Technical Specs For Sugar Plant Sugauli - Final

Doc No.
: GDP/EPC-BID-S/09-10/023(F)
Date : June 8, 2009
Assign No. : GPD/SDE/HPCL/08-09/045
Date : September 12, 2008
ENGINEERING, PROCUREMENT & CONSTRUCTION
(EPC) BID DOCUMENT
3500 TCD Capacity Sugar Plant
Village Sugauli, District East Champaran, Bihar
Technical Specifications
Prepared For
Hindustan Petroleum Corporation Ltd. (HPCL)
(A Govt. of India Enterprise)
Petroleum House, 17, Jamshedji Tata Road,
Mumbai 400 022
Prepared By
MITCON Consultancy Services Ltd. (MITCON)
Kubera Chambers, Shivajinagar
Pune - 411 005
June, 2009
EPC Bid Document for Sugar Plant at Sugauli, Dist. East Champaran, Bihar, Technical Specifications
Doc No. : GDP/EPC-BID-S/09-10/023(F)
Date : June 8, 2009
EPC BID DOCUMENT
CONTENTS
Chapter No. Title Page No.
1. Intent of Specifications 1
2. Project information 2
3. Design Basis, Scope of Supply, Services & Terminal
Points
5
3.1 Design Basis 5
3.2 Scope of Supply 7
3.3 Services 10
3.4 Terminal Points 11
4. Technical Specifications 15
4.1 Cane un-loading / loading 15
4.1.1 Weigh Bridges 15
4.1.2 Cane Un-loading & Handling 15
4.2 Cane Preparation 20
4.2.1 Cane Stabilizer & Density Enhancer 20
4.2.2 Cane Cutter 21
4.2.3 Swing Hammer Type Heavy Duty Cane Fibrizor 22
4.2.4 Rake Cane Carrier 23
4.2.5 Auto Cane Feed Control System 24
4.2.6 DSM Screens for RJ 26
4.3 Cane Diffusion 26
4.3.1 De-watering Mills 26
4.3.2 Rake Type Intermediate Carrier (RIC) after Diffuser 29
4.3.3 Mill Auxiliary System 31
4.3.4 Cane Diffuser 36
4.3.5 Bagasse Elevator 38
4.3.6 Mass Flow Meters 39
Date : June 8, 2009
EPC BID DOCUMENT
CONTENTS (CONTD.)
4.4 Sugar Process House 40
4.4.1 Juice Heating & Clarification 40
4.4.2 Sulphur Furnace 42
4.4.3 Air Blower Fans 43
4.4.4 J uice Sulphiter & Auto pH Control System 43
4.4.5 Syrup Sulphitation 44
4.4.6 Milk of Lime Preparation 45
4.4.7 Juice Clarifier 45
4.4.8 Rotary Vacuum Filter 46
4.4.9 Juice Evaporator Station 47
4.4.10 Online Conductivity Measurement 50
4.4.11 Syrup & Molasses Storage Tanks 50
4.4.12 Molasses Conditioning Units 51
4.4.13 Automatic Brix & Temperature Control Equipment,
Molasses Conditioners
51
4.4.14 Batch Type Vacuum Pans 52
4.4.15 Seed & Vacuum Crystalizers 55
4.4.16 Condensers 55
4.4.17 Injection & Spray Water Pumps 56
4.4.18 Spray Nozzles & Pond 57
4.4.19 Cooling, Curing & Grading Plant 57
4.4.20 Centrifugal Machines 58
4.4.21 Pug Mills, Magma Mixers & Transient Heaters 60
4.4.22 Air Compressor & Magma Pumps 61
4.4.23 Sugar Melter, DSM Screen & Dry Seed Conveyor 61
Date : June 8, 2009
EPC BID DOCUMENT
CONTENTS (CONTD.)
4.4.24 Automatic Brix & Temperature Control Equipment, Sugar
Melter
62
4.4.25 Grass Hoppers, Sugar Elevator, Sugar Grader & Dust
Catcher
62
4.4.26 Fully Automatic Sugar Silo & Weighing Machines 64
4.4.27 Molasses weighing, Final Molasses Tanks & Water Tanks 64
4.4.28 Sugar Go-downs 66
4.4.29 Water Conservation & Circulation 66
4.4.30 Miscellaneous Equipment 66
4.4.31 Supporting Structure & Material Specifications 69
4.5 Other General Design Criteria 70
4.6 Interface Piping 75
5. Energy Efficiency Improvement 78
5.1 Steam Consumption 78
5.2 Power Consumption 79
6. Electrical Distribution System 81
6.1 General Design Basis 81
6.2 Scope of Work 86
6.3 Diesel Generating Set 87
7. Control & Instrumentation System 89
7.1 Introduction 89
7.2 Statutory Requirements 89
7.3 DCS based Automation 93
Date : June 8, 2009
EPC BID DOCUMENT
CONTENTS (CONTD.)
8. Ci vil Works 94
8.1 General 94
8.2 Design Philosophy & Criteria 94
8.3 Buildings & Civil Works 114
8.4 Important & Common Notes 124
9. Spares 126
10. Inspection & Testing 127
11. Drawings, Data & Information 128
12. Guaranteed Performance Parameters 129
12.1 Cane Preparation, Milling & Diffusion 129
12.2 Clarification 129
12.3 Evaporation & Boiling Section 130
12.4 Cooling, Curing & Grading of Massecuite 131
12.5 Reduced Boiling House Recovery 132
12.6 Steam Consumption 132
12.7 Power Consumption 132
12.8 Performance Trial Period 132
12.9 Input & Output Flow Rates 133
12.10 Performance Parameters for Bank Guarantee 134
Date : June 8, 2009
LIST OF APPENDICES
Appendix No. Title
I Schedule for dismantling of existing buildings & civil works
II List of Approved Makes
III Data Sheets & Drawings to be Submitted by the Tenderers
IV Sketches & Drawings
V Indicative Steam & Condensate Balance
VI Indicative Material Balance & Flow Chart
VII Indicative Water Balance
VIII Condenser Water Cooling System
IX Indicative Continuous Evaporation System with Extensive Vapor
Bleeding
X General Construction Specifications
XI List of Workshop Equipment
XII List of Spares
XIII Preliminary Plant Layout, Integrated Sugar, Ethanol & Cogen Power
Project
XIV Terms & Conditions for Erection & Commissioning
1
Chapter 1
Intent of Specifications
The main intent of the specifications has been to define the equipment, electrical,
auxiliaries and civil works for the proposed 3500 TCD capacity modern technology based
& efficient sugar plant, being set up co-extensively with 60 KLPD ethanol plant and 20
MW high efficiency grid connected cogen power plant, at Sugauli in East Champaran
district of Bihar State, as well as for undertaking demolishing work of existing buildings
& civil works at the project site.
The sugar plant will be equipped with energy efficient equipment in all sections and will
in-house commer cially pr oven diffusion pr ocess for optimum juice extr action, for
diver sion of 50% juice to ethanol plant and balance to sugar pr ocess house for
manufacturing white plantation sugar.
The intent of the specifications also has been to achieve continuous and efficient
operations throughout the crushing season of the cane preparation, diffuser and the
boiling house sections. This will provide continuous un-interrupted supply of bagasse to
the concurrent cogeneration power plant and supply of 50% juice to the concurrent
ethanol plant.
The main goals set are as under:
(a) Providing specific equipment, associated systems, electrical distribution system
a nd a ssocia ted civil wor ks, ma inly to achieve the tar geted cr ushing rate,
ext r a ct i on a nd boi l i ng house effi ci enci es a nd l owest stea m a nd power
consumption of the sugar plant, as well as achieve continuous operation.
(b) The design basis for selection of all equipment will consider average crushing rate
of 150 TCH (or 3600 TCD) on 24 hr basis.
(c) Achieving targeted electricity consumption for the sugar plant of 19 kWh / MT,
with electrical by dr iven cutter , Fibrizer and de-watering mill and total steam
consumption of 22% on cane for 50% capacity of sugar processing house, at
average crushing rate of 150 TCH (or 3600 TCD) on 24 hr basis.
(d) Demolishing of existing buildings & civil wor ks at the pr oject site (Refer
Appendix I).
2
Chapter 2
Project Information
Name and Address : DGM (Pipeline Projects)
M/s. Hindustan Petroleum Corporation Ltd.
(A Govt. of India Enterprise)
8, Shoorji Vallabhdas Marg
Ballard Estate, Mumbai 400 001
Ph : 022 2263 7153, 2265 4110 (D)
Fax : 022 2263 7184
E-mail : rln@hpcl.co.in
Project Site : Near Village Sugauli,
District East Champaran, Bihar
Constitution & Type : A Government of India Enterprise
Project Title : En gi n eer i n g, Pr ocu r emen t , Con st r u ct i on &
Commissioning of Sugar Plant at the Project Site
EPC Consultant : MITCON Consultancy Services Ltd.,
" Kubera Chambers" , 1
st
Floor
Shivajinagar, Post Box No. 923,
PUNE-411005, (INDIA)
Ph. No.: 020 2553 3309 / 2553 4322
Fax No.: 020 2553 0305 / 2553 3206
Products : White Plantation Sugar & mixed juice for Ethanol
(co-extensively with 60 KLPD ethanol & 20 MW
Co-generated Power plants)
3
Project overview : This EPC bid is invited for dismantling of existing
buildings and civil works at the project site, as well
a s f o r design, engi neer i ng, ma nufa ct ur e,
procurement, supply, transportation to site, transit
and stor age, insur ance, stor ing at site, pr oject
ma na gement , ci vi l wor ks, mecha ni ca l wor ks,
el ect r i ca l wor ks a n d I & C wor ks, er ect i on ,
installation, testing, commissioning, performance
testing, putting into successful commercial operation
and handing over of 3500 TCD sugar plant as
specified, so as to achieve targeted crushing rate of
150 TCH and steam and power consumptions of 22
% on cane for 50% sugar process house capacity and
23 kWh/MT respectively, at average crushing rate of
150 TCH (peak 167 TCH) on 24 hr basis.
Installed Capacities of the
Integrated Project
: 3500 TCD, on cane diffusion process & 1750 TCD
for sugar process house (average 130 crushing days
per season)
Site location : Near Sugauli town
Distance from nearest town /
city
: Sugauli, 2 Km
Di s t a n c e f r om n e a r e s t
railway station
: Sugauli, 0.5 Km
Motihari, 25 Km
Distance from nearest airport : Patna, 185 Km
Distance from nearest water
source
: Gandak River, 2 km
Distance from nearest BSEB
EHV substations
: Sugauli, 33 KV (2 Km) & Bettiah (132 KV), 20 Km
Annual Rainfall : 1241 mm
Ambient air temperature
Maximum
Minimum
:
:
46
0
C
5
0
C
Data for Seismic Design : Zone IV
Relative Humidity : 70% (average)
Climatic Conditions : Tropical, dry & arid
4
Design wind pressure : In accordance with provisions of Indian Standards
IS:875.
De s i g n c o o l i n g wa t e r
temperature
: 32
0
C
Soil characteristics at site :
Iso-ceramic level (No. of
stormy days/year)
: 20
Construction power & water : Constr uction power and water is in the scope of
vendor.
5
Chapter 3
Design Basis, Scope of Supply, Services & Terminal points
3.1 Design Basis
3.1.1 Manually har vested, whole, loose & entangled cane supply by bullock-carts,
tractor-trailers and trucks up to cane carrier, with side tippers and grab un-loaders
for trailers & trucks, in line with general practice in the State of Bihar.
3.1.2 Average cane crushing rate of 3500 TCD or 150 TCH will be achieved with Cane
Diffusion Process.
3.1.3 Optimum capacity utilization efficiencies at all sections will be achieved with the
help of equipment like suitable cane magnets, Cane flow Stabilizer & Density
Enhancer (CSDE), high efficiency de-watering mill, continuous cane diffusion
and continuous evaporation station (with two separate evaporator sets, one in
operation and one set always standby).
3.1.4 Pol extraction efficiency of +98.5%.
3.1.5 Automatic juice proportioning device for screened mixed juice at the outlet of the
diffusion process to transfer 45-50% of Mixed J uice (MJ) to sugar process house
and balance 50-55% to the Ethanol Plant.
3.1.6 Double sulphitation clarification process.
3.1.7 Reduced Boiling House Efficiency (RBHE) of +91.5%.
3.1.8 High efficiency evaporators and vacuum filters, with optimum no. of pumps in
operation and gravitational discharge of press mud (for dir ect loading in the
trailers from the vacuum filters).
3.1.9 Suitable gravity flow type vacuum pan station.
3.1.10 Batch type vacuum pans for A, B and C massecuite.
3.1.11 Total Steam and power consumptions respectively of 22% on cane and 19 kW/
TCH.
3.1.12 Filtrate juice treatment with Vibro screens or direct transfer to the Ethanol plant.
3.1.13 DSM screens for Sugar Melt filtration.
6
3.1.14 Syrup and melt clarification to achieve very high sugar qualities (optional process
may be quoted separately).
3.1.15 Fully automatic 3-bins system for sugar silos, with minimum 12 hours storage
capacity.
3.1.16 Use of optimum quantity of condensate within the sugar plant to ensure zero
water discharge, with pr ovision to tr ansfer excess good condensate to cogen
power plant, Ethanol and Bio-composting.
3.1.17 Sugar plant layout with optimum space for movement of men & materials.
3.1.18 DCS based automation system for entire sugar plant.
3.1.19 Total maximum electrical load of 2850 KW, at average crushing rate of 3500
TCD or 150 TCH on 24 hr basis (16 KW / TCH or 1800 KW for cane preparation
/ diffusion / de-watering mill section and 12 KW / TCH or 1050 KW for sugar
process)
3.1.20 11 KV for fibr izor motor s, 660 V for thyr istor contr olled DC motor for de-
watering mill and 440 V for all other applications.
3.1.21 Design consideration for selection of electrical equipment, power supply & power
distribution are indicated below:
Ambient temperature : 50 C
Humidity : 90%
Altitude : >1000 M above MSL
System Fault Level : 40 kA for 1 Sec. for 132kV system
: 40 kA for 1 Sec. for 11kV system
: 50 kA for 1 Sec. for 415V system
: 9 kA for 1 Sec. for lighting circuits
132 kV + 10%, 50Hz + 5 %, 3 Phase for Grid Connection
11 kV + 10%, 50Hz + 5 %, 3 Phase for Generation and Power Supply
to 11KV Eqpts.
660V + 10%, 50Hz + 5 %, 3 Phase for Mill Drives in Sugar Plant
415 V + 10% , 50Hz + 5 % , TPN for plant load operating at 415V
supply
Control Voltage 110V AC, 50Hz for MCCs and PCCs
Power Supply for Space Heaters, Plug Sockets, Lighting : 230 V,50 Hz,
1Ph.
Power Supply for Tripping and Closing Circuits of Circuit breakers :
110 V, D.C.
7
Power will be generated at 11KV, 3Ph, 50Hz with Steam Turbine. Power
will be stepped up to 132KV for Grid Connection and Evacuation to
BSEB
11kV power supply will be given to Sugar Plant Switchboard. Further
downstream power distribution will be done in Sugar Plant
11kV/433V distribution transformers are provided to cater power to 415V
rated equipments in plant
230 V Single phase power supply shall be der ived thr ough Phase &
Neutral for single phase power consumer
3.2 Scope of Supply
3.2.1 General
The scope of wor k will include design, engineering, manufacture / procure,
supply, erection and commissioning of equipment, associated systems, internal
electrical distribution system and associated civil works for the entire sugar plant,
as detailed hereunder for achieving the guaranteed performance parameters
specified for each section and for steam & power consumptions. The Contractor
wi l l a l so n eed t o compl et e a l l a ssoci a t ed el ect r i ca l , mech a n i ca l a n d
instrumentation work required for installation, commissioning of the entire
equipment, and proving the performance at site.
The contractor will also be responsible for dismantling of all defined existing
buildings & structures at site, prior to installation of equipment under the scope.
The Contractor will be responsible for providing an efficient, reliable and state of
art technology equipment. The specifications in this section, attempt to define the
scope and specifications. However , the onus of pr oviding the appr opr iate
equipment and auxiliaries for successful commissioning, performance proving
and operation, entirely rests with the Contractor.
