :
Capacity:
Material
Type:
Size:
9,000 kg per hour

Wet Nuts
Full flight screw
300
mm dia.
As per drawing
As per drawing
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:

Solid carbon steel
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
56
375
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:
2.2
KW Vendor to advise
SUMITOMO, Renold, HANSEN, EPG ElectoPower
FAG, SKF, NTN
Page 1 of 1
J 1.
1
NUT BUFFER HOPPER
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NUT BUFFER HOPPER
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
J 2.
QUANTITY / UNITS
GENERAL
Scope

Function:
To receive nuts and act as buffer storage before feeding

into the nut ripple mills or crackers.
SPECIFICATIONS
Quantity
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NUT FEEDER
DELIVERY
NW
REVISION No.
LOCATION
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.
SPECIFICATIONS
Quantity
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
RIPPLE MILL
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
RIPPLE MILL
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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
Construction
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
CM CONVEYOR No.1
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
J 5.
QUANTITY / UNITS
GENERAL
Scope
Function:
SPECIFICATIONS
Quantity
Material to convey
Capacity:
Type:
Size:
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:

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
Solid carbon steel
56
rpm

flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
2.2
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:
FAG, SKF, NTN
1450
56
375
>
rpm
rpm
Nm (min)
1.5
Page 1 of 1
C.M CONVEYOR NO.2
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CM CONVEYOR No.2
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey cracked micture from Winnowing System

to C.M Conveyor No.3
SPECIFICATIONS
Quantity
One ( 1 ) Cracked Mixture Conveyor No.2
Material to be conveyed
Capacity:
Type:
Size:
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
Casing:
Wear plate:

Solid carbon steel
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
56
375
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
2.2
KW
APPROVED MAKES
Motor:
Gear reducer:

Coupling:
Bearing:

FAG, SKF, NTN
Page 1 of 2
J 6.
1
C.M CONVEYOR NO.2
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CM CONVEYOR No.2
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
Page 2 of 2
J 6.
1
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
CM ELEVATOR
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
J 7.
QUANTITY / UNITS
GENERAL
Scope

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 :

9,000 kg per hour.
As per drawing
As per drawing
Casing:
Sprocket

Bucket:
Chain rail:
Chain:
Mild steel
Mild steel angle
breaking load
Drive:
Shaft Speed:

30
rpm
1
Speed Reducer:
Input speed:
Output speed:
Output torque:
1450
30
1194
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:
3.75
KW
Specified or equivalent
Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
OTHER REQUIREMENTS
Page 1 of 2
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
CM ELEVATOR
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
Page 2 of 2
J 7.
1
VIBRATING TROUGH
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
VIBRATING TROUGH
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
Separating of un-cracked nuts and feeder to Winnowing column
SPECIFICATIONS
Quantity
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PRIMARY WINNOWER
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
J 9.
QUANTITY / UNITS
GENERAL
Scope

Testing, commissioning, handing over and guarantee
Function:
To separate the cracked mixture from light particles using

air separation method
SPECIFICATIONS
Quantity
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:
Diameter:
Drum Speed:
Drive System:
Rotary vane
2
As per drawing
As per drawing
Mild steel
300
mm
45
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
45
212
>
rpm
rpm
Nm (min)
1.5 (min)
Power:
Type:
1
KW
Motor:-
Ducting
Basic dimensions:
Diamater:
Thickness:
Cyclone 1 stage
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PRIMARY WINNOWER
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
J 9.
QUANTITY / UNITS
Sheet 2.
Airlock for Cyclone
Type:
Quantity:
Diameter:
Drum Speed:
Drive System:
Rotary vane
1
As per drawing
As per drawing
Mild steel
600
mm
45
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
45
467
>
rpm
rpm
Nm (min)
1.5 (min)
Power:
Type:
2.2
KW
Motor:-
Fan
Type:
Flowrate:
Static Pressure:
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
Motor coupled to fan shaft by belt and pulley
To be provided
Floor
Power:
Type:
approx. 30 kw Vendor to advice

APPROVED MAKES
Motor:
Fan:
Coupling:
Gear reducer:
Bearing:
Transmission Belt:

Renold, Fenner
SUMITOMO, HANSEN, Renold, EPG ElectroPower.
NTN, SKF, FAG
Fenner
Page 2 of 2
WINNOWING COLUMN DAMPER CONTROL SYSTEM
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
WINNOWING DAMPER
CONTROL
PREPARED
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
J 10.
QUANTITY / UNITS
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.
SPECIFICATIONS
Quantity
One (1) Primary Winnowing Damper Control System as follows:The control shall be based on the following process variables :
b. Pre-determined separation air velocity in the Primary Winnowing column.

