INTRODUCTION

Industrial Background.
LSM (Layyah Sugar Mill) was establishing in 1964 start as a small industry. Now it
become a big industry of sugar. The industry will be start from sugar produce but
now a days it will be produce sugar and electrical power which sent to wapda grid
station. LSM located near G.C university layyah campus.

Organ gram of Industry.

LSM has these departments,

ADMIN DEPARTMENT
TECHNICAL DEPARTMENT
ACCONT DEPARTMENT

In technical department 3 major departments are electrical, mechanical and

instrument department.

Products of industry.
Major products of LSM are sugar and electrical energy. Waste material like ash and
cane waste juice also product but it is minority level. 9MW plant produces
electricity which sent to wapda.

TRANING WORK.
Machines installed in industry.

MOTORS
VFDs (variable frequency drives)
TURBINES
GENERATORS
BOILERS
VACCUM CIRCUIT BREAKERS
CRUCSHER (cutter)
UNIGRATOR
BOILING HOUSE
GRAIN DRUMS
CENTRIFUGAL MACHINES
CONVERE BELT AND PACKING

MOTORS.
Approximately 700 motors installed in total industry, some motors have heavy
rating and some are low rating. 1MW rating motor installed at cane crusher at new
mill house. 400KW motor installed at old mill crusher house. The purpose of both
motors is crusher or convert the cane in small pieces.
2 motors are installed in old mill house of 1MW rating each which seperate the
juice from cane. Old mill house other low rating motors also installed for different
purpose like seperate the outer shell of cane from juice and send it to boiler
through convear belt.
Similarly new mill house different power rating motors installed for different
purpose. But main purpose of new mill house is separate the cane shell to juice.
Boiling house is main part of LSM where boil the juice through steam which
produce in the 135 ton boiler (ton is the steam pressure). The coast of boiler
approx RS.70000000.
170 to 180 different power rating motors installed in boiling house. Its majority
rating 100KW each motor and its start with DOL starter.
Grain house make grain in boiling juice of cane. Here required high power motors
so here use 500KW rating motors and use some small motors for pumping
purpose. These big power motors start with star delta starter because load is high
on motors.
Centrifugal house is very important house of industry because it is final step where
sugar produse. Here 75KW motors installed and start with star delta starter. Here
these motors rotate the grains of sugar with high speed and produce final sugar
which pass through a standard sugar process.
Each motor of industry is connect with proper safety system like each motor have
VCB (vacuum circuit breaker) which protect the motor.

VFDs (variable frequency drives):

VFDs use for induction motor speed control because speed of
induction motors control with frequency.
N= 120f/p

So we change the rpm of motor with vfd. It is expensive method because vfd price
high and we need air conditioner for vfd cooling. Electronic circuits not proper work
at high temperature.

TURBINES:
Turbines are use for different purpose in sugar industry like operate with generator,
couple with unigrator, couple direct with rotating machines etc.
Majority of turbines use for generator moving purpose. Two turbines are use for
3MW and 6MW generator which provide supply to wapda and 2 turbines are
connected with two 16MW generators. One 16MW generator is off and other 16MW
generator supply to mill and colony.
1 new plant is in process of installing with turbine and generator import from India.
The power of this system is 26MW.
When this system installed then production of this system send to wapda (Mapco).
The new plan is grid station prepares for this system and 11KV convert in 132KV
then send to wapda.

GENERATORS:
3MW and 6MW generator use for provide to wapda supply. 16MW generator use for
colony and mill load. Another 16MW and 26MW which install process is plan to use
for wapda supply. All generators are coupled with steam turbines mean that steam
power plant. 26MW generator and turbine buy from india.

BOILERS:
Boiler is the main component where produce steam. Three boilers are use in LSM.
One big boiler 135 ton and other two are 50 ton capacity. The capacity of boiler in
ton actually steam pressure which provide us boiler. The capacity of boiler always
mention in tons. The height of 135 ton boiler is 45 to 50 feet. 135 ton boiler run
those turbines which supply to wapda mean that 9MW. Other two boilers run 16MW
generators turbines which provide supply to mill and colony load.

VACCUME CIRCUIT BREAKER:

All the mill load connect through VCBs. It is a protection device. The wapda supply
also pass through the VCBs. Mill load VCBs operate at 6.6KV but our generator
produce 11KV power, so we use step down transformer and convert 11KV in to
6.6KV. But wapda supply pass through 11KV breaker and our generation is 6.6KV
so we use step up transformer and convert to 11KV and then operate VCB.
VCBs consist at relays, timers, connecters,av meters, small circuit breakers, star
delta stators and on off buttons.
We connect and disconnect the VCB through push pull button and use also open
trolley which situated below the VCB.

We use VCB here because

Low price.
Low weight.
Low size.
Connect and disconnect easy compare as OCB.

These are the general electrical equipments which are using in LSM. Now we
discuss the other parts of mill which are related to mechanical also.
It is the process how sugar makes through major steps.

CRUCSHER (cutter):
Crusher converts the cane in to small pieces for easy process. Here heavy rating
motor used which move to crusher cutter blades. These blades have very Sharpe.
After cutting cane move with a conveyer in unigrator.

UNIGRATOR:
Unigrator is a total mechanical machine which moves through a steam turbine. We
not use motor here because unigrator have a big load and motor cannot move this
load for a long time properly.
The basic purpose of unigrator is small pieces of cane convert in to very small size
like grains or waste material and separates the juice of cane from waste material.
The cane juice go in to drums and pumps suck the juice and flow in to pipe with
pressure, then juice go in to boiler house.

BOILING HOUSE:

Boiling house provide heat to juice. Steam come here from boiler and this steam
heated to the juice and water flew up in the form of evaporate from juice. Now this
juice is ready for sugar making process.
Steam and juice come in boiling house and go in to next process through motor
pumps. 170 to 180 motors are installed in boiling house and these motor rating is
100KW rating.

GRAIN DRUMS:
This stage is very sensitive stage because here make little grains of sugar which
test with microscope. The grains made in juice with a special ratio, this is also a
chemical stage. Some chemicals are used in this stage with a percentage.
Here we use big drums and heated use come in drums and flow one drum to other
drum. So the juice travels in different drums which situated in line.

These drum not fill at all full capacity, approximately 30 to 40 % fill. The motors
rotate the gears which connected with the drum rotor actually. The juice rotates in
the drums.

CENTRIFUGAL MACHINES:
This stage is last stage where sugar is ready. The grains come in to centrifugal
machines and these machines rotate the grains with high speed and mix some
chemicals in sugar. After 7 to 10 mints sugar ready for use.

CONVERE BELT AND PACKING:

After sugar prepare it pass through a vibrating machine which separate big and
weak or very small grains. Big grains are a good quality sugar. Then it will be pack
50Kg, and send in to stores for sell.
At the corner make some pounds to store waste or bad cane juice which is also for
sell. And some plane place is free for ash store and after sells it to.

Maintenance schedule:
Duration of maintenance in off season 7 to 8 months. In this maintenance every
part of machines separate completely and wash it carefully and then fit it again.
On daily basis maintinance is also part of maintenance schedule. If small problem
occurs in motor or machine then urgently solve this problem because production

depends on each machine. If create a big problem like burn winding of motor then
its motor replace with back up and this motor send in workshop for winding.