The scope of work for the equipment, associated systems and civil works covered
under the specifications will include, but not limited to the following.
(a) Design, engineering, supply, fabrication, manufacture, assembly, shop
t est i n g a n d i n spect i on a t ma n u f a ct u r er ' s wor ks, er ect i on a n d
commissioning
(b) Providing all labourers, materials and equipment for testing at shop / site,
as required.
(c) All spare parts required for the commissioning.
8
(d) Spare parts required for two (2) years of trouble free operation
(e) Special tools and tackles r equir ed for oper ation and maintenance,
inspection, and repair of the equipment / systems offered.
The specifications are intended to cover the design, engineering, manufacture /
procure, supply, er ection, testing and commissioning of entir e sugar plant
equipment, associated systems, electrical distribution system, necessary piping /
supports / valves / instruments, DCS based control & instrumentation system,
necessary structures and civil works.
Supplies and services shall be rendered in conformity with proven engineering
pr inciples, taking into account the cur r ent state of the ar t technology. The
requirements of the contract must be fulfilled in its entirety.
The supplies and services within the scope shall be rendered inclusive of all
appliances and interconnecting arrangements with other supplies, necessary for
installation of all accessories and for satisfactory operation, maintenance and
repair.
The scope of supply and services shall include all necessary work and supply of
equipment and material whether mentioned in these specifications or not, but
which are necessary for the satisfactory, reliable, safe operation, maintenance and
required for achieving guaranteed performance parameters.
Any equipment, devices or material even if not included in this EPC bid, but
found necessary for the safe and satisfactory functioning of the unit under this
EPC bid, shall be supplied, erected and commissioned by the Contractor at no
extr a cost to the Owner , as though, such equipment, mater ial or wor k wer e
originally specified and formed part of the scope of work.
3.2.2 Major Equipment
(a) Weigh br idges, cane un-loading & handling arrangements, cane feed
tables, cane carrier s, pr epar ator y devices like cane flow stabilizer &
density enhancer , cane cutter , swing hammer type heavy duty cane
fibrizor, rake cane carrier, auto cane feed control system, DSM screens for
raw juice, etc.
9
(b) Cane diffusion process including efficient standard vertical head stock
type de-watering mill equipped with 3 rollers type GRPF, Donnelly type
chutes, rake type intermediate carriers and drive arrangements, DC motor
for mill drive with thyristor converter station, mill gearing trains, open
gear and pinion, perforation like lotus for mill and GRPF rollers except
top roller, remaceration juice equipment and mixed juice pumps, water
flow meter for imbibitions water, hot water imbibitions pumps, automatic
imbibitions water flow and temperature control system, mill house crane
& gantry, etc.
(c) Cane diffuser and all accessories like bed plate, enclosure, feeder drag
conveyor, slide gates, side and end wall panels, juice collecting trays, juice
scalding pr ocess equipment, per for ations on fixed bottom scr eens,
loosening screws for moving bagasse mat, counter current extraction, un-
screened & screened juice pumps, self rotating drum press, de-juicing rake
inter carrier with perforated bottom and trough, de-watering mill, milk of
lime dosing system, chain cleaning & greesing arrangement, re-circulation
r emacer ation juice pumps, lagging & cladding, dr ives for var ious
accessories, automation & instrumentation, etc.
(d) On-line mass flow meters for mixed juice, juice heaters, sulphur furnace,
air blowers, juice & syrup sulphiters, sulphur burning furnace, air blower
fans, juice sulphiter and automatic pH contr ol system, milk of lime
preparation, clarifier and vacuum filters, juice evaporator station with
quintuple effect evapor ator and extensive vapour bleeding, on-line
conductivity measurement, syrup and molasses storage tanks, molasses
conditioning units, automatic brix and temperature control system, batch
type vacuum pans with automation, seed and vacuum cr ystallizer s,
condensers, injection and spray water pumps, spray nozzles and pond, etc.
(e) Crystalizers, fully automatic flat bottom type centrifugal machines for A
massecuite, continuous centr ifugal machines for B & C massecuite,
transient heaters, hot monorail crane, pug mills & magma mixers, air
compressor & magma pumps, sugar melter, DSM screen and dry seed
conveyor, automatic brix and temperature controller for sugar melter, dry
seed conveying system, etc.
(f) Grass hoppers, sugar elevator, sugar grader, sugar dust catcher, fully
automatic sugar silo and weighing machines, molasses weighing scale,
final molasses and hot / cold water tanks, sugar go-downs, ground water
conservation and re-circulation system, etc.
10
(g) Miscellaneous equipment including pressure reducing and de-superheating
systems, headers and valves, bagasse baling machines, all juice / vapor /
ma ssecuite / stea m / wa ter / condensa te pipelines a long with a ll
accessories / supports / instrumentation, insulation & lagging, DG set for
emergency power, effluent treatment plant.
(h) All steam and power consumption reduction equipment for achieving the
related guaranteed performance parameters.
(i) Water supply & distr ibution equipment for 6000 KL / day capacity
including jack well, pumps, piping up to main water stor age tank,
distribution header outside the storage tank, including all accessories,
supports, etc.
3.2.3 Electrical Distribution System
All internal electrical distribution system within the sugar plant for 11 KV, 660 V
and 440 V systems including power & control cables, accessories, earthing &
l i ght eni ng pr ot ect i on s, a l l ma n da t or y safety devices, instr umentation,
illumination, etc. will be included in the contractor s scope.
3.2.4 Control & Instrumentation
All necessary control & instrumentation equipment for efficient operation of the
proposed sugar plant equipment, associated systems and electrical distribution
system or other wise for the entir e sugar plant, will be in the scope of the
Contractor.
3.2.5 Civil Works
All necessary civil works including foundations, structural, earth work, etc.
requir ed for installation of the pr oposed sugar plant equipment, associated
systems and electrical distribution system will be in the scope of the Contractor.
The Contractor to arrange for local statutary requirements / approvals for civil
structures / buildings.
3.3 Services
3.3.1 Design and Engineering
(a) Preparation of design calculations and detailed drawings
(b) Preparation of BOQ
(c) Preparation of manufacturing drawings
11
(d) Preparation of quality assurance and inspection plans and implementation
schedule.
(e) Preparation of schedule for site testing and commissioning.
3.3.2 Erection & Commissioning
(a) Inspection of civil work in foundations, trenches and allied jobs.
(b) Unloading, unpacking, shifting to locations, positioning, aligning and
fixing of equipment which are included in contract
(c) Pre-commissioning checks.
(d) Commissioning , testing and trials runs and performance proving
(e) Completion of documentation and records.
3.3.3 Statutory Approvals
(a) Obtaining approvals and all licenses on drawing and designs from local
authorities, as required.
(b) Arranging inspections and approvals for commissioning of plant electrical
from Local authorities and Chief Electrical Inspector.
(c) Obtaining permission from Irrigation Department, Govt. of Bihar for
lifting required quantity of water , as well as required permissions from
agencies like road, PWD, railway, etc. for laying the line
3.3.4 Inspections / Review Meetings
(a) Making the arrangements for periodical and final inspection of all major
equipment at own or sub-contractor s works.
(b) Attending the periodical review meetings at site or at the agreed locations.
3.4 Terminal Points
3.4.1 Sugarcane
At the weigh bridge inlet of the cane carrier
12
3.4.2 Raw water
At the specified intake point at the nearby Gandak river
(Contractor s scope covers suitable water lifting scheme, pumps, pipelines, valves
/ fittings, gr ound water r eser voir , common distr ibution header , r aw water
reservoir, raw water transfer pumps & accessories, pipeline from reservoir up to
sugar plant and internal water distribution, including all fittings / supports /
valves, etc. for 6000 m3/day water supply / storage / distribution. The Contractor
also to arrange water supply from bore wells at defined locations and storage
facility for 8-10 days).
3.4.3 Screened & Mixed Juice
At the discharge end of juice mass flow meter (after proportioning device & juice
transfer pumps, including valve), located in the diffusion section, for transfer of
50-55% of juice to ethanol plant (balance 50-45% of juice to be transferred to
sugar process house by the Contractor).
3.4.4 Steam supply
At the LP header of cogen power plant located at 1.5 m level beside the
powerhouse building, towards the sugar plant side.
(Contractor s scope covers LP steam pipeline from LP header of cogen power
plant up to sugar plant and internal distribution pipelines, including all flanges,
valves, accessories, supports, etc.)
3.4.5 Power supply
At 2 nos. 11 KV feeders identified in 11 KV switchboa r d in cogen pla nt TG
building.
(11 KV (UE), XLPE insulated aluminium conductor cables from cogen power
plant up to the sugar plant, 11 KV incomer panel & switchboard for cutter /
fibrizor motors to be located suitably, related protections including VCB panel,
etc., 11 KV network near main gate for power supply to colony, 11 K V /
440 V distribution transformers and 440 V internal power distribution system
including related panels / switchboards / starters / cables / protections, 11 KV /
690 V converter transformers, thyristor control panels and related distribution
system including panels / switchboards / starters / cables / protections, etc. for DC
motor & all earthing will be in the contractor s scope).
13
3.4.6 Compressed air
Necessary size compressor & accessories, distribution header & pipelines, valves,
fittings, etc. required for the sugar plant included in the contractor s scope.
3.4.7 Consumable such as Lime, Sulphur & Chemicals
Quicklime powder / liquid and phosphate at the storage sheds suitably located in
the sugar plant. Sulphur powder at the sulphur shed suitably located in the sugar
plant.
3.4.8 Imbibition Water
At the discharge valve of hot water overhead tank of condensate water in the
sugar process house (entire hot water circulation pipelines, pumps, accessories
included in the Contractor s scope).
3.4.9 Bagasse
At the discharge chute of the bagasse elevator
3.4.10 Molasses
At the delivery header of the molasses transfer pumps, near the molasses storage
tank located in sugar plant.
3.4.11 Condensate
At the outlet header of condensate transfer pumps, including valve, located in the
sugar process house.
3.4.12 Filter Cake
At the discharge chute end, below the vacuum filters
3.4.13 White Plantation Sugar
At the outlet of sugar stacker in the sugar go-downs
3.4.14 Effluent
Up to one point in the nur ser y plantation ar ea, tr eated effluent meeting the
BSPCB norms.
14
3.4.15 Civil Works
Entire civil works & structural in the sugar plant area along with civil works for
jack well, foundations for pumps / distribution pipelines, water storage tank, bore
wells, etc. will be in the Contractor s scope. Also, the demolishing of all existing
structures / buildings at site and removal of all debris at the entire site will be in
the Contractor s scope(for all the upcoming plants, about 65 70 acres area).
15
Chapter 4
Technical Specifications
4.1 Cane Un-loading / Loading
4.1.1 Weigh Bridges
The weigh bridges will be pit mounted, fully automatic electronic, load cell type,
along with digitized software control. The specifications of required weighbridges
will be as under:
Nos. Capacity, MT Platform Size, m x m
1 50 16 X 3
2 30 16 X 3
3 5 4.8 X 2.4
Weigh bridge units will be along with platforms, suitable compression type load
cells, suitable junction boxes, digitizers, screened cables and standard weights for
calibration (Contractor to give performance guarantee for two crushing seasons
for trouble free operation).
4.1.2 Cane Unloading & Handling
Equipment / Machinery Capacity, Nos. &
type
Remarks
Cane Un-loading Bridge 2 Nos. 2-motion type
Cane Un-loading Gantry 10m lift, 30 m span
& 40 m length
According to local situation
Cane Un-loading
trolleys
5 MT each x 4 Nos. Capacity of cane un-loading
trolley will depend on the
type of cane loading in the
vehicles
Lifting crane bar / grab Will depend on loading of
cane in the vehicles
16
The cranes shall be of 2-motions electrically operated, overhead type unloading
cranes, conforming to Class IV IS specifications and capable of 20 lifts per hour.
In each lift, sling bar shall lift at least 4 MT cane and grab shall lift at least 3 MT
cane. The cr ane shall be complete with its accessor ies, gantr y columns &
attendant plat-form, along the length of the gantr y on both sides, 2 Nos. cat-
ladders, etc.
They shall be heavy-duty type and suitable for continuous outdoor working. All
operations shall be electrically controlled from the operator' s fixed cabin. The
crane gantry span shall be 30 meters. The crane gantry shall be 40 meters in
length, with gantry columns 10 meters apart.
The bridges shall be of box type construction made of IS 2062. Gantry columns
shall be L shape constr uction but the 4-end columns should have double L
construction at 90 deg. End columns shall be provided with the tie beam on each
end.
The applicable design codes will be IS 3177 & 807. All electric motors shall be
of crane duty, with T.E.F.C. enclosures suitable for 300 operations per hour and
will have following specifications:
Particulars Type of motor kW Rating Duty
Hoisting Drum Drive Squirrel cage 20 1 hr. S4
Holding Drum Drive Squirrel cage 20 1 hr. S4
Long travel drive Slip ring 7.5 hr. S4
Cross travel drive Slip ring 4.0 hr. S4
For operation of these motors, push button type panel shall be provided and its
location shall be in the cabin attached to the trolley. The following speeds shall be
provided for various motions:
Operation Speed
Hoisting 12 meters/minute
Holding 12 meters/minute
Long Travel 15 meters/minute
Cross Travel 15 meters/minute
The sling bars and hydraulically operated grabs shall be provided for quick and
fast operations, according to local arrangements of loading of sugar cane in
vehicles.
17
The height of the lift shall be 10 meters. All gear boxes shall be totally enclosed,
dust proof, helical type gear and shall be designed with a service factor of 2.0. All
couplings shall be of flexible gear type with periodically greasing arrangement.
All brakes shall be of electro-hydraulic thruster operated type. Ratio of the pulley
dia (PCD) to wire rope dia shall not be less than 20. The crane shall be provided
with grab attachment. Suitable sheds shall be provided on the trolleys.
Cane Feed Tables
4 nos. cane feeder tables of minimum 6-meters width and 7 meters in length shall
be installed at right angle to the cane carrier; two on RHS and two on LHS of
cane carrier no. 1.
Each feeder table shall be of all steel construction fitted with 8 strands of 150-mm
pitch heavy-duty steel drag type chains having breaking strength of minimum
40,000 kg. The feeder table shall be complete with cast steel sprocket wheel
having machine cut teeth (tips of sprockets shall be chamfered sharp for easy
engagement even with little misalignment), shafts, bearings etc. The feeder table
shall be driven by a 10 kW, VFD AC motor so as to provide speed regulation
from 1 to 3 meters/min.
The feeder table shall be suitably suppor ted on steel str uctur e designed to
withstand heavy shocks. The tail end shall be located just above the ground level.
The slope of table shall be adjusted to discharge all cane vertically to the centre of
the cane carrier.
Operator s common control cabin, to control all tables by a single operator, on a
suitable height shall be provided to have a clear view of the loading of the cane
carrier. Suitable ladders shall be provided to this cabin.
Cane Carriers & Preparatory Devices
Equipment / Machinery Size & Nos. KW rating
Cane carrier-1 1 x 1830 mm x 72 40
Cane carrier-2 1 x 1830 mm x 72 40
18
Cane Carrier No. 1:
One cane carrier 1830 mm / 72 wide and horizontal loading length 40 meters
shall be provided. The cane carrier shall be installed just above ground level of
500 mm clearance. The length of its inclined portion shall be such that it gives an
inclination of 18 deg. for the leveller with a minimum length of 8 meters. It shall
have three strands of chains of 150 mm pitch IS: 8465. The breaking strength of
the chains shall be minimum 40,000 kg. The cane carrier and its structure shall be
of all steel construction, the slats 6 mm thick shall be as per IS: 8236 and fastened
to chain by bolts and check nuts.
It shall be driven by 40 kW with constant torque characteristic and operating
speed range. The VFD motor with AC variable frequency with panel shall be
directly coupled to helical gear box with open gearing to provide 3 to 7 m/minute
variable speed.
Cane flow stabilizer shall be installed on the first cane carrier. The rotary cane
magnet shall be installed on the discharge chute of first cane carrier. Arrangement
for adjusting the clearance up to 1000-1100 mm between the tip of CSDE knives
and the slats shall be provided. 3 nos. of machined packing shall be provided for
the foundation frames of CSDE, gear box and motor.