1. PLC unit system.
3. Air flow meter.
Manuals

General

Page 1 of 1
SECONDARY WINNOWER
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
SECONDARY WINNOWER
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:

SPECIFICATIONS
Quantity
System consist of:
One ( 1 ) Secondary Winnowing system as follows :

Material for Process


9,000 kq per hour.
Separation Column
Column size:
As per drawing
As per drawing
Mild steel
600
Ducting
Basic dimensions:
Diamater:
Thickness:
Cyclone
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
SECONDARY WINNOWER
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
J.11
1
Sheet 2.
Airlock
Type:
Quantity:
Diameter:
Drum Speed:
Drive System:
Rotary vane
1
As per drawing
As per drawing
Mild steel
300
mm
45
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
45
467
>
rpm
rpm
Nm (min)
1.5 (min)
Motor:Power:
Type:
Fan
Type:
Flowrate:
Static Pressure:
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
To be provided
Floor
approx. 22kw Vendor to advice

Renold, Fenner
NTN, SKF, FAG
Fenner
Page 2 of 2
SECONDARY WINNOWER DAMPER CONTROL
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
SECONDARY WINNOWER
DAMPER CONTROL
PREPARED
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
J.12
QUANTITY / UNITS
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.
SPECIFICATIONS
Quantity
One (1) Secondary Winnowing Damper Control System as follows:The control shall be based on the following process variables :
b. Predetermined separation air velocity in the Secondary Winnowing column.
1. PLC unit system.

3. Air flow meter.
Manuals

General

Page 1 of 1
C.M CONVEYOR NO.2
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
CM CONVEYOR 3
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
J 13.
QUANTITY / UNITS
GENERAL
Scope

Function:

SPECIFICATIONS
Quantity
Capacity:
Type:
Size:
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:

Full flight screw
300
mm dia.
As per drawing
As per drawing
Solid carbon steel
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
Motor:-
Power:
Type:
1450
56
512
>
rpm
rpm
Nm (min)
1.5
3
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:

FAG, SKF, NTN
Page 1 of 1
C.M CONVEYOR NO.2
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
CM CONVEYOR 4
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:

SPECIFICATIONS
Quantity
Capacity:
Type:
Size:
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:

Full flight screw
300
mm dia.
As per drawing
As per drawing

Solid carbon steel
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
56
512
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
3
KW
APPROVED MAKES
Motor:
Gear reducer:

Coupling:
Bearing:

FAG, SKF, NTN
Page 1 of 1
J 14.
1
HYDROCYCLONE
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
HYDROCYCLONE 3 STAGE
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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:
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
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
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 NAME
DATE: 13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
WET SHELL TRANSPORT

SYSTEM
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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
Diameter:
As per drawing
As per drawing
API 5L Gr B Sch 40 pipe
150
mm
Cyclone
Diameter:
As per drawing
As per drawing
Mild steel
mm
Airlock
Type:
Quantity:
Diameter:
Drum Speed:
Drive System:
Rotary vane
1
As per drawing
As per drawing
Mild steel
300
mm
45
rpm
flexible coupling
Gear box:
Input speed:
1450
Output speed:
45
Output torque:
467
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
2.2
KW
Page 1 of 2
WET SHELL TRANSPORT
PROJECT NAME
DATE: 13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
WET SHELL TRANSPORT

SYSTEM
DELIVERY
DRAWING NO.
NW
REVISION No.
LOCATION
ITEM No.
QUANTITY / UNITS
J.16
1
Sheet 2.
Fan
Type:
Flowrate:
Static Pressure:
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
Motor directly coupled to fan
To be provided
Floor
Vendor to advice

Renold, Fenner
SUMITOMO, HANSEN, Renold
NTN, SKF, FAG
Fenner
Page 2 of 2
WET KERNEL TRANSPORT SYSTEM
PROJECT NAME
DATE: 10-Oct-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
WET KERNEL TRANSPORT SYSTEM

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey Wet Kernel from the recovery station to feed the

battery of kernel dryers
SPECIFICATIONS
Quantity
Capacity:
Type:
Size:
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:
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

Solid carbon steel
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
56
640
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:
3.75
KW

FAG, SKF, NTN
Page 1 of 2
J. 17
1
SHELL BUNKER STRUCTURE
PROJECT NAME
DATE: 13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
SHELL BUNKER & STRUCTURE

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To store shell material from the various separation systems

and Structure to support the shell bunker, cyclones & fans
SPECIFICATIONS
Quantity
General Arrangment:
One ( 1 ) unit Shell Bunker of 4 compartments

and Structure as follows :
As per drawing
Volumn
Structures:
Plaform
Handrail:
As per drawing
Mild steel sections

40mm dia.black pipe
High tensile
OTHER REQUIREMENTS
1. Handrail shall be 900mm high with intermediete poles at 2000 c/c
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
WET SHELL ELEVATOR

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey wet kernel from Hydrocyclone to the Kernel Silo
SPECIFICATIONS
Quantity
Type:
Capacity:
One ( 1 ) Wet Kernel Elevator.