Cane Carrier No. 2
One cane carrier 1830 mm wide shall be provided. The length of its inclined
portion shall be such that it gives an inclination of 18 deg. for the cutter with a
minimum length of 8 meters having a slope of not more 6 deg. before fibrizer. It
shall have suitable elevation to suit the installation of fibrizer. It shall have three
strands of chains of 150 mm pitch IS: 8465. The breaking strength of the chains
shall be minimum 40,000 kg. The cane carrier and its structure shall be of all steel
construction, the slats 8 mm thick shall be as per IS: 8236 and fastened to chain
by bolts and check nuts.
It shall be driven by 40 kW VFD AC motor with constant torque characteristic
and operating speed range. The VFD motor with AC variable frequency panel
shall be directly coupled to helical gear box with open gearing to provide 3 to 7
m/minute variable speed.
The cane cutter shall be installed on the cane carrier no. 2. The cane fibrizer shall
be installed on the head of cane carrier no. 2.
19
The carrier frame work of mild steel plate extending along the complete length of
the carrier shall be not less than 6 mm thick except at the place of cane flow
stabilizer and density enhancer where the thickness should be 10 mm for about
2500 mm length. Stainless steel cladding of 4 mm thick plate shall be provided in
the working portion of side plates of cane carrier near CSDE and cane Cutter.
The framework shall be adequately stiffened at the top and bottom by angle iron
welded to the side plates. The side plates shall be bolted to and supported by
rolled steel 250 mm x 75 mm channels or sections of equivalent strength and be
provided with base plate of ample area reinforced by gusset plates of angle
plates. Four foundation bolt holes would be provided in each base plate. The
columns in the immediate vicinity of the cane knife sets shall be 250 mm x 75
mm double channels. All the Columns at drive end should be adequately braced
by angle cross pieces of heavy section secured by gusset plate and bolts or by
welding.
Three longitudinal 150 mm ISMB runners with r enewable 10 x 65 mm thick
spr ing steel wear pads would be bolted on the top side of the cr oss pieces to
suppor t the cane car r ier chain r oller s. The distance between the adjacent
suppor ting columns should not exceed 3.50 meter s. The r unner s would be
lowered slightly where the chain arrives at and leaves the runners. 8 mm x 75
mm spring steel flat should be tack welded on the side plates of the cane carrier so
that cane carrier slats touch the flat iron only to avoid wearing on side plates.
The return side of the apron shall be supported on idler pulleys of 60 m/m width,
280 mm dia with 75 mm dia of 40C8 shaft r unning in anti-friction bearings,
housed in the cast steel pedestals, with grease cup one each for each bearing.
The carrier chain driven by means of cast steel sprockets having machine cut teeth
(fully chamfered at tips) at least 16 in number and mounted on minimum 250 mm
central dia. head shaft of 40 C8 quality and shall run in 200 mm size spherical
roller bearings housed in the cast steel Plummer blocks.
The columns under the head shaft and carrier drive shall be of extra heavy section
to withstand vibrations. At the non-driving end of the cane carrier, the chain shall
be mounted on cast steel sprockets having machine cut teeth on minimum 140
mm central dia tail shaft of 40 C8 quality running in minimum 120 mm size
spherical roller bearings housed in the cast steel Plummer blocks and slide rails
with tension bolts for tightening the chain. The margin for tensioning the chains
shall be of 325 mm.
20
The head and tail shaft shall be hot forged and ultrasonically and tested with
magnetic particle tests. Rotary brushes to be provided on the head shaft of cane
carrier to clean slats and chains to remove cush-cush and dirt from the carrier
chain
Rotary Cane Magnet
A rotary cane magnet shall be installed in the discharge chute of cane carrier no. 1
the angle of discharge chute shall be 80
0
to horizontal plane. The effective width
of the drum of the rotary magnet shall be of not less than 2000 mm. The dia of
magnet drum shall be of 1200 mm.
The pick up capacity of magnet shall be of 200 kg tr amp ir on pieces. The
electromagnet capacity shall be of 15 kW. The rotary magnet shall be driven by
the suitable sprockets and roller chain mounted on the head shaft of the cane
carrier no. 1.
4.2 Cane Preparation
4.2.1 Cane Flow Stabilizer & Density Enhancer (CSDE)
One no. CSDE set having not less than 32 knives secured to cast steel hubs of IS:
1030 grade 280 520W mounted on a forged steel shaft of 200 mm dia. of 40 C8
qualities. The dia. over the tips of knives shall be not less than 1600 mm. The
knife shaft shall be supported at 1600 mm bore, heavy duty self aligning double
row spherical roller bearings with adopter sleeve in the cast steel plummer blocks.
The knives shall be of special cross edges, special shock resisting steel having
hard faced cutting edges, hardness 45 to 48 HRC and tenoned into the hubs
eliminating the shear on the bolts which should be of EN8 steel with nut bolts and
check nuts. The knives shall conform to IS: 8461. A suitable fly wheel of CI
grade FG 260, IS 210 duly machined and well balanced shall be provided at the
outer end of the shaft.
The CSDE set shall be driven by a continuously rated drip proof/screen protected
slip ring motor of 90 kW and 1440 rpm synchronous speed at a total slip of 15
percent. It shall be coupled through suitable helical gearbox having service factor
not less than 2.0 by means of geared coupling, also having service factor of 2.00,
to get final speed of 288 RPM capable of transmitting 90 kW continuously. The
motor shall be complete with starter (current not exceeding 300% of FLC) and
suitable buffer resistance.
21
The knife set of CSDE shall be installed on the horizontal portion of the carrier
and clearance in between the slats and Knives tips shall be maintained as 1100
mm The knife set shall be totally enclosed by suitably reinforced hood of 10 mm
thick and mild steel plate attached to the cane carrier frame work and provided
with suitable swing flaps and bolted door s at top of the hood to suit r ever se
rotation. The hood cover shall be extended towards the cane yard at least 4.00 m
from the centre of CSDE. Stopper of suitable size having clearances of 25 mm
shall be fitted on the top of CSDE to restrict overriding of cane pieces.
4.2.2 Cane Cutter
One no. cane cutter set having not less than 48 knives secured to cast steel hubs of
IS: 1030 Grade 280 520W mounted on a forged steel shaft of 250 mm dia. of 40
C8 quality. The dia. over the tips of knives shall be not less than 1600 mm. The
knife shaft shall be supported at 200 mm bore, heavy duty self aligning double
r ow spher ical r oller bear ings with adopter sleeve, housed in the cast steel
plummer blocks. The knives shall be of special shock resisting steel having hard
faced cutting edges, hardness 45 to 48 HRC and tenoned into the hubs eliminating
the shear on the bolts which should be of EN8 nut bolts and check nuts. The
knives shall conform to IS. 8461
A suitable fly wheel of CI gr ade F G 260, I S - 210 duly machined and well
balanced shall be provided at the outer end of the shaft.
Cane cutter set shall be dr iven by a continuously r ated dr ip pr oof / scr een
pr otected slip r ing motor of a 250 kW and 600 RPM, AC 11 kV synchronous
speed at a total slip of 15 percent.
The motor shall be complete with starter (starting current not exceeding 300% of
FLC) with suitable buffer resistance. I t shall be dir ectly coupled by gear ed
coupling, having ser vice factor y of 2.00, capable of tr ansmitting 250 kW
continuously.
The knife set shall be installed on the inclined portion of the cane carrier no. 2 and
be provided with a suitable device for adjusting clearance in between the knives
tip and slats fr om 25 to 150 mm. The knife set shall be totally enclosed by
suitably reinforced hood of 10 mm thick and mild steel plate attached to the cane
carrier frame work and provided with suitable swing flaps and bolted doors at top
of the hood.
22
4.2.3 Swing Hammer Type Heavy Duty Cane Fibrizer
Swing hammer type heavy duty cane fibrizer shall be located at the head end of
cane carrier no. 2, to suit 1830 mm wide cane carrier having not less than 160
hammers. Weight of each hammer shall be not less than 20 kg. The hammer
shank shall be 50 mm thick minimum.
The fibrizer should have detachable hammers made up of Boiler quality alloy
steel shank IS: 2002 - 1962 Grade 2-B of special shock resistance alloy steel, hard
faced, by L& T-6006 hard facing electrodes to 600 BHN and secured through 50
mm dia En 24 alloy steel pins, the hammer shank and fibrizer disc should have
GM bushes to suit En 24 pins. 50 mm hubs shall be of CS forged steel fitted on
rotor shaft. Deflector plate of 20 mm thickness with 4 mm S.S. lining shall be
provided.
The rotor shaft shall be heavy duty minimum 400 mm dia at the hubs and 260 mm
dia. at the bearing journals and shall be 40 C8 steel as per IS: 1570.
Anvil plate shall be of pocketed design, having wrap angle of 150-deg. The base
plate thickness of the anvil shall be minimum 25 mm. Hard facing on the anvil
working surface shall be having minimum hardness 600 BHN. Anvil plate shall
have provision for adjusting the anvil clearance. A suitable long radius, guide
floating flap of 20 mm thick, having dead weight balancer, shall be provided at
the entry point of anvil.
Rotor shall be supported on two heavy duty self aligning double row spherical
roller bearings. Bearing shall be mounted on shaft with adapter sleeve. Tip dia. of
hammers shall have 1830 mm [swing dia] when running at 750 rpm.
The fibrizer rotor shall be completely covered by reinforced mild steel fabricated
hood made out of 12 mm thick plate attached to the cane carrier frame work and
will be complete with deflector plate, adjustable mild steel fabricated anvil plate,
anvil suspension gear, front adjustable cover, rear chute of 12 mm thick with 4
mm thick SS lining on side plates and guide plate, bolted doors on the top of the
hood.
Rotor bearing plummer blocks shall be cast steel. Pressure oil lubricating system
for bearings shall be provided with 2 nos. pumps, 2 nos. coolers (one each as
standby) oil reservoir, pressure gauge, piping, return line, needle valve fitting etc.
with provision for auto start of standby pump on LP oil. The working speed of
SKF spherical roller bearings chosen shall be not less than 750 rpm with grease
lubr ication and 800 r pm with the oil lubr ication (must follow the speed
recommendations of original manufacturer of SKF Sweden bearings).
23
The PI shall be 92-94% on pol basis should be achieved throughout the season
without stoppage for any maintenance work.
Drive for Fibrizer
Swing Hammer type heavy duty Cane Fibr izer shall be dr iven by 11 kV AC
motor with 750 rpm and rated power of 1500 kW.
Cane fibrizer shall be driven by a continuously rated drip proof / screen protected
slip ring 11 kV AC motor of 1500 kW having speed 750 rpm. The AC motor will
be designed to 11 kV synchronous speeds at a total slip of 15 percent. Motor
shall be directly coupled by geared coupling capable of transmitting 1500 kW on
one end continuously. The motor shall be complete with starters (starting current
not exceeding 300% of FLC) and suitable buffer resistance.
4.2.4 Rake Cane Carrier
Rake type conveyor to be installed after fibrizer shall be of a steel construction
having suitable width trough to accommodate 1830 mm rake width and of suitable
length to suit minimum feeding height. The tail shaft centre of rake carrier shall
be in line with head shaft centre of cane carrier. The rake carrier and its structure
shall be of all steel construction with two strands block type forged steel chain
of 229 mm pitch, ha ving 60, 000 kg br ea king str ength ha ving locking
arrangement with check nuts. Flights would be made out of 10 mm thick mild
steel plate of suitable shape and profile and welded on pipe construction slats.
The slats shall have suitable arrangement for fitting with the chain attachment at
every third link with the help of bolts and check nuts.
The rake cane carrier should have runners of channels angle iron with 10 x 65
mm wear flats and 10 mm thick mild steel bottom trough plate with stiffeners
and should be supported on steel channel columns of adequate strength provided
with rigid base plate. Stainless steel liner of 4 mm thick plate shall be provided in
the bottom trough of the rake cane carrier. The columns should be adequately
braced to avoid vibrations. The elevator chain shall be driven over two cast steel
sprockets having minimum 14 machine cut teeth (chamfered sharply at tips),
mounted on 175 mm central dia. head shaft of 40 C8 qualities running in
minimum 140 mm size anti friction spherical bearings housed in the cast steel
pedestals secured to head shaft columns.
24
The tail shaft of minimum 140 mm central dia 40 C8 quality should have two
cast steel sprockets having 14 machine cut teeth (chamfered sharply at tips) to
guide the chains and would r un in minimum 120 mm size spher ical r oller
bearings housed in the cast steel plummer blocks - pedestals attached to the rake
carrier boot. The portion of the chain below the fibrizer shall be suitably covered
to avoid damage due to prepared cane thrown by the fibrizer. The tightening
arrangement shall also be provided near the centre of carrier in vertical direction
by providing idler sprockets. The margin of tensioning shall be 750 mm in the
direction at right angles of chain.
Rake Cane Carrier Drive
Rake cane carrier - 25 kW VFD Motor drive
Speed of Rake cane carrier - 7 to 25 meters/minute variable
The rake cane carrier drive shall have a constant torque characteristic over
operating speed range. The motor with AC variable frequency panel shall be
directly coupled to helical gearbox having service factor of 2.0 with open gearing
to provide desired speeds.
4.2.5 Auto Cane Feed Control System
The automatic cane feeding control system shall be installed on cane carriers.
The system shall ensure the uniform feed r ate to the diffuser with provision to
change the feed rate at any time having a variation not more than 5 % set rate.
First cane carrier shall follow speed of secondary cane carrier in a fixed ratio.
Load of all cane preparation devices shall override the speed signal of each cane
carrier. When load of any cane preparation device exceeds 80% of rated load, the
speed of that cane carrier shall be proportionately reduced. If load exceeds 100%
of r ated load, that cane car r ier will stop. I t will r estar t automatically when
over load condition on that cane pr epar ation device becomes nor mal. These
overload settings shall be adjustable from the control panel. The system shall have
the following provisions.
Sensors:
The load sensing of cane preparatory devices such as CSDE, cutter & fibrizer,
shall be done with suitable current transformers / two wire electronic analogue
pressure transmitters with capacitance sensing technology with 4-20 mA DC
output and configurable for calibration to the required pressure ranges within the
designed pressure span of the transmitter. In addition to this level sensing of
prepared cane at diffuser shall also be considered.
25
Control Action:
The system should be provided with two control actions i.e. proportional and ON-
OFF control actions. Proportional control shall be as per the diffuser load. ON-
OFF control shall be as per the high load settings of the cane preparatory devices
and diffuser.
Set Points:
Following settings will be provided,
1. For loads of various cane preparatory devices and diffuser precision load
setters of 1 K 10 Turns helipots with dial knobs.
2. For average height and feed rate precision 10 K 10 Turns helipots with dial
knobs.
Visual Indication:
Colored lamp indicators shall be provided for the high set load values.
Carrier Speed Adjustments:
The speed of the cane carriers can be adjusted from zero to the rated RPM with
the settings provided on the control panel at operators console.
Indicators:
Analogue load indicators (i.e. current or pressure indicators) and speed indicators
shall be provided.
Power Supply:
230 V AC, 50 Hz
26
4.2.6 DSM Screens RJ
Machinery & Equipment Specifications Qty.
DSM Screen for Raw J uice
(RJ)
2.134 m Width & 0.70 mm
Slit
3-Numbers
Each screen shall be of stainless steel stationary wedge bar type having 45
0
slope,
complete with all necessary fittings. All screens shall be mounted on suitable
staging by on the rake cane carrier no. 2 at the elevated position to achieve gravity
dischar ge of juice and wet cush-cush and shall be pr ovided with attendant
platfor m. The back side plate of juice box shall be left wide open to achieve
manual brushing of the screens to keep underneath the wedge wire gaps free from
formation and growth of Leuconostoc Mesenteroides Microbial.
4.3 Cane Diffusion
Cane diffusion process only shall be considered to achieve juice pol extraction
above 98.50%. Br oad specifications ar e given in the following par agr aphs.
However, the Tendererss are free to make minor changes in the specifications to
achieve guaranteed performance parameters, based on the proven performance
a ch i eved by t h ei r t ech n ol ogy / equ i pmen t su ppl i er s h a vi n g patented
specifications. The cane diffusion process will envisage, one de-watering mill
after the cane diffuser.
4.3.1 De-watering Mill
Installation of vertical head stock and three roller type mill of 915 mm pc dia. x
1830 mm length (36 x72), with 3-rollers GRPF, as a dewatering mill.
Each mill roller shall be having minimum nominal shell pc dia. of 915 mm x 1830
mm length and journals of minimum 480 mm dia x 630 mm length and journal
centre distance of minimum 3000 mm. The rollers shall be of coarse grain cast
iron having hardness 180 -210 BHN. The composition of the shell material shall
conform to IS: 1985 and shall be:
Sr. No. Element % composition
1. Total carbon 3.20 to 3.60%
2. Manganese 2.20 to 3.20%
3. Silicon 1.20 to 2.20%
4. Phosphorus 0.50% Max
5. Sulphur 0.15% Max
27
The cast iron shell shall be hot shrunk on forged steel shaft of 40C8 quality
conforming to IS: 1570 having a minimum tensile strength of 58 kg/sq.mm. All
the shafts shall have square ends, not less than 380 mm square. Top roller shall be
fitted with stationary flanges and juice rings in two halves. The bottom roller shall
be provided with juice rings and removable guards to prevent entry of juice into
the bearings. The cast steel crown pinions shall have minimum 550 mm face
width and conform to IS: 2708 Grade 3 having 17 number machine cut teeth,
keyed to roller shaft and suitable mild steel guards and troughs.
The headstocks shall be of cast steel as per IS: 1030 grade 280/520 W, having
standard vertical design and having vertical mill setting facility. The apex angle
should be 77
0
to 80
0
. These will be of king boltless type. Removable gun
metal wearing plates on feed side as well as discharge side and with continuous
grease lubricating arrangement between top roller bearings and wearing plates
shall be provided. The vertical head stock design should be integral and able to
accept 3-more GRPF rollers. The pressure chute length shall be very short. The
feed roller shall be removable without disturbing pressure feeding device GRPF
assembly.
The top and side caps shall be of cast steel as per IS: 1030 grade 280/520 W and
shall be securely locked in position for quick assembly. Stainless steel strip of 8
mm thick shall be provided in the side roller bearing face of the head stock. The
eccentricity between top roller bearing centre and hydraulic cap centre shall be
kept suitably towards the feed side of the headstock preferably by 40 mm.
All roller shells shall be coated with surface roughening electrode material, except
mill feed r oller . The bear ings shall be of cast steel with gun metal and with
efficient water cooling arrangement. The top, top bottom and side roller bearing
shall be of cast steel housing with renewable gun metal liners as per IS: 318 -
1965.
The Bearing housings shall have efficient water cooling arrangement. The top
roller bearings shall be interchangeable. Similarly the feed side and discharge side
roller bearings shall be inter changeable by their respective bearings.
The mill shall be provided with cast steel trash beam as per IS: 1030 grade 280
/ 520W and supported on heavy steel brackets with pivoted journals fitted in the
head stocks and adjustable by means of tie rods and fitted with removable cast
steel trash plate as per IS: 1030 grade 280/520 w, bolted by high tensile bolts
and nuts. Top roller scrapers shall be of floating type. Scr aper s for top and
discharge rollers shall have renewable cast iron tips.
All mechanical parts of the mill shall be designed for crushing capacity of 3500
TCD and fibre content of 17% on cane.
28
The mill shall be provided with hydraulic loading system, consisting of hydro-
pneumatic accumulator, one for each of the journal of the top roller, one extra
as spare and accessories such as pumping set, receiver tank, suitable pressure
gauges, remote control panel and roller movement indicator mechanical as well
as electronic type . The dia. of the hydraulic ram for top cap shall be minimum
380 mm. The hydr aulic system shall be designed for oil pr essur e of 280
kg/sq.cm.g.
Centralized grease lubrication system having positive displacement pump at about
400 bar pressure having dual delivery lines made of SS 304 x 3.20 mm thick (DIN
standard) of 20 mm dia for main line on both sides of the mill with changeover
valves, relief valves and distributors with delivery adjustment arrangement with
feed line of 10 mm dia SS x 3.2 mm thick provided to the bearings, complete with
contr ol panel pr essur e gauges and audio/visual alar m with suitable timer
arrangement for controlling pump operations.
J uice trough under the mill shall be made of 6 mm thick stainless steel 409 M
grade plates. The troughs shall be bolted to the headstocks with stainless steel
bolts and copper washers. J oint shall be suitably sealed to prevent any juice
leakage.
The mill shall be high set so that no part of the juice tank and pump are situated
below ground floor level. The mill shall have common gangway on both sides
having width not less than 800 mm with gratings and one for bagasse elevator
side and one from mill drive platform, along with the necessary cross. One stair
case and working platforms shall be provided for the operations, maintenance and
washing of DSM screens.
Necessary approach stair cases, platforms and railings shall be provided between
diffuser and dewatering mill.
Access from mill platform to rake elevator drive platform with suitable cat ladders
shall be provided. All gangways and staircase shall have hand railings.
Three Roller type GRPF (Grooved, Pressure Feed Rollers, one set for de-
watering mill)
29
Cast iron grooved shell of GRPF, having perforations like Lotus, hot shrunk fit ,
grooved inter-meshing type under feed roller of the same material as that of
mill roller having minimum nominal diameter 80% of the mill roller nominal
diameter shall be provided. The shafts shall be of 40C8 quality conforming to IS:
1570 and of suitable central dia. and supported by means of continuously grease
lubricated gun metal bush bearings of suitable bore.
The GRPF rollers and light duty guide roller shall be driven by separate couplings
and tail bars taken out from the final motion bull gearing train. Main DC motor
for mill will be common for mill as well as for 3-GRPF pressure feeding device.
The surface speed of GRPF rollers shall be about 25-30% higher than the mill
roller surface speed.
The GRPF rollers shall have arrangement to adjust the setting in axial direction by
plus-minus 35 mm (axis joining centre line of feed and top roller). The pressure
chute shall be of shortest possible length.
Donnelly Type Chute
The Donnelly type chute fabricated out of 6 mm thick duly reinforced SS 409 M
plates shall be provided for dewatering mill. It shall have arrangements to adjust
the blanket thickness from back side. Side plates of chute shall have suitable
height transparent sheet to see the level of bagasse.
Suitable indication shall be provided to indicate feed level of bagasse in the chute
of dewa ter ing mill. Level sensing device sha ll ha ve on off contr ol of
intermediate carrier and shall have sequence inter lock.
4.3.2 Rake Type Intermediate Carrier (RIC) after diffuser
RIC after diffuser will be with perforated bottom for good juice drainage.
The width of the rake inter carrier trough shall be suitable to accommodate 1830
mm rake width and its cross section suitable for handling bagasse for 3500 TCD
crushing rate with imbibition up to 350% on fibre, fibre of 17% on cane.
The rake carriers shall have runners of channel with 8 mm spring steel wear flat
and 8 mm mild steel bottom trough plate with stiffeners and be supported on steel
channel column provided with rigid base plate. The columns shall be adequately
braced wherever necessary.
The net effective height of Donnelly chute above GRPF of dewatering mill should
be of suitable height to suit the set up.
30
The inclination of rake inter carrier shall be 45 deg max. The tail shaft centre of
rake carrier shall be in line with head shaft centre of cane carrier. The rake
carrier and its structure shall be of all steel construction with two strands block
type forged steel chain of 229 mm pitch, having 60,000 kg breaking strength
having locking arrangement with check nuts. Flights would be made out of 10
mm thick mild steel plate of suitable shape and pr ofile and welded on pipe
construction slats. The slats shall have suitable arrangement for fitting with the
chain attachment at every third link with the help of bolts and check nuts.
The rake inter carrier should have runners of channels angle iron with 10 x 65
mm wear flats and 10 mm thick mild steel bottom trough plate with stiffeners
and should be supported on steel channel columns of adequate strength provided
with rigid base plate. Stainless steel liner of 4 mm thick plate shall be provided in
the bottom trough of the rake cane carrier. The columns should be adequately
braced to avoid vibrations. The chain shall be driven over two cast steel sprockets
having minimum 14 machine cut teeth (chamfered sharply at tips), mounted on
175 mm central dia. head shaft of 40 C8 qualities running in minimum 140 mm
size anti friction spherical bearings housed in the cast steel pedestals secured to
head shaft columns.
The tail shaft of minimum 140 mm central dia 40 C8 quality should have two
cast steel sprockets having 14 machine cut teeth [chamfered sharply at tips] to
guide the chains and would r un in minimum 120 mm size spher ical r oller
bearings housed in the cast steel plummer blocks - pedestals attached to the rake
carrier boot. The tightening arrangement shall also be provided near the centre of
RIC in direction right angles to chains travel, by providing idler sprockets. The
margin of tensioning shall be of 750 mm in the direction at right angles of chain.
RIC shall be provided with special perforated bottom plate to achieve efficient
juice drainage and juice collection trough. The bottom plate shall be of SS-304
material of 10 mm thickness and strengthened with SS-304 flat bar stiffeners on
the bottom side and having divergent hole-perforations of 5 mm at the top face
and 8 mm at the bottom face. The ligament of holes shall be of 15 mm. all drained
juice shall be collected at the boot of the RIC and lead further to the pump to re-
pump and achieve efficient juice remaceration process to achieve high juice-pol
extraction and minimize moisture of bagasse leading to the dewatering mill.
Driving Arrangements For RIC
The rake inter carrier drive shall consist of the TEFC VFD AC motor of 25 kW,
1440 RPM with enclosed helical speed reducer, with open gearing, fluid coupling,
and common bed frame. The linear speed shall be not more than 20 m /minute.
31
4.3.3 Mill Auxiliary System
Mill drive (Thyristor Controlled Variable speed, DC Motor Drive)
The mill will have 660 V DC motor s with thyristor controllers, with power
requirement of 525 KW for mill and 225 KW for GRPF (total 750 KW per mill).
The 36 x72 mill shall be driven by continuously rated 750 kW individual D.C.
electric motor.
The DC motor shall be forced cooled with air filters SPDP, IP 23 with class V
overload duty S1 continuous. The motor base speed shall be 1000 RPM and shall
have constant tor que char acter istics between 20% to 100% base speed and
constant power characteristic between 100 to 110% at base speed.
Detailed specifications of the DC motor shall be as under:
Particulars Specifications
Rating Continuous
No. of motors 1
Motor size, speed, class &
duty
750 kW, 1000 rpm, Class V& Duty S1
Over load duty Class V
Armature voltage 660 V
Field voltage 220 V
Protection IP 23 SPDP(force cooled with air filters)
Class of Insulation F, Temp. rise limited to class B at continuous
rating
Mounting Horizontal foot mounted
Ambient Temp. 50
o
C
The motor shall be designed for variable speed operations, contr olled by the
thyristor converter station, and shall have constant torque characteristics down to
continuous operating speed of 20% of the rated speed.
ETD for temperature detection of motor winding shall be provided. Thermesters
shall be provided for thermal protection of the DC Motor. RTD shall be provided
for bearings. Necessary thermester relays & RTD scanner with tripping facility
shall be provided in the thyristor panel.
The digital type thyristor Converter Stations for operation and control of the
D.C. motor
32
Converter cubical fabricated from 12 SWG cold rolled steel sheets, free standing,
passivated, and painted with anti-corrosive paints.
The cubicle will house all protective switch gear, thyristor modules, regulation
circuit, interlocking r elays, mounted on passivated plates; the cubicle will
conform to IP-30 protection.
All necessary indications, annunciations, controls will be neatly arranged on
cubicle fr ont door with neopr ene gaskets on all edges of panel. Ventilation
openings shall be pr ovided at the top of panel and on side cover s by louver s
suitably covered by fine wire mesh.
The thyristor drive panel shall be as per following specifications:
Armature converter
Particulars Specifications
No. & r ating of DC motor
to be controlled
750 kW, 1000 rpm, Class V& Duty S1
Rated DC voltage 660 V
Incoming AC supply 11KV / 440 V, 3 phase, 50 Hz
(11KV / 660 V through converter transformer)
Torque rating 100% continuous, 150% for 2 hours and 200%
for 1 min, class V, constant for rated full speed
Type of Thyristor bridge 3 ph, 6 pulse, fully controlled non regenerative
Voltage grade of thyristor 1500 V PIV (approx)
Panel shall be complete with field converters, regulators, tacho feedback, safety
protection, (electronic thermal overload, instant O/L , phase seq. Phase loss, field
failure ,tacho/ speed loss & earth fault) indication meters, push buttons, switch
gears and controls.
Drive bi - directional in operation with field reversal in the speed range of 50% to
100% of speed at constant torque. Speed regulation will be + 1% of base speed at
base speed by tacho feedback. The panel will have facility to accept 4 to 20 mA
signal for speed setting in auto mode. Speed regulation with armature voltage feed
back shall operate in case failure of tacho feed back.
Auto visual window annunciator s will be pr ovided. The pressure ventilation
system with electric motor driven blower with filter will be provided for panel.
The thyristor panels to be supplied along with AC Room to be provided by the
Supplier as a turn key job.
33
Mill Gearing Train
The mill dr ive shall be coupled thr ough flexible gear coupling to enclosed
reduction gear and single stage low speed reduction gearing unit capable of
transmitting 750 kW for mill.
The total reduction ratio of the gearing unit should be such that the mill roller
surface speed should be of 12.94 m / min (mill roller speed of 4.50 rpm), when
motor is run at its base speed.
The enclosed reduction gear box shall have hardened and ground internals and
shall have minimum service factor 2.0 with forced grease lubrication system.
The pinion should be of EN-24 and gears of cast steel conforming to IS-2708 Gr
III hardness of pinion and gears should be minimum 250 BHN and 220 BHN
respectively.
Final Open Gear & Pinion
The open spur gearing shall be designed to transmit 750 kW for mill. The gearing
train shall be designed to give continuous rating for mill rollers surface speed of
12.94 m / min; under shock load conditions and shall confirm to IS: 4460-1967.
The low speed reduction gearing unit shall have machine cut teeth by gear
generating process in both cases. The module of the open gearing should be not
less than 30.
Suitable bed plates made in sections, mild steel guards for completely
enclosing the gears and pinions (low speed), shall be provided. Shafts of these
gears shall be of 40 C8 quality conforming to IS: 1570 having minimum tensile
strength of 58 kg /mm and supported on cast steel plummer blocks with gun
metal bearings provided with centralized forced mechanical grease lubrication
arrangement with needle valve, standby pump reservoir and return pipe line with
auto start of standby pump.
The gearing unit shall be complete in all respects. The mill top roller shall be
connected to transmission gear shaft by means of forged steel tail bar of 40
C8 quality conforming to IS: 1570 and two couplings each set. The length of the
tail bar shall be not less than 2000 mm.
The margin for normal working lift of the top roller shall be kept 12 mm for the
dewatering mill. Two suitable cast steel couplings, one of lesser cross section so
as to act as a fuse to safeguard reduction gearing units and drive with provision
of greasing for each face under load shall be provided.
34
Perforations like lotus for all mill & GRPF rollers except top rollers
All GRPF, mill feed and mill discharge rollers of the mill, shall be perforated like
lotus rollers to avoid mill juice flooding, achieve efficient juice drainage and
improve the mill extraction to the very high level. Suitable juice guard rings shall
be fitted for all of these rollers to avoid juice entry to bearings and journals of mill
rollers. Such perforations shall not be provided for light duty under feeder roller
and top roller.
Provision of Grooving Pitch, Grooving Angles & Roller Surface Arcing
The grooving pitch, grooving angles and roller surface hard facing of mill rollers
shall be carried out as under:
Grooving Pitch:
Description Dewatering Mill
Grooving pitch mm 35 mm
Grooving Angles & Other Details:
Sr.
No.