4,500 kg/hr dry kernel
As per drawing
As per drawing
Casing:
Sprocket
Bucket:
Chain rail:
Chain:
Drive:
Shaft Speed:
Speed Reducer:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:

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
30
rpm
1
1450
30
700
>
rpm
rpm
Nm (min)
1.5
2.2
KW

Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
OTHER REQUIREMENTS
Page 1 of 1
J 19.
1
WET KERNEL CONVEYOR NO.2
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
WET KERNEL CONVEYOR 2.
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
from Wet Kernel Elevator to kernel silo.
SPECIFICATIONS
Quantity
Material to be Conveyed
Capacity:
Type:
Size:
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
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:

Solid carbon steel
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
56
640
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
3.75
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:

FAG, SKF, NTN
Page 1 of 1
J.20
1
KERNEL SILO
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
KERNEL SILO & FAN
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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
Mild steel
Air Duct
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
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
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DRY KERNEL CONVEYOR No.1

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey dry kernel from Kernel Silo to kernel Transport
SPECIFICATIONS
Quantity
Capacity:
Type:
Size:
One ( 1 ) unit Dry Kernel as follows :

Dry Kernel
Full flight screw
300
mm dia.
As per drawing
As per drawing
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:

Solid carbon steel
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
56
375
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
2.2
KW
APPROVED MAKES
Motor:
Gear reducer:

Coupling:
Bearing:

FAG, SKF, NTN
Page 1 of 1
J. 22
1
PROJECT NAME
DATE:
13-May-00
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DRY KERNEL ELEVATOR

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey Dry Kernel
SPECIFICATIONS
Quantity
Type:
Capacity:
One (1) unit Dry Kernel Elevator

Dry Kernel
9,000 kq per hour ( for 90MT FFB / hr )
As per drawing
As per drawing
Casing:
Sprocket
Bucket:
Chain rail:
Chain:
Drive:
Shaft Speed:
Speed Reducer:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:

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
30
rpm
1
1450
30
955
>
rpm
rpm
Nm (min)
1.5
3
KW

Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
OTHER REQUIREMENTS
Page 1 of 1
J. 23
1
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
KERNEL WINNOWING
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:

SPECIFICATIONS
Quantity
System consist of:
One ( 1 ) Primary Winnowing System as follows :

Material to be separated
Palm Nuts Cracked Mixture

9,000 kg per hour.
Separation Column
Size:
As per drawing
As per drawing
Mild steel
600
mm dia.
Ducting
Basic dimensions:
As per drawing
As per drawing
Mild steel
Diamater:
Thickness:
Cyclone
Basic dimensions:
Airlock
Type:
Quantity:
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
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
45
467
>
Page 1 of 2
rpm
rpm
Nm (min)
1.5 (min)
J. 24
1
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
KERNEL WINNOWING
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
J. 24
1
Sheet 2.
Motor:-
Power:
Type:
2.2
KW
Fan
Type:
Flowrate:
Static Pressure:
Centrifugal, self-cleaning
3
18,000 m /hr
375 mm wg
Casing:
Impeller:
Shaft:
Pulley:
Mild steel
Carbon steel
Carbon steel
Cast steel
Speed:
Drive System:
Belt guard:
Type of Mounting:
Baseframe:
Motor:-

To be provided
Floor
Power:
Type:
approx. 22kw Vendor to advice

APPROVED MAKES
Motor:
Fan:

Coupling:
Gear reducer:
Bearing:
Transmission Belt:
Renold, Fenner
NTN, SKF, FAG
Fenner
Page 2 of 2
DRY KERNEL TRANSPORT
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DRY KERNEL TRANSPORT

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To transport dry kernel from KERNEL SILO to the Kernel Bulk Silo
SPECIFICATIONS
Quantity
System consist of:
One ( 1 ) Dry Kernel Transporter as follows :

Ducting, cyclone, airlock, fan and supporting fixtures
Dry Kernel
9,000 kg per hour.
Ducting
Diameter:
As per drawing
As per drawing
API 5L seamless Sch 40 pipe
250
mm
Cyclone
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:
Casing:
Impeller:
Shaft:
Pulley:
Speed:
Drive System:
Belt guard:
Type of Mounting:
Mild steel
Carbon steel
Carbon steel
Cast iron
Motor directly coupled to fan
To be provided
Floor
Baseframe:
Motor:Power:
Type:

APPROVED MAKES
Motor:
Coupling:
Bearing:
Fan:

NTN, FAG, SKF
Novenco, James Howden, Phoenix
Page 1 of 2
J. 25
1
DRY KERNEL CONVEYOR
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
DRY KERNEL CONVEYOR No.2
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey dry kernel from Kernel Silo to kernel Transport
SPECIFICATIONS
Quantity
Capacity:
Type:
Size:
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:
Conveyor Speed:
Drive System:
One ( 1 ) unit Dry Kernel as follows :

Dry Kernel
Full flight screw
300
mm dia.
As per drawing
As per drawing
Solid carbon steel
56
rpm
flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
1450
56
375
>
rpm
rpm
Nm (min)
1.5
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:
NW
2.2
KW

FAG, SKF, NTN
Page 1 of 1
J.26
1
BULK KERNEL SILO
PROJECT NAME
DATE:
7-Aug-99
PREPARED
NW
MACHINE NAME
PROJECT CODE
OIL PALM MILL
KERNEL BULK SILO
DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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:
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
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 authoritys
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 manufacturers 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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
FUEL CONVEYOR
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No.
QUANTITY / UNITS
K. 1
1
GENERAL
Scope