Description Specifications
1. Grooving Angle
0
F, T, D for 2-mills Feed: 40
0
, Top: 45
0
, Discharge: 45
0
2. Hard facing of Rollers All rollers except Mill feed roller
3. Ha r d fa ci n g of t r a s h pl a t e s &
scrapers
All trash plate and all scraper tips
4. Messchaert grooves Not to be provided
5. Chevron grooves Not to be provided
Remaceration Juice Equipment & Mixed Juice Pumps
The juice from dewatering mill shall be collected in individual cylindrical
whirler tank with conical bottom of 1500 mm dia and 1300 mm height and made
of 6.0 mm thick SS 409 M connected to mill juice trough through 5.00 mm
thick SS 409 M gutter. The collected juice shall be pumped and spread on the
diffuser before the dewatering pressure feed drum at the outlet end of diffuser.
The mixed juice from diffuser and primary mill shall be sent to the set of DSM
screen for screening.
35
The screened juice shall be collected in a 5 mm thick SS 409 M cylindrical tank
of 200 HL capacity. Suitable strained juice pumps (one as stand by) each of 60 m
head shall be provided for pumping the 50% screened juice to juice heaters of
sugar plant and remaining 50% juice to the Ethanol plant through suitable juice
flow meters.
All unscreened and screened juice pumps to have SS bodies, SS impellers and SS
shafts. All the juice pumps should have suction and delivery lines of SS 409 M
having suitable sizes for crushing rate of 3500 tcd. Long bends having radius of
1.0 m shall be provided for the delivery lines to avoid choking.
Water Flow Meter For Imbibition Water
Imbibition water online mass flow-meter of 100 MT/hr at 100C capacity shall be
provided for the accurate weighment of water.
On line calibration facility for check weighment with prover tank of suitable
capacity shall be provided for random checking of imbibition water delivered by
mass flow meter without stopping the crushing.
Hot Water Imbibition Pumps
2 Nos. (1 as standby) Hot water imbibition pumps of 100 m
3
/hr capacity shall be
provided.
Automatic Imbibition Water Flow & Temperature Control System
Imbibition water flow will be controlled to maintain a fixed ratio of imbibition
water to cane. The desired ratio will be fed through the keyboard and the load on
the dewatering mill and brix of LEJ will be measured. The flow of imbibition
water will be r egulated to maintain the r atio at var ious loads. I f load of
penultimate mill and brix of LEJ is below the minimum running level, imbibition
water flow will stop.
Sensor:
On-line brix measurement of LEJ with Coriolis density sensor with dual U tube
design or single full bore straight tube design having following specifications.
Accuracy + or - 0.0005 gm/cc
Ambient Temperature effect 0.001 % of nominal flow rate per
0
c
36
Power supply 85-230 V AC
Housing NEMA 4X
Load of dewatering mill with two wire electronic analogue pressure transmitter
with capacitance sensing technology having 4 20 mA DC out put or current
transformer out put for recorder and controller.
Sr. No. Equipment Specifications
1. Controller Mi cr opr oces s or ba s ed mu l t i l oop P I D
controller.
2. Control Valve It shall be suitable for controlling the flow of
i mb i b i t i o n wa t e r c o n t i n u o u s l y wi t h
proportional control.
3. AC Variable Drive Suita ble for contr olling the speed of the
electric motor employed for imbibition water
pump.
Imbibition Water Temperature Control System
Sensor Suitable RTD PT 100
Transmitter Two wi r e electr onic analogue type with 4-20 mA DC
output
Controller Microprocessor based single loop indicating type
Control Valve Suitable for controlling the flow of water in well designed
and fabricated condensate - water mixing arrangement
Mill House Crane & Gantry will be suitable for the de-watering mill
4.3.4 Cane Diffuser
Cane Diffusion Process
The cane diffusion process shall be designed for 3500 TCD/24 hrs or 150 TCH
and will be from commercially proven technology / equipment suppliers. The
fibre in cane assumed for diffusion process will be 17% on cane. The Preparatory
Index (PI) will be 92-94%. The guaranteed performance parameter will be juice
pol extraction of minimum 98.5%. Metallurgy shall be designed in such a way
that the working life of all components of Diffuser shall be not less than 20 years
(The tenderer to provide detailed specifications of the cane diffuser and associated
equipment for evaluation, along with the bid).
37
Automation & Instrumentation, Operations of Diffuser
Full automation and instrumentation shall be done at the diffuser to achieve
consistent performance with minimum work force.
All transmitters shall be of the electronic type with a 4-20 mA output. All the
controls except actuators shall be electronic solid state type. Actuators shall be
pneumatically operated. All controls and actuators shall be interfaced with the
contr ol systems thr ough I /P conver ter s and then with the pneumatic Auto /
Manual stations which in turn shall be connected to the valves and actuators.
The auto / manual station shall be mounted near the diffuser for use by the
operator. In manual mode, the operator shall be able to operate the valves and
actuators without the micro processor. Local control shall override automatic /
remote controls.
The following PLC (Micro Processor) based closed loop controllers shall be
installed:
Cane bed level in the diffuser,
Speed of bed (if applicable),
Juice pH controller,
Juice temperature controller,
The diffuser in the auto mode with the DCS / PLC based controllers shall
maintain the pr ocess par ameter s connected to the PC based super visor y
workstation, which shall have bar graphic display of all process parameters.
Full day, 24 hours trends shall be made available on colour video for:
J uice flow,
Cane level in the diffuser,
Flow of imbibition water and other liquids like press juice if taken,
Pneumatic auto / manual stations shall be provided for imbibition water flow and
steam flow.
It shall be required that in the event of high bagasse bed level; the cane feed shall
be reduced down in proportion of levels desired. In the case of excessive level in
the diffuser the prepared cane supply shall be stopped.
There shall be tripping devices of diffuser moving bed in case of jamming of any
screw in the bed.
38
The level transmitters and indicators shall be provided for level of cane bed, liner
speed, grease tanks and all juice tank levels.
4.3.5 Bagasse Elevator
One set of 1.80 m width to carry 60 MT/hr bagasse
One steel r ake type bagasse elevator of all steel constr uction of 1800 mm
effective width and suitable length (inclination not to exceed 45 deg. with the
horizontal) to carry about 60 tones of bagasse per hour and driven by TEFC
electric motor of 25 kW through helical speed reducer with open gearing to give a
linear speed of 20 meters/minute shall be provided. It shall have two strands of
chains of 150 mm pitch. The br eaking str ength of chains shall be minimum
40,000 kg.
The bagasse elevator chain shall be driven over two cast steel of 40C8 sprockets
with machine cut teeth only mounted on 175 mm dia., head shaft running in 160
mm size anti friction spherical roller bearings with adapter sleeves and lock nuts,
housed and secured in cast steel plummer block pedestals.
The tail shaft shall have two cast steel spr ockets having machine cut teeth
mounted on 140 mm central dia. Shaft shall be running in 120 mm size anti
friction spherical roller bearings and adapter sleeves and lock nuts, housed and
secured in cast steel plummer block housings with side rails and tension bolts for
tightening the chain. The head and tail shaft shall be of 40 C8 steel qualities. The
bagasse scrapers would rise on the bottom side of the elevator and discharge by
means of mild steel chute bolted to head columns into the main bagasse carrier.
The trough side and bottom plate shall be of 8 mm thick mild steel.
Sliding screens shall be provided on the elevator for screening the bagacillo. The
screening area shall be 7.0 sq.m for the boiling house of 75 TCH capacity. Each
screen shall have a blind portion for sliding it in the elevator portion for cleaning
and changing the screens while working. Width of each screen shall be not more
than 600 mm. The screen shall have punched conical holes having 6/8 mm dia.
(top/bottom) size on the sur face facing the bagasse elevator . Platfor m and
staircase shall be provided for approaching on both sides of the elevator.
The bagacillo should be extracted and available at the rate of 9 kg/TCH. Suitable
bagacillo blower and piping shall be provided accordingly.
39
4.3.6 Mass Flow Meters
One mass flow meter will be installed for sugar process house & another for
Ethanol plant
Sr.
No.
Machinery & Equipment Capacity,
m3/hr &
Head, m
Numbers
1) Juice Mass Flow Meter 100, 60 2
2) Juice Pumps 100, 60 4
(2 in operation & 2
stand by)
Each J uice flow measuring system shall have computerized, instantaneous and
integr ated system, to be installed in scr eened mixed juice line with check
weighment arr angement. Beam scale of suitable capacity to be pr ovided for
random verification with suitable capacity MS tank to be kept at a height for
gravity flow of juice to recovery tank.
Specifications for each mass flow meter for mixed juice will be as under:
Sr.
No.
1. Type Coriolis Dual U Tube design or single full bor e
straight tube design.
2. Wet t ed P a r t s
and connection
Tube, Manifold, and Pr ocess flanges in 316 SS
welded design, enclosur e in SS 304 and should
fulfill NACE standard.
3. Accuracy 0.10% of mass flow rate
4. Ambient Temp
Effect
0.001 % of Nominal flow rate per
0
c
5. Repeatability 0.05% of rate
6. I na ccur a cy in
Current output
None
7. Core processor I t should be micr opr ocessor based with digital
communication having meter diagnostic capabilities
and multivariable measurement with 4 wire system
between the sensor and transmitter.
8. Outputs i) 4-20 mA for mass flow rate
ii) 0-1000 Hz frequency for mass flow rate
iii) Digital HART for remote configuration
9. Power Supply 85-250 V AC / 24 V DC
40
Sr.
No.
10. Electrical
Connection
inch NPT
11. Electrical
Housing
NEMA 4X
12. Temperature
Limits
0 to 100
0
C
13. Indication
facilities
Flow rate in TPH; Current hour flow in tones; Last
hour flow in tones Separ ate display for measured
liquid during check weighment.
14. Communication
Ports
a) RS 232/RS 485 for PC communication
b) Centronic parallel port for printer
On line calibration facility for check weighment with transfer tank of suitable
capacity shall be provided for random checking of juice delivered by the mass
flow meter without stopping the crushing. Suitable arrangement for preparation,
storage and pumping of phosphoric acid solution shall be provided for the sugar
plant juice flow measurement. The tank of stainless steel with stirrer, rubber lined,
piping of PVC, dosing pump of suitable capacity shall be provided.
4.4 Sugar Process House
(for 50-55% mixed juice on cane or equivalent to 1750 1925 TCD on 24 hr
basis or 75-80 TCH, conventional Double Sulphitation Process)
4.4.1 Juice Heating & Clarification
Juice Heaters
J uice heaters shall be provided in such a way that heating is done with various
vapours to minimize steam consumption as under:
Raw J uice (RJ) heating will be done in three stages,
Secondary Juice (SJ) heating will be done in three stages,
Clear Juice (CJ) heating will be done in three stages,
Indicative heating surfaces and numbers of juice hea ter s wi l l be as under
(Tendererss may design heating surfaces and number of juice heaters to achieve
guaranteed performance parameters).
41
Description Specifications, nos. x sq. m.
Dynamic juice heater 2 x 150
Vapor line juice heater 2 x 150
Direct contact juice heater 12 nos. of suitable size
Clear juice heater 6 x 120
There will be 2 separate sets of quintuple evaporator and the dynamic, vapour line
and direct contact juice heaters will be installed accordingly.
One evaporation set will be in operation with extensive vapour bleeding and one
set will be always standby to work while one of the sets is under cleaning. All RJ ,
SJ and CJ will be heated thrice with the vapours, non condensable gases and
condensa t es fr om t he r espect i ve eva por a t or bodi es t o mi ni mi ze st ea m
consumption. Heating surface of each juice heater shall be suitable to achieve
proper heating divided in three stages.
All dynamic and vapour line juice heaters shall have SS-304 tubes of 16 SWG
(1.625 mm) wall thickness. All dynamic and vapour line juice heaters shall be of
16 passes each to minimize pressure drop.
All vertical tubular juice heaters shall be of multiple circulation type, designed to
have juice velocity of 1.25-1.50 m/sec max. The body shall be constructed from
16 mm shell, cover plates of 30 mm and top tube plate of 25 mm thk and bottom
tube plates of 30 mm thick each.
Arrangements shall be provided to drain of all juice heaters, drained juice to go to
separate collection tank along with suitable pump to deliver the drained material
to juice sulphiter. The platform shall be provided below the juice heaters for
opening the covers, draining and repairs etc. Each juice heater shall have mercury
filled 150 mm dial type thermometer in inlet and outlet branch of juice and for the
steam chest.
One compound gauge shall also be provided in the steam chest. Tightening bolt T
type or eye type shall have individual fixing pin and pitch shall less than 120 mm.
The partition plate and header shall be not less than 12.00 mm thick M.S. plate
and flexible cord fixing arrangement with self locking system shall be made of 30
sq. mm with dove tail arrangement.
Annealed stainless steel tubes as per AISI-304 of 45 mm outside dia and 1.625
mm (16 SWG) thick shall be used for raw and sulphited juice heaters of dynamic
and vapour line type. Ligament of the tubes shall be minimum 12 mm. The length
of tubes shall be about 4000 mm.
42
Dynamic and Vapour Line juice heaters will be made suitable for two vapour
passes.
J uice heater shall be provided with individual condensate receiver for exhaust and
vapour condensate along with suitable pumps of suitable capacities of 10 cu.m/hr,
and suitable delivery head.
Direct contact juice heaters shall be designed and installed according to the
temper atur e r ise expected to achieve minimum steam consumption for juice
heating.
4.4.2 Sulphur Burning Furnace
Equipment HS, sq. m & Numbers
Sulphur furnaces (2 working, 1 spare) 50x3
Each sulphur furnaces shall be of continuous type, suitable for burning 50 kg of
standard quality sulphur per hour. Each sulphur burner shall have a minimum
0.50 sq.m burning area capacity. All sulphur feeding valve spindles and seat shall
be of stainless steel. The melting chamber for sulphur burner shall be made out of
12 mm thick mild steel plate. The combustion chamber shall be 16 mm thick mild
steel with refractory lining.
The furnace shall be complete with, water jacketed counter current cooling
ar r angement for the ver tical gas pipe( mater ial for cooler pipe shall be of
schedule 80), mild steel water jacketed scr ubber s of 16 mm t hi ck, et c.
Exothermic heat energy of SO
2
gas will be re-used.
Sulphur pipeline from all the furnaces shall be so designed that both juice and
syrup could be sulphited from any of the furnaces either singly or jointly. Sulphur
pipeline and crosses shall be of Cast Iron conforming to IS 210-1978. Suitable
glass lined r ubber diaphr agm valves shall also be pr ovided. Temper atur e
indicators for indicating temperature of molten sulphur and SO
2
gas shall be
provided and automatic control for sulphur furnace shall be provided.
Use of Exothermic Heat Energy:
Electrical vaporizer shall be provided for the initial starting of sulphur melting
and generation of sulphur dioxide gas. Once the process is started the exothermic
heat of gas will be re-used to melt sulphur powder.
43
4.4.3 Air Blower Fans
Air rotary blower fans, 3 Nos. of 200 cu.m/hr free air delivery capacity each,
pressure of 1.25 kg/sq.cm.g (2 working & 1 stand by).
Each Air blower shall be provided with necessary pipe lines, gauges, valves etc
arrangement to supply moisture free air (with air refrigeration system) with
suitable filter of adequate capacity, air receiver with suitable relief valve etc. All
furnaces shall be connected in such a way that any furnace could be worked with
either air blower.
4.4.4 Juice Sulphiter & Auto pH Control System
Juice Sulphiter:
One continuous juice sulphitation unit of 115 HL capacity designed as per NSI
specifications for a crushing rate of 75 TCH with 115% juice, retention time
not less than 7.0 minutes and working height of juice column above the gas
distribution not more than 2.0 m. It shall consist of a reaction tank, stack gas
recovery tower, one suitable cylindrical receiving tank, and three [one as standby]
suitable centrifugal pumps of 82 cu.m/hr, at 60 m head each capable of pumping
juice through three juice heaters in series, to the flash tank of the clarifier. The
speed of stir r er used shall be ar ound 16 r pm. Design of the unit shall have
arrangement for pre sulphitation, pre liming, shock liming and sulphitation.
Telescopic valve to regulate the juice level in the sulphiter shall be provided.
The continuous juice sulphitation unit shall be made from 12 mm thick mild steel
plate and be complete with milk of lime proportioning arrangement, SO
2
gas pipe
shall be of CI conforming to IS-210-1978. Line and sparger shall be of SS 316
grade.
The filtrate from vacuum filter station shall also be pumped to Juice Sulphiter.
Automatic pH Control System For Juice Sulphitation
The microprocessor based two loop pH control system shall be considered. Lime
dosing into juice sulphiter shall be automatically controlled based on pre-set ratio
to juice flow. Lime flow will be measured to give feed back signal to the lime
dosing control loop. pH of treated juice will be measured and signal given to
control speed of sulphur dosing pump in case of thin film type sulphur burner
option. Combustion temperature of thin film type sulphur burner will be measured
and air vent valve will be adjusted to control operation of sulphur burner. The
system shall have following specifications.
44
Sr.
No.
Equipment Specifications Other Arrangements
1. Sensor Ruggedized industrial
gr a de combi ned pH
e l e c t r o d e wi t h
automatic temperature
compensation. It shall
be f i el d r epa i r a bl e
type.
Suitable magnetic flow meter
for the measur ement of MJ
(mixed juice with filtrate) and
MOL
2. pH
Analyzer
Microprocessor based
d e s i g n wi t h LCD
di spl a y f or pH a n d
temperature value with
following facilities:
Output : 4 -2 0 mA d c f o r
recorder/controller
Power : 230 V AC
Supply
Mounting : Panel/Field
Alarm : High/Low
Housing : NEMA 4X
Diagnostic : F o l l o w i n g
Diagnostic featur es featur e
shall be provided
Electronic failure
Electrode coating
Electrode breakage
3. Controller Microprocessor based
multi loop contr oller
with
f o l l o wi n g ma i n
facilities:
Ca s ca de con t r ol a n d s el f
tuning Communication port RS
2 3 2 o r RS 4 8 5 f o r P C
commu n i ca t i on Cen t r on i c
Parallel port for printer
4. Control
Valve
S u i t a b l e f o r
controlling the flow of
l i m e a n d S O
2
con t i n u ou s l y wi t h
pr opor tional contr ol
shall be provided.
5. Recorder Suitable recorder shall
be provided.
4.4.5 Syrup Sulphitation Unit
One continuous syrup sulphitation unit of 45 HL working capacity of NSI
design shall be provided, capable to process syrup of 65 deg. Brix, with working
height of 1.50 m. of syr up column above the gas distr ibution, stack gas
recovery unit constructed of 10 mm thick mild steel plate complete with SO
2
gas absorption arrangement and all necessary pipelines, valves etc.
45
SO
2
pipe and sparger shall be of SS 316 grade, three suitable sulphited syrup
pumps of 25 cu.m/h, 30 mH, each (one as standby); gr it catcher s and one
sulphited syrup receiver of suitable capacity with sight and light glasses, inlet,
outlet, and equalizing connections shall be provided.
4.4.6 Milk of Lime Preparation
Equipment Capacity & Numbers
Lime Slaker 500 kg/hr x 1
MOL storage, 2.64 HL 100 HL x 2
Lime Slaker:
One lime slaker shall be provided capable of slacking about 1000 kg of quick lime
per hour. A Koran flash tank type lime classifier with grit remover or rake type
lime classifier and Vibro-screen shall be provided to remove all grit from the
MOL. Two milk of lime storage tanks each of about 100 HL capacity] and two
pumps (one as standby) plunger type each of suitable capacity of 3.50 cu.m/hr,
delivering milk of lime at 20 m head each and two grit catchers common for
both pumps.
The slaker shall be of continuous type, driven by electric motor, through suitable
reduction gearing arrangement to generate 6 to 8 rpm. The storage tanks shall be
made of 6 mm thick mild steel plates and shall be complete with stirrers with
independent drive for each tank and connected through girt catchers to milk of
lime pumps. Separate gutters shall be provided over the milk of lime storage tanks
for the milk of lime coming from the slaker and return milk of lime.
Milk of Lime pipe lines shall be pr ovided up to juice sulphitation with return
piping and to mud overflow tank and to condenser outlet.
4.4.7 Juice Clarifier
Clarifier 170 cum & 22 dia x 1
One number of 6705 mm or 22 feet dia. clarifier of 444-design with four
compartments, each compartment to have height of 1524 mm. Each clarifier shall
have separate juice and mud outlet from each compartment. The flocculating
compartment complete with skimmer and feed well shall be installed separately.
46
The clar ifier shall be made of mild steel plates having following minimum
thicknesses:
Sr. No. Part Thickness, mm
1. Bottom 8
2. Shell 6 (with stiffeners)
3. Tray (intermediate) 8
4. Tray (Top) 6
5. Top Cover 6
6. Flocculating Compartment 6
The continuous clar ifier shall be complete with mild steel flash tank and
withdr awal boxes, 2 nos. for clear juice and one no. for mud with sleeves,
telescope pipes and O-rings, hinge type squeezers, driving mechanism with
variable speed drive head with motor consisting of sprocket, chain and drive
guards, all inside and outside clear juice piping and mud piping, all valves and
pipe fittings etc, and complete with peripheral walkway, angle iron bracket
supporting angles, piping for railing, rail support etc; 4 manholes one for each
compartment, each manhole to have platform, railing and access ladder; pumps
tank with support, insulation material etc.
Mud liquidating pump of 25 cu.m/hr. and 30 m head of CI construction with
br onze fittings complete with dr ive motor shall be pr ovided. Two clear juice
centrifugal pumps each of 80 cu.m per hour and not less than 30 m head and SS
construction with SS fittings complete with drive motor and suitable column
having sight and light glasses shall be provided for pumping juice through clear
juice heater to 1st body of evaporator sets. Provision of recirculation of juice in
the clarifier shall be also provided. Arrangement of preparation and dosing of
flocculent shall be provided.
The centre tube of each clarifier will be made of seamless steel in one piece. The
gland portion of sealing rings shall be provided with additional SS 304 material
gland rings having 12 mm thick x 100 mm width duly machined and ground to
keep compartments sealed and leak proof.
4.4.8 Rotary Vacuum Filter
Vacuum Filter 36 sq.m Filtering Area (FA), 8 x 16 size, 2 nos.
Two rotary vacuum filters shall be installed, each of 2.44 m dia x 4.88 m long
drum (8 x16) having filtering area of 36 sq. m each.
47
Each rotary cane mud vacuum filter shall have nominal filtration area of 36 sq.m
and installed at a height so as to have a operating level of min. 8 meters from
factory floor level, shall be complete with 5.00 mm thick SS 304 grade drum, 8
mm thick SS heads with MS structural reinforcement, cast iron trunnions, SS 304
grade internal piping and decking, SS screens, MS trough, agitator, two numbers
valves, one on each side consists of br onze valve body, br onze wear plates,
washing assembly and scrapper, variable speed drum drive and constant speed
agitator drive.
The drum drive shall be of 1.50 kW TEFC motor having means to vary the drum
speed from 30 RPH to 10 RPH. The agitator drive shall be of 1.00 kW TEFC
motor. The rotary filter shall be complete with two numbers filtrate receivers
fitted with gun metal vacuum release assemblies and copper floats, one number
vacuum regulating valve, two nos, filtrate pumps each capable to extraction 85
cu.m / hr (one as standby) filtrate under vacuum of 500 mm (20 ) mercury and
discharging at 20 meters head, one cascade condenser, one entrainment separator
with sealing arrangement to discharge the entrained juice to mud receiving tank,
feed mixtur e, one vacuum pump of 12 cu.m/minute capacity against 500 mm
mercury, complete with motor and drive, one over flow tank of 45 HL capacity
with steam coil and trap, one centrifugal blower, one bagasse cyclone suitable for
separating bagacillo with mild steel adjusting fin, 400 mm inlet connection and
out let two wa y va lve fitted with ma nua lly oper a ted fla p door , two mud
circulation non clog centrifugal pumps each of 25 cu.m/hr capacity at 20 meter
dischar ge head complete with motor dr ive, one injection water pump of 15
cu.m/hr capacity at 25 meter discharge head complete with motor drive, one cake
wash water pump of 10 cum/hr capacity at 30 meter discharge head complete with
motor drive etc.
The bagacillo blower shall be complete with 400 mm dia. blowing pipe from mill
house to bagacillo cyclone along with pipe fittings etc. Filter cake shall be
discharged by gravity in a common chute to enable to avoid belt conveyors. The
feed mixer, Air blower and cyclone separator shall be of suitable sizes.
4.4.9 Juice Evaporation Station
Two sets of quintuple Effect Evaporator with Extensive Vapour Bleeding will be
provided to achieve continuous and non stop evaporation process.
Evaporator
2400 sq. m., 5 bodies x 2 sets, with extensive vapor
bleeding
48
The heating surfaces given for quintuple effect evaporator are indicative. The
Tendererss ma y wor k ou t heating surfaces so a s to pr ovide gua r a nteed
performance parameters.
Item Value for each body Total
1 2 3 4 5
Distribution of
Heating Surface
30% 35% 18% 10% 7% 100%
A-set: Cap 150 tch x
32 = 4800 sq.m
720 840 433 240 167 2400 sq.m
B-set standby 720 840 433 240 167 2400 sq.m
Extensive Vapour
Bleeding:
CLJ-3 ABC-VP, SJ -
3, CJ-2, Pan
washing
SJ-2 SJ-1
RJ-3
RJ-1 RJ-2 By
condensate
heater
Clear juice-1 heating by clarifier s flash vapours
Ther e will be 2-separate evaporator sets each consisting of 5-evaporator bodies
and multiple numbers of juice heaters. One set will be always in operation and
one standby; to be used whenever the operating set is under cleaning. All bodies
in each evaporator set will be of Robert type having 2.5 m height calandria each.
Suitable relief valve spring loaded type shall be provided to ensure that pressure
in the vapour space of 2
nd
body of evaporator does not exceed 1 kg/sq.cm.g. All
the bodies shall have a vapour space height (between the top tube pate and the
bottom of the umbrella or cylindrical portion of the vapour space) shall not be less
than 2.50 times the calandria height. Suitable arrangement for light and heavy
noxious gas removal shall be provided. Boxes shall be provided for easy removal
of condensate from calandria. Manhole shall be provided in bottom saucer and
vapour space. Suitable connection for soda washing and draining for juice shall
be provided. Safety valves shall be provided on calandria of first body.
The Robert type bodies of heating surface of 720 and 840 sq.m HS, shall have
minimum thickness of mild steel plates for calandria and body of 16 mm, bottom
saucer 22 mm and tube plates 32 mm at top and 38 mm for bottom tube plate.
The Robert type bodies of heating surface of 433, 240 and 167 sq.m HS shall
have minimum thickness of mild steel plates for calandria and body of 12 mm,
bottom saucer 16 mm and top tube plate 25 mm and bottom tube plate of 32 mm.
49
The bottom saucer shall be welded to the calandria. The domes of the bodies of
Robert type evaporators shall have efficient save all of baffle and centrifugal type.
A suitable external save-all for fitting in the vapour pipe after the last body going
to the condenser shall be provided.
Each body shall have three sight glasses and one light glass; lowest sight glass
shall be not higher than 1.50 m from the working platform and 250 mm from top
tube plate.
The Robert type bodies shall have, annealed stainless steel tubes confirming to IS:
13316 of 45 mm outside dia and 1.225 mm thick and 2500 mm length shall be
used. The pitch of the tube shall be such that the ligament is not less than 10 mm.
Adequate tie rods shall be fixed to avoid movements of tube plates due to thermal
shocks for evaporator bodies having 720 and 840 sq.m HS.
The placement of the tubes shall provide effective steam distribution arrangement.
The eva por a t or set s sha l l be compl et e i n ever y r espect with fittings for
satisfactory operation, 8 mm thick mild steel interconnecting vapour pipes. Syrup
extraction system with suitable columns connected to two syrup extraction pumps
(one as standby) of 25 cu.m/hr capacity each at 30 m. head through grit catchers
of SS: 304 screens shall be provided. Continuous syrup sampler and sampling
ar r angement fr om each body shall also be pr ovided. Suitable individual
condensate extraction pumps with receiver bottles to be provided to all bodies.
The speed of condensate pumps should be not more than 1500 rpm.
Condensate flash heat r ecover y systems shall be added to minimize steam
consumption by 2 - 2.25% cane.
Condensate outlet pipe from various units shall have sight glasses at eye level in
addition to sight glasses in extr action columns. The sample cocks shall be
pr ovided at all units individually for testing condensate for sugar tr aces for
condensate pumps delivery lines, which shall have suitable connection with
valve for draining as and when sugar traces are found in the condensate.
Sample cocks shall also be fitted for each evaporator body at inlet of first body, at
outlet of last body and in between all evaporator bodies to calculate evaporation
rates. There should be sampling cocks provided for un-sulphited and sulphited
syrups.
50
A working platform with staircase from ground level under the bodies for
cleaning, repairs and maintenance shall be provided. Platforms with stair cases
shall be provided on the top of bodies for operation and maintenance. Walk ways
to be provided on top of evaporator bodies for opening valves and man holes.
For open soda boiling, reduced steam entry and vapour outlet to atmosphere at top
shall be provided in each body.
Suitable arrangement for preparation of caustic soda solution and pumping the
same to the evapor ator bodies with r ecir culation ar r angement shall also be
provided. Capacity of the tank shall be 200 HL; pump capacity shall be of 20
L/second against a head of 15 meters.
4.4.10 On-Line Conductivity Measurement Of Condensate Water
On line conductivity measurement system shall be provided for measurement of
conductivity in condensate return lines from 1
st
and 2
nd
body of evaporator set.
The system shall have following specifications.
Sensor cum Analyzer:
Based on conductivity principle with tefzel body SS 316 electrode and built in
temperature element for automatic temperature compensation. Cell constant for
conductivity sensor shall be 0.1 or suitable for low conductivity measurement.
Output: 4-20 mA DC for remote indication and recording
Alarm : High/Low contacts for Alarm annunciators.
4.4.11 Syrup & Molasses Storage Tanks
Total 12 tanks each of 150 HL capacity
Each tank shall be of 150 HL capacity to store syrup, molasses and melt etc at the
pan floor. These tanks shall be of rectangular shape. Each tank shall have level
indicating device with SS-304 floating ball.
Two or three tanks shall be arranged in one nest depending upon the material to
be stored with the provision of separate nest for syrup, each molasses and melt.
The tanks shall be made of 8 mm thick mild steel plate duly cross braced with 65
x 65 x 6 mm angle at top, bottom and sides and have 4-numbers tie rods at the
top. Molasses stor age tank shall be pr ovided with vapour -condensate water
heating coils with necessary valves and non-return valves, draining arrangement,
pipes, gutters, valve etc.
51
The wash out connection of each tanks shall be connected by a pipe to juice
check weighment tank with pr oper dilution with water and pumped to juice
sulphitation tower with suitable valves. All tanks shall be covered with gratings.
Necessary pipe lines with right angle valves from the tanks to the pans i.e. for
syrup, melt, A-light molasses etc. for A-heavy molasses and B- light molasses, B
heavy and for C-light molasses shall be pr ovided, for r espective A, B, and C
massecuite pan.
4.4.12 Molasses Conditioning Units
Three sets: AH=12 MT/hr, BH=6 MT/hr, CL=4 MT/hr
Three Molasses conditioning units complete with inter connecting pipes, valves
and sampler shall be provided; one for A-heavy molasses, one for B-heavy and
one for C-light molasses. These molasses conditioners will be designed with
following capacities in t/hr of molasses:
A-heavy of 12 MT/hr
B-heavy of 6 MT/hr
C-light of 4 MT/hr
Automatic control of temperature and brix system shall satisfy the following
requirements:
i) Temperature of conditioned molasses - 70
o
C
ii) Brix of conditioned molasses - 70
0
- 75
0
iii) Conditioned molasses shall contain no fine grains
4.4.13 Automatic Brix & Temperature Control Equipment, Molasses Conditioners
The automatic brix and temperature control system for molasses conditioners
shall be provided. For each molasses conditioner, the system shall include two
control loops consisting of various control system components as specified.
52
Sr.
No.