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
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
1.43
Gear box:
Input speed:
Output speed:
Output torque:
1450
50
>
rpm
rpm
1,433 Nm (min)
1.5
Motor:Power:
Type:
7.5
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:

Renold, Tsubaki
Bearing:
NTN, SKF, FAG
OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness

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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
FUEL CONVEYOR No. 2
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No.
K. 2
QUANTITY / UNITS
GENERAL
Scope
Scope of works include the design, fabrication, delivery, erection

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
Chain:
Drag Plate:
Frame:
Sprocket:
Wear Plate:
Conveying Section:
Inclination:
Dimension:
Drive:
Variable Speed Reducer:
Input speed:
Output speed:
Output torque:

breaking load
Mild steel
Mild steel sections
493.2mm PCD, grey cast iron
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
>
rpm
rpm
3,534 Nm (min)
1.5
Motor:Power:
Type:
7.5
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:
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
Page 1 of 2
FUEL CONVEYOR - Inclined
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
FUEL CONVEYOR No. 2
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No.
QUANTITY / UNITS
6. Contractor to provide drawing and detail specifications.
Page 2 of 2
K. 2
1
FUEL FEED CONVEYOR
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
FUEL CONVEYOR No. 3

DELIVERY
REVISION No.
LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

testing, installation, commissioning and guarantee.
Function:
To convey Oil Palm solid waste fuel to the Boiler.
SPECIFICATIONS
Quantity
Type:
Capacity:
One ( 1 ) unit Fuel Feed Conveyor as follows :

Drag chain c/w scrapper plate
30,000 kg/hr of mixed fuel
Chain:

breaking load
Drag Plate:
Frame:
Sprocket:
Wear Plate:
Conveying Section:
Inclination:
Dimension:
Drive System:
Mild steel
Mild steel sections
250 mm PCD, grey cast iron
Horizontal S-Type
35
rpm
As per drawing
chain & sprocket

Gear box:
Input speed:
Output speed:
Output torque:
1.43
Motor
11
KW
Power:
Type:
1450
50
>
rpm
rpm
2,101 Nm (min)
1.5
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:

Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
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
PROJECT NAME
PROJECT CODE
DATE:
OIL PALM MILL
DELIVERY
MACHINE NAME
FUEL AND BOILER OPERATING

PLATFORM
PREPARED
REVISION No.
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:
Structures:
Plaform
Handrail:
One lot Fuel and Boiler Operating Platform.

As per drawing
As per drawing
Mild steel sections
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
Page 1 of 1
FUEL FEED CONVEYOR
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
FUEL CONVEYOR No. 4

DELIVERY
REVISION No.
LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey shell and fibre from the inclined fuel conveyor

to Boilers fuel feeder
SPECIFICATIONS
Quantity
Type:
Capacity:
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.
Chain:
Drag Plate:
Frame:
Sprocket:
Wear Plate:
Conveying Section:
Dimension:
Drive System:
Gear box:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:

breaking load
Mild steel
Mild steel sections
250mm PCD, grey cast iron
35
As per drawing
rpm

chain & sprocket
1.43
1450
rpm
50
rpm
1,433 Nm (min)
>
1.5
7.5
KW
Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
6. Contractor shall provide drawing and detail specification.
Page 1 of 2
K. 4
1
FUEL STORAGE PLATFORM
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
FUEL PLATFORM
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No.
QUANTITY / UNITS
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
Structures:
Plaform
Handrail:
As per drawing
Mild steel sections
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
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
EXCESS FUEL CONVEYOR

DELIVERY
REVISION No.
LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To convey excess fuel from the boiler fuel feeder conveyor

for disposal
SPECIFICATIONS
Quantity
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.
Housing
Screw
Frame:
Wear Plate:
Top cover
6 mm thick ms plate
Mild steel
Mild steel sections
6 mm thick ms plate
Conveying Section:

Dimension:
Drive System:
35
rpm
As per drawing
chain & sprocket
1.43

Gear box:
Input speed:
Output speed:
Output torque:
1450
50
>
rpm
rpm
1,003 Nm (min)
1.5
Motor:Power:
Type:
5.25
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:

Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
6. Contractor shall provide drawing and detail specification.
Page 1 of 1
K. 6
1
SUPPORTING STRUCTURE
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
STRUCTURE FOR K 6.
DELIVERY
NW
REVISION No.
LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No.
K. 7
QUANTITY / UNITS
GENERAL
Scope

Function:
Steel Structure to support the excess fuel conveyor
SPECIFICATIONS
Quantity
General Arrangment:
One lot Supporting structure as follows:

As per drawing
Structures:
Walkway Plaform
Handrail:
As per drawing
Mild steel sections
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
Page 1 of 1
FUEL RETURN ELEVATOR
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
FUEL RETURN ELEVATOR
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No.
QUANTITY / UNITS
K. 8
1
GENERAL
Scope

Function:
To convey solid waste fuel from the storage area back to the
fuel feed conveyor
SPECIFICATIONS
Quantity
Type:
Capacity:
Casing:
Sprocket
Bucket:
Chain rail:
Wear plate:
Chain:
One (1) unit Fuel Return Conveyor