Control
System
Specifications
1. Brix Control
System
Brix Control System
2. Sensor Based on conductivity principle with tefzel body SS
316 electrode and built in temperature
Element for automatic temperature compensation
3. Transmitter Two wire electronic analogue type with 4-20 mA DC
output
4. Controller Microprocessor based single loop indicating type
5. Control Suitable for contr olling the flow of water in valve
molasses continuously with proportional control
6. Temperature
Control
System
Temperature Control System
7. Sensor Suitable RTD PT 100
8. Transmitter Two wire electronic analogue type with 4-20 mA DC
output
9. Controller Microprocessor based single loop indicating type
10. Control
Valve
Suitable for controlling the flow of steam entering into
t h e mol a sses con di t i on er Con t i n u ou sl y wi t h
proportional control
11. Recorder Suitable recorder for recording the controlled brix and
temperature of the molasses.
4.4.14 Batch Type Vacuum Pans
All vacuum pans will be of Low Head (LH) Batch type
All A, B & C LH
batch type pans
40 MT/strike, 5 nos.
Boiling Time: A-2.5= say approximately 3 Hr, B-4 Hr, C-8 Hr
Five LH batch type 40t/str vacuum pans shall be installed.
53
Each pan shall have double tangential steam/vapour entries. The vacuum pans
shall be low head rapid boiling calandria type each having normal strike capacity
of 40 tones (280 HL) massecuite. Graining volume in each pan shall preferably
not exceed 45 % of strike capacity. Cross section area ratio of all tube ID to down
take shall be 140%.
The heating surface of each pan shall be so designed that the ratio of heating
surface (m
2
) to volume (m
3
) is not less than 6.60. The length of the tube shall not
exceed 750 mm.
The tubes shall be of Stainless steel confirming to IS: 13316-92 having 90 mm
outside dia. x 1.625 mm thickness. The pitch of the tubes shall be such that
ligament is not less than 16 mm. Mild steel tube plates shall be 25-mm thick
calandria and body 12 mm, bottom saucer 16 mm. Vapour pipe 8 mm thick. The
bottom saucer shall be welded to the calandria in which case suitable arrangement
for expansion of tubes in the bottom tube plate shall be provided. Bottom saucer
shall be of ring supported design of minimum 750 mm height.
A vapour space of 2.50 m shall be provided in the cylindrical portion above the
strike level. The pan shall have internal save-all having centrifugal and baffle
type catchall of efficient design. The vapour pipe dia. going to the condenser
shall be 900 mm. Each pan shall have feed-check valve after the feed manifold.
Pans shall have 7 Nos. sight and 2 Nos. light glasses of 200 mm dia size, light
glass with reflector to illuminate the whole tube plate, calibration scale, vacuum
gauge and thermometer in vapour space and a compound gauge and thermometer
in the calandria.
Each vacuum pan shall be complete in every respect with necessary fittings for
satisfactory operation including the pneumatically operated efficient discharge
valve of ample capacity, various pipe lines (vapour, syrup, high and low grade
molasses, movement water, inter connecting cut over pipe lines etc.) key sampler,
vacuum and atmospher e venting. Hot water meter cum r ecor der capable of
measuring 15 m
3
/hr of hot water shall be provided. Panometer with automatic
feed contr ol system and pneumatically oper ated dischar ge valves shall be
provided.
The condensate extraction system shall consist of two closed cylindr ical
receivers installed at the 3.50 meter level on steel staging. The capacity of exhaust
condensate receiver shall be 50 HL and that for vapour condensate receiver 125
HL. These tanks shall be complete with level indicator outside the tank and
necessary venting arrangement. The condensate piping shall be such that the
condensate fr om low gr ade pans could go to either of these tanks wher eas
condensate from high grade pans could go to vapour condensate receiver.
54
The condensate pipes in these r eceiver s shall lead up to
th
height from the
bottom of the receiver for sealing purpose. Two pumps (one as common stand
by) each of 30 m
3
/hour capacity and one pump of 15 m
3
/hour capacity against
a head of 30 m. shall be provided for pumping the condensate from these tanks
to hot water tank.
These pumps shall have minimum 25% leak off to the receivers for maintaining a
constant level of the tanks.
Each pan shall have one common vapour inlet valve of 400 mm. Dia. B/C pans
shall have common valve for 2 Nos. vapour connection.
Automation of Batch Type Vacuum Pans:
1. Feed control loop: - A feed control loop has to be provided for each vacuum
pan. Contr ol loop should consist of conductivity electr odes (self cleaning
type) conductivity monitor , micr o pr ocessor based PI D contr oller s, I P
converters and pneumatic control valve. The conductivity monitor shall have
to be calibrated for purity range of massecuite during boiling such that ideal
brix to be maintained in vacuum pan and is noted vis--vis the conductivity
monitor to enable set the desired value of conductivity on PID controller.
2. Seed Magma Feed Control: A system for varying the RPM of the metering
pump through the signals received from the pressure transmit the monitoring
the vapour pressure in the calandria at pre set value should be available.
3. Absolute Pressure: A facility to r egulate condenser water quantities
automatically should consist of one absolute pressure transmit PID controller
and an electro pneumatic control valve. The control valve should be fitted on
water inlet pipe of the spray nozzles. The water quantity is to be regulated
corresponding to the vacuum in the pan.
All control valve sizing should be calculated to ensure an output of each vacuum
pan capacity.
General
The complete system consisting of the various above loops, should be provided
with a main control panel fitted with all monitors, controllers, indicating lamps,
alarm annunciators and hooters.
55
In addition to the above, the following will also be provided.
1) Molasses quantity flow indicator with integrator
2) Level indicator in the seed magma storage crystallizers.
3) Level indicator in the molasses storage tank with low level annunciation.
4.4.15 Seed & Vacuum Crystallizers
Two Nos. seed cr ystallizer s of 25 MT net working capacity each and three
vacuum crystallizers of 25 MT capacity each.
All the crystallizers shall be fitted with stirrer, coupled to 3 kW, TEFC motor with
high efficiency planetary reduction gear unit and necessary fittings. The speed of
the stirrer shall be about 60 RPH.
These crystallizers shall be installed on pan floor. Necessary interconnecting
pipelines between these crystallizers and pans shall be provided.
The shell of the vacuum crystallizers shall be made of minimum 8-mm thick M.S.
plate with necessary stiffeners and the end plates minimum 16-mm thick M.S.
plate with stiffeners. The seed crystallizer shell shall be 8 mm thick and end plate
16 mm thick with stiffeners.
Vacuum crystallizer shall have four sight glasses on the side and one light glass
with reflector at top. One manhole of 500-mm dia. and arrangement for sight
glass washing shall be provided. A ladder shall be provided for the approach of
seed and vacuum crystallizer. Cut over valves of this crystallizer shall be operable
from the pan floor.
Vacuum crystallizers should be near C Pans and Seed crystallizers towards A
Pans.
4.4.16 Condensers
Two For Evaporators: - Suitable for 600 mm dia vapour pipe.
Five For Vacuum Pans: Suitable for 900 mm dia vapour pipe.
Type of the Condenser Energy Efficient Type
56
Each condenser shall be made of 5 mm. thick SS 304 with M.S. hoop rings & tail
pipe shall be 3 mm thick of S.S. 304. Suitable platfor m with railings, access
staircase for inspection, repair etc. of the condenser shall be provided. J et & spray
nozzles shall be of SS 304. Condenser shall be so designed that the approach
temperature (temp. difference between saturation vapour temp. and tail pipe outlet
water temp) should not be more than 5
o
C.
Injection water line shall be provided with online strainers. Each strainer shall be
outside the condenser at the inlet to enable to clean dirt during operation, through
100 mm dia gate type valve.
Two pressure gauges shall be provided one in inlet and another in outlet of
strainer of each condenser.
Special cladding SS-304 material 200 mm dia x 10 mm thick round plates shall be
welded in front of each spray nozzle to avoid damages to the body of condenser
due to erosion because of force and impingement of water sprays.
Automation of all condensers shall be done to minimize water to vapour ratio to
26:1.
4.4.17 Injection & Spray Water Pumps:
Injection pumps:
Capacity of 1000 m
3
/Hr 24 m Head 3 Nos (1 No. standby)
Spray pumps:
Capacity of 1000 m/Hr 15 m Head 2 Nos (both in operation)
The above pumps shall be of centrifugal type, bronze impeller and fittings and
directly coupled to SPDP slip r ing induction motor with suitable star ter for
continuous wor king. Pr iming pumps for injection and spr ay pumps shall be
provided. The starting current should not exceed by 300% of full load current.
The injection water pipe connection to condenser should have valve for regulation
purpose. A pressure gauge in water line is to be provided. A common header of
600 mm dia and 10 mm thick size shall be pr ovided. Each pump shall have
isolating & NRV in delivery line and 2 Nos. drain connection of 100 mm dia with
blind shall be provided.
57
4.4.18 Spray Nozzles & Spray Pond:
No. of nozzles: 200
1he main header of Spray Pond shall be MS construction 9 m 4 and minimum
10 mm thickness. The branch piping 13 Nos. on one side and 12 Nos. on other
side each of 150 mm dia installed at 5.0 meter centr e and fitted with 5 Nos.
nozzles of 2.20 m. center shall be PVC with support of RCC pillars. Nozzles shall
be of thermo engineering plastic with SS insert at throat of nozzle & arranged on
the branch piping with single nozzle arrangement. The discharge capacity of each
nozzle should be 14.5m/hr.
The cooling system for the water shall be so designed that at least a drop of 13
o
C
or within 7
o
C of wet bulb temperature, whichever is less should be achieved.
Spray pond and masonry water channels shall be suitably designed.
4.4.19 Cooling, Curing & Grading Plant
Crystallizers
Crystallizers Capacity, MT & Numbers
A- AC (air cooled) 45 MT x 4
B-WC (water cooled) 45 MT x 1
C & R 45 MT x 1
C-WC-MVC 150 MT x 1
(i) Four Nos. air cooled each of 45 tones batch type horizontal crystallizers for
A massecuite;
(ii) One no. water cooled crystallizers of 45 tones capacity horizontal batch type
for B massecuite;
(iii) One no. water cooled cr ystallizer of 45 tones capacity as r eceiver for C
massecuite;
(iv) One no. 150 tones capacity vertical continuous crystallizer for C massecuite;
The batch crystallizers for A massecuite shall be complete with efficient stirring
arrangement of sturdy construction. Air cooled crystallizers shall rotate at the
stirrer speed of not more than 60 RPH.
58
Necessary cooling surface to be provided in case of B massecuite cooling, so
that the massecuite temperature is cooled from 65
o
C to 50
o
C when supplied with
cooling wa t er a t 30
o
C. Hor izontal type water cooled cr ystallizer for B
massecuite shall be rotated at the stirrer speed of not more than 20 RPH.
In case of C massecuite necessary cooling surface shall be provided so that the
temperature of the massecuite is cooled from 65
o
C to 40
o
C in 15 hours, when
supplied with cooling water at 30
o
C. Provision in the design shall also be made
for a maturing period of 4-5 hours in case of low-grade continuous crystallizers.
The cooling surface (m
2
) to volume (m
3
) ratio shall be minimum 2.0. The heat
exchange elements shall be tested at pressure of 6-kg/cm
2
g complete with all
accessories suitably designed to give a stirrer speed of not more than 20 RPH.
All cr ystallizer s should be dr iven by shaft mounted high efficiency suitable
helical planetary drive system each of 4 kW.
The heat exchange elements of vertical continuous crystallizer should be of Boiler
quality or heavy-duty ( C class) MS pipes as per I S-1239 and disc type for
horizontal water cooled crystallizer.
The shell of the horizontal crystallizers shall be made of minimum 10 mm thick
mild steel plate and end plates 16 mm thick mild steel plate duly reinforced.
For pumping C massecuite from receiver crystallizer to vertical crystallizer and
for liquidation of C massecuite from vertical crystallizer: 2 Nos. pumps (1 as
stand by) each of 20 t/hr capacity and 30 m head shall be provided.
4.4.20 Centrifugal Machines:
Fully automatic flat bottom plough discharge recycling type machines
Type of massecuite & Machine Capacity, Kg/charge & Nos.
A-massecuite
A-machines (22 cycles / hr, 2 working & 1
stand by) 650 x 3
Drive: D.C. thyristor controlled drive shall be provided with 22 cycle /hr. All
operations of the automatic recycling type machines including charging and
discharging, changing the speed, switching of motor polarity if any, application of
superheated wash water, molasses separation, operation, bottom valve closing etc
shall be automatic. Manually operated brakes shall also be provided with process
logical control programme shall be provided such that the plough should not be
operated at higher basket speed than ploughing speed of 60 RPM.
59
Each machine shall have individual switch fuse isolator of suitable rating, an
ammeter, and thyristorised/ air break-contactor for operating the machine in
manual and fully automatic r ecycling with a separ ate selector switch. All
operations such as charging, bringing the machine at different speeds, retardation,
water wash, pugmill gate opening and closing, syrup separation, cycle over etc.
shall be given on contr ol box and indicated by differ ent lamps. All these
applications shall also be possible to be applied by push button/rotary switch in
manual or automatic position of the selector switch from the control box except
bringing the machines at different speeds, retardation and cycle over.
Necessary arrangement in the panel shall be provided for tripping of the machine
in case of high temper atur e on sensing thr ough ETDs of the motor s. The
centrifugal machines shall be complete with super heated wash water system
working on hot condensate water and AH and AL efficient separation devices.
Continuous Centrifugal Machines:
Type of massecuite & Machine Capacity & Nos.
B & C-massecuite 1100 mm x 5
Transient heaters 3 Nos.
Five Nos. Continuous centrifugal machines for C foreworker dia 1100 mm shall
be capable to cure C massecuite of minimum 100 brix and 52 purity at a rate of 6
MT/hour and shall have a Minimum gravity factor of 2200.
Continuous centrifugal machines for ' B' curing and C afterworker dia 1100 mm.
capable to cure 12 MT/hour & shall have minimum gravity factor of 2000, C
massecuite shall be double cur ed.
The continuous centrifugal machines shall be complete with mild steel monitor
casing designed to provide a sturdy support for all machine elements, separate
compartment for sugar and molasses, hinged doors for access to the sugar
chamber, sugar sampler and water / steam washing arrangement, stainless steel
basket construction, stainless steel inner supporting screen, pure nickel
chromium plated working screen, stainless steel accelerating cone, receiving
cup, hot water/steam washing arrangement with metering device to measure the
wash water, drive arrangement having motor, pulley, V-belts / direct drive and
bearings, massecuite feeding device, etc.
60
The angle of basket shall be 30 deg for B & C massecuite. Screen for ' C'
foreworker machines shall have perforations of 0.06 mm and not less than 7%
open area. Screen for B and C afterworker machines shall have perforations of
0.09 mm and 9% open area. The bearing lubrication system shall have built in
protecting arrangement to trip the machine incase of failure of lubrication system
and or bearing temperature rise.
Oper ator s push button panel shall have pr ovision for oper ating motor , an
ammeter and ' ON' indication.
Incoming panels for both batch and continuous type centrifugal shall be designed
for a symmetrical fault level of 35 KA (rms) of one second, at unit load factor. All
incoming panels shall consist of an ACB, an ammeter, and voltmeter with fuse
and selector switch and ' ON' indication. Suitable interlocking arrangement shall
also be provided in each self-discharging machine panels such that not more than
two machines are started at a time.
Hot monorail crane for all machines:
Monorail with 3 MT capacity chain pulley block over the centrifugal machines
shall be provided.
4.4.21 Pug Mills, Magma Mixers & Transient Heaters
Pug mills & magma mixers for high & low grade machines:
Suitable pugmill made out of 6 mm thick mild steel plate and mounted over the
machines shall be pr ovided having stir r ing ar r angement, dr iven by electr ic
motors, coupled to reduction gear unit. The pugmill feed valve for batch machines
shall be operated pneumatically. For low-grade massecuite separate header with
transient heater for individual C/F machine shall be provided. Pugmill with drive
will be pr ovided for C after and B machines. All the fore -workers and low
gr a de ma ssecuite a fter wor ker ma chines to discha r ge dir ectly into the
corresponding magma mixer of suitable capacity and design. The shell of the
magma mixer s shall be of 6 mm thick mild steel plates having double beater
paddles, coupled to electric drive through suitable reduction gear.