30,000 kg Solid waste fuel per hour.
As per drawing
As per drawing

Mild steel
Mild steel angle
Steel c/w hardened steel flanged rollers, 150mm pitch, 13600 kg
breaking load
Drive:
Shaft Speed:
Speed Reducer:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:

25
rpm
1
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Transmission Chain:
Conveyor Chain:
Bearing:
Renold, Tsubaki
Renold, Tsubaki, PC
NTN, SKF, FAG
1450
25
2865
>
rpm
rpm
Nm (min)
1.5
7.5
KW
OTHER REQUIREMENTS
Page 1 of 1
WATER TUBE BOILER
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
WATER TUBE BOILER
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No.
QUANTITY / UNITS
GENERAL
Scope
SPECIFICATIONS
Quantity
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
WATER TUBE BOILER
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No.
K. 9
QUANTITY / UNITS
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
WATER TUBE BOILER
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No.
K. 9
QUANTITY / UNITS
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 authoritys 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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
ASH REMOVAL CONVEYOR

DELIVERY
REVISION No.
LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No.
QUANTITY / UNITS
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:
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
Casing:
Wear plate:
Screw
Shaft:
Shaft joint:
Hanger bearing:

Solid carbon steel
Conveyor Speed:
Drive System:
56
rpm

flexible coupling
Gear box:
Input speed:
Output speed:
Output torque:
Motor:Power:
Type:
2.2
KW
APPROVED MAKES
Motor:
Gear reducer:
Coupling:
Bearing:

FAG, SKF, NTN
1450
56
375
>
rpm
rpm
Nm (min)
1.5
Page 1 of 1
K. 11
1
GROUND FEED TANK
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
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
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
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE OIL PALM MILL
PREPARED
NW
SOFTENER BOOSTER PUMP

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
BOILER WATER FEED
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

Function:
To pump clarified water to the Softeners
SPECIFICATION
Type
Connection
Two ( 2 ) Softener Booster Pumps as follows :

OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Deleivery Head
Speed
NPSH available
60
water
ambient
1
60
2900
3
m3/hr
m liquid
RPM (Max)
m liquid
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
Power:
Type:
APPROVED MAKES
5.5 kw Vendor to advice

Pump:
Motor:
Coupling:
Bearing:
Robuschi, SIHI, Grundfos

NTN, SKF, FAG
OTHER REQUIREMENTS
Page 1 of 1
L 2.
2
DEAERATOR FEED TANK
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DEAERATOR FEED TANK
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
BOILER WATER FEED
ITEM No.
QUANTITY / UNITS
L 3.
1
GENERAL
Scope

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
Mild steel
80mm thk Rockwool insulation c/w gauge 0.7mm
aluminium sheet cladding
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
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DEAERATOR FEED PUMP

DELIVERY
REVISION No.
LOCATION
BOILER WATER TREATMENT
DRAWING NO.
ITEM No.
QUANTITY / UNITS
GENERAL
Scope

SPECIFICATION
Quantity
Type
Connection
Two ( 2 ) Deaerator Pump as follows :

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
Ns/m2
KPa
RPM (Max)
m liquid
Cast Iron GG-C25

Cast Iron GG-C25 or bronze
carbon steel
Gland Packing
Flexible
Power:
Type:
APPROVED MAKES
Pump:
Motor:
Coupling:
Bearing:
18 kw - Vendor to advice
Robuschi, Warman, MTP
NTN, SKF, FAG
OTHER REQUIREMENTS
Page 1 of 1
L 4.
2
DUPLEX WATER SOFTENER
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DUPLEX WATER SOFTENER

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY
L 5.
1
GENERAL
Scope

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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CHEMICAL DOSING PUMPS

DELIVERY
DRAWING NO.
REVISION No.
LOCATION
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
VACUUM DEAERATOR
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
VACUUM DEAERATOR
DELIVERY
REVISION No.
LOCATION
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
Construction

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.
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
VACUUM DEAERATOR
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
VACUUM DEAERATOR
DELIVERY
REVISION No.
LOCATION
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
Construction

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.
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
DEAERATOR EXTRACTION PUMP
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DEAERATOR EXTRACTION
PUMP
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
QUANTITY
GENERAL
Scope

SPECIFICATION
Two ( 2 ) Deaerator Extraction Pump as follows :
Type
Connection
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Deleivery Head
Speed
NPSH available
90
water
ambient
1
60
2900
3
m3/hr
m liquid
RPM (Max)
m liquid
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
Power:
Type:
11 kw - Vendor to advice
OTHER REQUIREMENTS
Page 1 of 1
L 8.
2
DIESEL SKID TANK
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DIESEL SKID TANK

DELIVERY
REVISION No.
LOCATION
DRAWING NO.
ITEM No.
POWER HOUSE
QUANTITY
GENERAL
Scope

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
Tank
Structural support
Mild steel
Mild steel
Nozzles:Uses
Diesel in
drain
Diesel out
Vent
Flanges:
Level Indicator:
Size
(mm)
100
50
50
100
Qty
1
1
1
1
Flange
PN 10
PN 10
PN 16
PN 10
Protrusion
(mm)
Material
## API 5L Gr B Sch 40

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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
OVERHEAD DIESEL SKID TANK
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
POWER HOUSE
DRAWING NO.
ITEM No.
QUANTITY
M 1.
1
GENERAL
Scope

Function:
To receive and store diesel oil for diesel generator
SPECIFICATIONS
Quantity
Capacity:
Basic Dimensions:
One ( 1 ) Overhead Diesel Skid Tank as follows:

18,000 litres
2,100 mm
4,200 mm
As per drawing
Tank
Structural support
Mild steel
Mild steel
Dia
SHL
Nozzles:Users
Diesel in
drain
Diesel out
Vent
Flanges:
Level Indicator:
Size
(mm)
100
50
50
100
Qty
1
1
1
1
Flange
PN 10
PN 10
PN 16
PN 10
Protrusion
(mm)
Material
150 API 5L Gr B Sch 40

Page 1 of 1
DIESEL UNLOADING PUMP
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DIESEL UNLOADING PUMP
DELIVERY
PREPARED
REVISION No.
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
OPERATING DATA
Capacity
Medium
Temperature
Specific Gravity
Deleivery Head
Speed
NPSH available
6000
Diesel
ambient
0.96
10
1500
3
lts per hour
m liquid
RPM (Max)
m liquid
CONSTRUCTION
Casing
Impeller
Shaft
Sealing
Wetted Parts
Coupling
Drive:
Motor:-
Cast Iron GG25

Cast Iron GG25
S.S AISI 304
Mech. Seal
S.S AISI 304
Flexible
Power:
Type:
approx. 1 kw Vendor to advice

OTHER REQUIREMENTS
Page 1 of 1
M 2.
1
BACK PRESSURE RECEIVER
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PREPARED
NW
BACK PRESSURE VESSEL

DELIVERY
REVISION No.
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
General Arrangement & Asembly:
O.D:
S.H.L:
Plate thickness:
Type of welds:
Material Standard:
Working Pressure:
Tolerance In term Of Straightness:
One ( 1 ) Back Pressure Receiver with components as follows :

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
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PREPARED
NW
BACK PRESSURE VESSEL

DELIVERY
REVISION No.
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

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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
BPR Controller
DELIVERY
PREPARED
REVISION No.
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
SPECIFICATIONS
Quantity
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DIESEL DAY TANK

DELIVERY
REVISION No.
LOCATION
POWER HOUSE
DRAWING NO.
ITEM No.
QUANTITY
GENERAL
Scope

Function:
To receive and store diesel oil for daily use of diesel

generator
SPECIFICATIONS
Quantity
Capacity:
Basic Dimensions:
One ( 1 ) Diesel Day Tank as follows:

1,500 litres
1.2 x 1.2 x 1.2 m
As per drawing
Tank
Structural support
Mild steel
Mild steel
Nozzles:Uses
Diesel in
drain
Diesel out
Vent
Flanges:
Level Indicator:
Size
(mm)
50
50
50
100
Qty
1
1
1
1
Flange
PN 10
PN 10
PN 16
PN 10
Protrusion
(mm)
Material

Page 1 of 1
M 5.
1
AIR COMPRESSOR
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
AIR COMPRESSOR
DELIVERY
REVISION No.
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
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DIESEL DRIVEN ALTERNATOR

150 KW
DELIVERY
PREPARED
REVISION No.
NW
LOCATION
DRAWING NO.
POWER HOUSE
ITEM No.
QUANTITY
GENERAL
Scope
Function:
SPECIFICATIONS
Quantity
M 8.
1

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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
DIESEL DRIVEN ALTERNATOR

350KW
DELIVERY
PREPARED
REVISION No.
NW
1
LOCATION
DRAWING NO.
POWER HOUSE
ITEM No.
QUANTITY
GENERAL
Scope

Function:
SPECIFICATIONS
Quantity
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
TURBINE DRIVEN
ALTERNATOR 1200KW
OIL PALM MILL
DELIVERY
PREPARED
REVISION No.
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
Function:
SPECIFICATIONS
Quantity
One ( 1 ) Steam Turbine drive 1200kw Alternator as follows :
Specifications.
The turbine shall be manufactures 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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
TURBINE DRIVEN
ALTERNATOR 1200KW
OIL PALM MILL
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
POWER HOUSE
DRAWING NO.
ITEM No.
M 10.
QUANTITY
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
TURBINE DRIVEN
ALTERNATOR 1200KW
OIL PALM MILL
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
POWER HOUSE
DRAWING NO.
ITEM No.
M 10.
QUANTITY
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
PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
TURBINE DRIVEN
ALTERNATOR 1200KW
OIL PALM MILL
DELIVERY
PREPARED
NW
REVISION No.
LOCATION
POWER HOUSE
DRAWING NO.
ITEM No.
M 10.
QUANTITY
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
GENERAL MACHINERY LAYOUT
02. FFB Loading Ramp.
FFB LOADING RAMP WITH CONVERYOR SYSTEM SIDE VIEW
03. FFB Conveyor Arrangement
FFB CONVEYOR ARRANGEMENT
04. FFB Cage
FFB CAGE ( cap: 7500 kg )
05. Cage transfer Carriage
CAGE TRANSFER CARRIAGE
06. Sterilizer Mobile Rail Piece
STERILIZER MOBILE RAIL PIECE
07. Sterilizer Vessel
STERILIZER VESSEL ( with double door, 2800mm dia. X 7 Cages of 7.5 mt FFB each. )
08. Sterilizer Section with details
STERILIZER SECTION WITH DETAILS
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 m )
24. Pure OIL Tank
24
PURE OIL TANK DETAILS ( cap: 30m )
25. Sludge Tank
25
SLUDGE TANK DETAILS ( cap : 30 m )
26. Sludge Settling Tank
26
SKIMMER DETAILS
SLUDGE SETTLING TANK ( cap: 20m )
27. Sludge Oil Recovery Tank
27
SLUDGE OIL RECOVERY TANK DETAILS ( cap: 150 m )
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 m )
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
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.
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.
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.
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.
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.
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.
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.
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)
For more complicated machinery the work orders / job cards need to be multiple and /
or in particular sections, i.e.:
MAINTENANCE WORK ORDER (Job Card)
Example as above for work order information with the following additions
for electrical
q wiring
q motor
q switch gear
for mechanical
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.
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
Thoroughly clean the machine.
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.
ROUNTINE MAINTENANCE.
2.1
Weekly
2.1.1
Check the systems 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.
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.
3.2
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.
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.
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.
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.
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 95C. The digester should be installed with
equipment such as the temperature control valve for steam injection to maintain the temperature
at 95C.
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 100C 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.
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 4245 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.
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 100C.
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.
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.
5.3 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.
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
Cylindric container
28/2
Temperature gauge
28
32/3
35
Cover and insulation
28
32/4
35
Steam piping
28/5
valves
28/6
Flanged T-piece
28/7
Steam trap
28/8
Pressure gauge with three-way-valve
28/9
Safety valve
28
32/10
35
Main shaft with nut
28/11
Pivot
28/12
Sleeve
28/13
Oil seal 60/80 x 10
28/14
Cover
28/15
Intermediate pipe
28/16
Intermediate pipe
28/17
Intermediate bipartite digesting arms
28/18
Base digesting arm
28/19
Base plate with seals
28/20
Bottom wearing ,Pate
28/21
Discharge cock 4
28/22
Discharge cock 2
28/23
Wear jacket
28/24
Wear jacket
28/25
Chute
28/26
Flat iron frame
28/27
Cover
28/28
Sight glass (Control opening)
28/29
Gasket 535/380 x 2
28/30
Gasket4lo/310x I
28/31
Gasket3lo/210x3
28/32
Shaft with fixing pins
28/33
Pinion
28/34
Rack valve
28/35
Flanged bearing with oil seal
28/36
Check ring
28/37
Chain wheel
28/38
Chain
28/39
Steam piping
28/40
Valve
28/41
Injectors
28/47
Split coupling (standard version)
28/48
Air vent
28/56
Hydro-flow coupling one side nave (standard version)
28/60
Coupling (special version) hydro-flow coupling;
28/61
double side nave (special version)
October 1990 Noel Wambeck
TWIN SCREW PRESS
TWIN SCREW PRESS
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
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
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
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
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.
TWIN SCREW PRESS
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
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
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 95C ) 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.
Remove the pulley circlip.
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
Remove the locknut and lock washer part No. 1020 + 1019.
Remove the cover plate part 1010 with oil seals.
Withdraw with care bearings No. 1021
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
OIL ON DRY FIBRE
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
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 / Q (
s -
l )] 0.5
where s and l are the densities of the solid and liquid respectively in g/cm3 , = 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 ( s - l )- 0.5
The above equations are unfortunately less successful in predicting the effect of changes in viscosity. Thus,
although the above equation shows
d50 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.
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
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.
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.
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
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.
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
3)
Fitting surfaces of both the large locking ring and bowl hood with molybdenum
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.
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
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
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.
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
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.
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.
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.
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 Vbelts 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.
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
0rings item 24
SIDE ELEVATIONS
PLAN VIEW
NUT CRACKER USE AND MAINTENANCE
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.
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
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.
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.
ROTOR ASSEMBLY PARTS LIST.
30th October 1999 Noel Wambeck
THE RIPPLE MILL USE AND MAINTENANCE.
The Ripple mill or de-hulling machine made its appearance in the oil palm mill in the late
1980s 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
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
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 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
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.
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.
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.
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.
10
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.
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
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.
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.
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.
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.
MAINTENANCE TERMINOLOGY
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.
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,
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
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.
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
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
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.
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.
10
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)
11
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.
12
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
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.
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.
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
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.
BEARING GLOSSARY
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.
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.
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.
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.
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.
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.
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.
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.
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.
10
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
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.
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.
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.
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
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.
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.
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:
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.
PUMPS MAINTENANCE
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.
PUMPS MAINTENANCE
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.
PUMPS MAINTENANCE
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.
PUMPS MAINTENANCE
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.
PUMPS MAINTENANCE
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
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...
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.
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?
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.
2.
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.
3.
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.
2.
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.
3.
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.
4.
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.
5.
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.
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
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.
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.
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
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.
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.
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.
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.
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.
Hardening of the elastomer
Charring of the elastomer, cracking, burned appearance
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.
Some easily overlooked causes for rubbing are:
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.
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.
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.
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.
10
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.
11
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.
12
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.
13
(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.
14
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.
15
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.
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.
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?"
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.
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.
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.
ROLLER CHAIN DRIVES INSTALLATION
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
1.5
2.5
Aligning Shafts
Aligning Sprockets
AC = Total Possible Mid-Span Movement

Depth of Free Sag = .866 AB, approximately.
ROLLER CHAIN MAINTENANCE.
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.
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.
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.
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.
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.
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.
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.
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.
ROLLER CHAIN DRIVE TROUBLESHOOTING
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.
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.
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.
Replace chain. Re-establish proper

lubrication.
Overload.

overload.
Extreme overload.
Replace chain. Replace sprockets if

indicated. Eliminate cause of overload or
redesign drive for larger pitch chain.
1
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.
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.
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.
Sprocket misalignment.
Chain pitch too large.
Too few sprocket teeth.
Wear on Inside of Roller Link Plates

and one side of Sprockets.
Chain Clings to Sprocket

Replace chain. Eliminate interference.

Tighten fasteners.
Retension chain..
Replace and retension 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 if needed.
Realign sprockets.
3 rd June 1999/ NW.
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 companys 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
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.
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.
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.
CHAINS TO BRITISH AND ISO STANDARDS
Complements of PRECISION CHAINS
STEAM AND CONVERSION TABLES
USEFUL CONVERSION TABLE
ELECTRICAL MOTOR SIZES, WEIGHTS AND SHIPPING SPECIFICATIONS

SYNOPSIS by Wambeck

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OIL PALM PROCESS SYNOPSIS

By Noel Wambeck. - June, 1999

Volume I OIL PALM MILL, SYSTEMS AND PROCESS

OIL PALM PROCESS SYNOPSIS

Volume 1 - OIL PALM MILL SYSTEMS AND PROCESS.

Continue next page >

OIL PALM PROCESS SYNOPSIS

A BRIEF OF THE WRITER's EXPERIENCE

TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL

SPECIFICATION FOR MACHINERY

MECHANICAL & ELECTRICAL DRAWINGS

Noel Wambeck June 1999.

OIL PALM PROCESS SYNOPSIS

A BRIEF OF THE WRITER's EXPERIENCE

WELCOME TO PRODUCTIVE MAINTENANCE

STORE AND PARTS MAINTENANCE

MAINTENANCE OF HYDRAULIC SYSTEMS

DIGESTER USE AND MAINTENANCE

TWIN SCREW PRESS USE AND MAINTENANCE

DECANTER FOR CLARIFICATION SYSTEM.

CENTRIFUGE OIL PURIFIER

SLUDGE CENTRIFUGE SEPARATOR

NUT CRACKING MACHINE

HYDRO CLAYBATH USE AND MAINTENANCE

GEARBOX & GEARMOTOR USE AND MAINTENANCE

MAINTENANCE GLOSSARY & TERMINOLOGY

COMPRESSED AIR TERMINOLOGY AND SYSTEMS

PIPE FITTING AND VALVE GLOSSARY & TERMINOLOGY

ROLLER CHAIN DRIVES

V-BELT INSTALLATION AND MAINTENANCE.

Noel Wambeck June 1999.

OIL PA LM PRO CE SS SYNO PSIS

Testing and Commissioning manual including specifications &

Oil palm mill maintenance manual including proprietary equipment

June 1999 Noel Wambeck.

A Brief on the writers experience.

Brief History of Oil Palm ( Its

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

THE HISTORY OF PLANTATIONS IN INDONESIA.

THE HISTORY OF PLANTATIONS IN INDONESIA

Period I. ( 1830 to 1870 )

THE HISTORY OF PLANTATIONS IN INDONESIA.

Period II ( 1870 to 1900 )

THE HISTORY OF PLANTATIONS IN INDONESIA.

Period III. ( 1900 to 1930 )

Period IV ( 1930 to 1940 )

THE HISTORY OF PLANTATIONS IN INDONESIA.

Period V. ( 1940 to 1950 )

Period VI. ( 1950 to 1970 )

THE HISTORY OF PLANTATIONS IN INDONESIA.

Period VII. ( 1970 to date )

Economic Products of the Malay Peninsula by I.H. Burkill dated 1935.

THE HISTORY OF PLANTATIONS IN INDONESIA.

OIL PALM MILL SYSTEMS & PROCESS

OIL PALM MILL, SYSTEMS AND PROCESS.

Commercially sound investment with state encouragement.

Practical Project Study Preparation.

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

OIL PALM MILL SYSTEMS & PROCESS

&THE REQUIREMENT OF A MODERN OIL PALM MILL.

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

To produce oil and kernels of the highest quality;

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

Designed for cost effectiveness for operation and maintenance.