Transient heaters:
C-massecuite centrifugal machines shall be fitted with suitable transient heater
one for each machine. All transient heaters should have 16 SWG wall thick AISI
304 grade SS tubes.
61
4.4.22 Air Compressor & Magma Pumps
The centrifugal station shall be complete in all respects and shall have necessary
accessories namely Air compressor 7 kg /sq.cm with receiver and refrigeration
dryer to supply moisture free air for pneumatic control, mild steel molasses
tanks, two of 3 cu.m capacity for A-heavy and A-light molasses and remaining
tanks of 2 cu.m capacity each, two molasses pumps of 30 cu.m/hour capacity at
30 meters head for A heavy and light molasses, suitable molasses pumps of
suitable capacity of 15 cu.m/hr at 30 meters head for B-heavy, C-light and final
molasses with a standby for final molasses.
Magma pumps of suitable capacity at 30 meter s head for B for ewor ker , C-
foreworker and C afterworker magma. Magma pumps shall be of rotary type with
cast iron rotor having replaceable gun metal or bronze strips and have by-pass
arrangements. All magma and molasses pumps shall have vapour-condensate
connections with non-return valves and suitable size return pipes with valves from
their delivery pipes to the respective tank. The speed of the magma pumps not to
exceed 36 rpm, 192 rpm for A & B molasses pumps and 144 rpm for C molasses
pumps.
All machines shall be suitably connected to respective molasses tanks for flow of
molasses.
4.4.23 Sugar Melter, DSM Screen & Dry Seed Conveyor
Type of massecuite & Machine Capacity & Nos.
Sugar Melter 15 MT/hr x 1
Automation for sugar melter 1-set
DSM Screen, 0.70 mm slit gap 2.134 m width x 1
Dry seed conveyor 4 MT/hr x 1
One continuous sugar melter of 15 MT/hour capacity for melting sugar lumps
and magma sugars and one melt pump of 20 m
3
/hour at 30 meters head shall be
provided.
A magma mixer and magma pump of 10 MT/hr at 30-meter head shall be
provided near the grader for taking dry seed for A massecuite. Necessary water,
vapour and other usual connections shall be provided.
One DSM screen of 2. 134 m width and 0.70 slit gaps shall be installed for
filtration of melt sugar. Washing of screen underneath shall be provided with
pressurized hot condensate water from third effect evaporator body.
62
4.4.24 Automatic Brix & Temperature Control For Sugar Melter
The automatic brix and temperature control system for sugar melter shall be
pr ovided. The system shall include two contr ol loops consisting of var ious
control system components as specified below:
Brix Control System:
Sensor Based on conductivity pr inciple with tefzel body SS 316
electrode
and built in temp element for automatic temperature
compensation
Transmitter Two wire electronic analogue type with 4-20 mA DC output
Control
valve
Suitable for controlling the flow of water in valve molasses
continuously with proportional control
Temperature Control System:
Sensor Suitable RTD PT 100
Transmitter Two wire electronic analogue type with 4-20 ma DC output
Control valve Suitable for controlling the flow of steam entering into
The melter continuously with proportional control
Recorder:
Recorder: Suitable recorder for recording the controlled brix and
Temp of the melt.
DRY SEED CONVEYING:
One no of suitable capacity of 4 MT/hr r ubber belt conveyor . Rubber Belt
conveyor of suitable capacity shall be provided near the grader for taking dry seed
for A massecuite.
4.4.25 Grass Hoppers, Sugar Elevator, Sugar Grader & Dust Catcher
Equipment & Machinery Capacity & Nos.
Hopper 1.250 m width x 3
Elevator & Grader 10 MT/hr x 1, each
Sugar dust catcher 5 bags/day (100 kg bag)
63
Grass Hopper
One single tray grass hopper conveyor of 1.250 M width and 12 m length shall be
installed under the " A" machines to convey the sugar discharged from the
machines to the first multi-tray grass hopper.
Two multi-tray grasshoppers, each of 1.250 m width and length not less than 12.0
m shall be driven by 6 kW TEFC electric motor with hot air blowing arrangement
on the first multi-tray unit and cold air blowing in the second shall be provided.
The hopper eccentricity shall be not less than 19 mm and its driving shaft speed
shall be 300 to 330 rpm. Portion of the hopper where connecting rod is fixed
shall be strengthened by 10 mm plate, 1.00 meter wide. The hopper shall not be
welded on longitudinal seams. Each hopper shall have two connecting rods. Sugar
lump separating unit shall be provided on second hopper. The drying arrangement
at hopper should be in such a way that the bagging temperature of sugar should
not be more than 42C when ambient temperature is note more than 36C.
All drive slats etc. shall be similar and interchangeable.
Suitable radiator type heat exchanger shall be provided to heat air by condensate
water.
Sugar Elevator
One No. sugar elevator to deliver 10 MT sugar per hour from the hopper to the
grader fitted with suitable components and PVC buckets and driven by a TEFC
electric motor coupled to enclosed worm reduction gear unit shall be provided.
Approximate height of the elevator shall be suitable for installation 3-bins sugar
silo system.
Sugar Grader
The sugar grader shall be of 10 MT/hr capacity having six decks and each deck
ca pa ble to sieve minimum 4 MT of suga r of a ny gr a de a nd sha l l be
mechanically/electrically vibrator type capable of screening any grade of sugar
according to IS specifications. The grader shall be driven by TEFC electric
motor. Magnetic iron separator shall be provided for each chute. One sugar
distributor for distributing the sugar over full width of grader screen shall be
pr ovided. The scr eens shall be of SS-304 quality material. Arrangement for
handling 100 kg and also 50 kg bags shall be provided. Suitable dust catching
arrangement shall be provided.
64
Sugar Dust Catcher
One sugar dust catcher shall be installed of capacity of 5 bags/day. Suitable and
efficient sugar dust catching ar r angement of wet type shall be pr ovided 5
bags/day, with bank guarantee performance.
4.4.26 Fully Automatic Sugar Silo & Weighing Machines
One set of 3-bins, of capacity 10 MT/hr, for 12 hours storage.
Fully automatic sugar silo and weighing machines shall be provided to handle
sugar of 10 MT/hr of various grades.
Three sugar bins shall be of suitable capacities to handle total sugar of 10 MT/hr.
The storage capacity of all bins of various sugar grades shall be having capacity to
store in bins the sugar production of 16 hours of each grade.
Three Nos. pre-determined balance weight type weighing machines each having
capacity to handle 100 kg and also 50 kg HBPE /PP bags of 35 bags/hr.
Suitable electrically operated double row stitch bag stitching machines with one
spare head for stitching machines should be as an emergency spare. The bag
stitching machines of conveyor type, each suitable for handling about 35 bags of
100 kg each per hour shall be provided. The length of conveyor shall be 4 meters.
Microprocessor based electronic load cells type fully automatic net weighing
bagging machines for packing sugar having weighing range of 100 and 50 kg
sugar bags, with pneumatic controlled charging and discharging and bag clamps,
facility to gener ate var ious packing r epor ts viz., hour ly, shift wise or daily
packing, overweight or underweight bags, having LCD display, facility for printer
attachment and transferring data to the computer and operator friendly controller
having membrane type key board. Weighing accuracy shall be of 30 gm.
Suitable bin (MS quality only) storage and automatic bag weighing and filling
system with continuous sugar bag stackers shall be adopted.
4.4.27 Molasses Weighing Scale, Final Molasses Tanks & Water Tanks
Molasses Weighing 1 MT/tip x 1
FM-Tank 3000 MT x 2
Hot &Cold-W-Tanks HL x N 150 HL x 3
65
One automatic molasses weighing scale of 1 MT per tip capacity, complete
with registering counter and other accessories, weighed molasses receiving
tank of 30 HL capacity and two pump sets (one as standby) each of 10
cu.m/hour for pumping the final molasses to the storage tank at a distance of
about 120 m from factory shall be provided. The delivery pipe line shall be raised
ver tically and the subsequent hor izontal por tion to have suitable gr adient.
Provision of check weighment with a suitable tank mounted on platform type
scale of 3 MT shall be provided.
Final Molasses Storage Tank
Two Nos. molasses storage tanks of 3000 MT each capacity.
Final molasses storage tanks shall be as per IS: specifications. Two pumps for
r ecir culation of molasses 10 cu.m/hr and 20 m head shall be pr ovided. An
overhead tanks of 10 cu.m each capacity shall be installed on staging at a height
of 5.00 meters from ground floor with a 300 mm discharge line and valve each to
supply molasses to the tanker directly by gravity. Two molasses pumps of 10
cu.m/hr capacity at 30 m head shall be supplied for recirculation and for loading
the molasses.
Arrangement for spraying water on all sides of all the molasses storage tanks shall
be provided.
Hot & Cold Water Service Tanks
Three overhead tanks each of 150 HL capacity
Four rectangular overhead tanks of 8 mm thick mild steel plates with stiffeners
and angle frame each having a capacity of 150 HL complete with valves, fittings,
pipes shall be provided. Bottom of the tanks shall be atleast 6.0 meters above
Pan floor level. Tanks shall be properly covered. Level indicators for each tank
shall be provided.
Two electric driven centrifugal pumps, each having a capacity of 120 cu.m/hour
at 30 meters head complete with pipes and valves from the pump to the service
tanks shall be provided at suitable place.
Two parallel strainers with isolating valves shall be provided in each of cooling
water lines to mill bearings, oil coolers, air compressors, vacuum pumps, etc, so
that one will be always stand by for periodical cleaning.
All bearings and oil cooling water shall be collected in a Masonry tank, which
should not be more than 15 m away from mill house factory building.
66
4.4.28 Sugar Go-Downs
Two sugar go-downs of storage capacity of 2 Lakh bags each. Sugar go-downs
shall be as per IS standards, having automatic humidity control devices.
4.4.29 Water Conservation & Circulation
It is necessary that the general service water intake shall be minimized near to the
zer o levels to achieve water conser vation. This also should apply to water
discharge. All excess water condensates from the sugar plant shall be cooled,
filtered, treated and recycled for the entire sugar plant. Excess cooled condensate
water shall be lead to the injection water make up pur poses after chemical
treatment to achieve desired neutral pH values.
Floor washing, juice heaters, evaporator bodies and vacuum pan washing and
brushing shall be done only with the help of these excess condensates.
Water Conservation Recirculation System
Necessary arrangement shall be provided for recirculation of cooling water from
mill bearings, enclosed mill drive gear boxes, crystallizers, air compressors and
sulphur burners etc. All equipments like M.S. fabr icated collection tank of
suitable capacity, 3-nos pumping sets (one as standby) piping, valves etc shall be
installed at suitable location. This water shall be pumped to raw water reservoir
through spray nozzles installed on the reservoir itself to achieve the atmospheric
cooling.
All of excess condensate water shall be cooled down and re-used for bearing and
coolers loop and make of spray water. Thus, there should be zero water discharge
to ETP.
4.4.30 Miscellaneous
Pressure Reducing & De-Superheating Systems (PRDS), Header & Valves
Capacity of 20 TPH. The PRDS System shall be provided with automatic steam
reducing valve to maintain a steady pressure of 1.75 kg/sq.cm.g pressure at 125
0
-
130
0
c in the receiver at the inlet of header at evaporator station for requirement of
exhaust steam for the sugar plant.
The capacity of steam r equir ed shall be 20 MT/hr minimum and 25 MT/hr
maximum.
67
Suitable automatic de-superheating arrangement and relating syst em t o be
provided to maintain a steady temperature of 130
o
C plus-minus 5
o
C, in the
exhaust steam receiver by automatic de-superheating of the entire exhaust
steam The de-superheated steam coming out of the exhaust steam receiver shall
be saturated and dry.
There shall be provision for adjusting the pressure in exhaust steam receiver at
any pre-set valve in the range of 1.50 to 2.00 kg/sq.cm.g.
Two water pumps with electric drive of suitable capacity (one standby) for
injecting water in the specified r educed pr essur e steam lines thr ough
pneumatically operated control valves shall be provided for de-superheating
the exhaust steam.
The reducing valve shall be provided with pneumatically operated pressure
controllers designed to maintain steady pressure with down steam flow rate
var iation fr om 10% to 100% of the r ated capacity with over r iding contr ol
system. One electric driven air compressor with receiver and piping shall be
provided for operation of the reducing valves and de-super heaters.
One steam flow meter shall be provided in the high pressure side of the
reducing valve system at the inlet of the exhaust steam header.
One steam pressure recorder capable of recording pressure from 1.50 to
1.75 kg/sq.cm.g shall be provided in the exhaust steam line near the Evaporator
station.
A dial ther mometer of 150 mm dia and 0-200
o
C r ange shall also be
pr ovided in the exhaust line. One temper atur e r ecor der to r ecor d the
temperature up to 200
o
C shall be provided in the exhaust line near the
Evaporator station.
Suitable bypass arrangements for each automatic reducing valve to be provided
for manual operation. Isolating valves shall be provided to isolate the automatic
valve for r epair s while wor king. Steam str ainer s at upstr eam side of each
reducing valve shall also be provided.
Provision only for start up & standby purposes:
The second branch shall be provided with one automatic steam reducing valve
to maintain a steady pressure of 7-8 kg/cm
2
g. in the receiver from the prime
mover of power plant by injecting steam up to 2 t/hr after reducing pressure from
boiler steam pressure to 7-8 kg/cm
2
g.
68
Suitable automatic de-super heating ar r angement and r elating system to be
provided to maintain a steady temperature of 170
o
C. Plus-minus 5
o
C in the
steam receiver by automatic de-superheating of the entire make-up steam. The
steam coming out of the steam receiver shall be dry.
Two pressure pumps with electric drive of suitable capacity (one standby) for
i nj ect i ng wa t er i n t he t wo r educed pr essur e st ea m l i nes t hr ough
pneumatically operated control valves shall be provided for de-superheating.
All the r educing valves shall be pr ovided with pneumatically oper ated
pressure controllers designed to maintain steady pressure with down steam
flow rate variation from 10% to 100% of the rated capacity with over riding
control system. One electric dr iven air compr essor with r eceiver and piping
shall be provided for operation of the reducing valves and de- super heaters.
One steam flow meter shall be provided in the high pressure side of the
reducing valve system.
One steam pressure recorder capable of recording pressure up to 2.50
kg/cm
2
g. shall be provided in the exhaust steam line near the Evaporator
station. A dial ther mometer of 150 mm dia and 0-300
o
C range shall also be
provided in the exhaust line. One temperature recorder to record the temperature
up to 300
o
C shall be provided in the exhaust line near the Evaporator station.
Suitable bypass arrangements as per IBR for each automatic reducing valve to be
provided for manual operation. Isolating valves shall be provided to isolate the
automatic valve for repairs while working. Steam strainers at upstream side of
each reducing valve shall also be provided.
Bagasse Baling Machines (to be located at suitable space in bagasse yard)
Two bagasse bailing presses of hydraulic type, to handle 2.50 MT / hr each of
bagasse having 50% moisture and complete with 20 kW slip ring induction motor
etc shall be provided.
69
4.4.31 Supporting Structure & Material Specifications
(Staging and structure for 3500 TCD juice extraction diffusion process and 1750
to 1925 TCD crushing capacity at sugar process house).
Factory pan floor levels shall be of gravity flow type. Necessary staging for all the
machinery including supporting columns, integral floor structure, staircases,
railings etc shall be provided. Mills, mill drive, diffuser, clarifier and lime slaker
shall be on RCC staging. Sulphur furnaces shall be on steel staging with RCC
flooring. Other machiner y except those on floor level sha ll ha ve its own
supporting steel staging.
Pipelines, cable tr ays, mill house cr anes, condenser s, flash tanks, cyclone
separators can be supported on building columns. No weight of other machinery
or platform shall be transmitted to building columns.
Mills and diffuser shall have mild steel grating flooring. Centrifugals shall have
chequerred plate flooring. In the boiling house chequerred plate flooring shall be
provided.
All gangways, passages, staircases, working platforms and railings shall be of
convenient chequerred plate thickness of minimum 5 mm.
Staging and str uctur e pr ovision shall be made in the space and ar ea, for
additional juice heaters, clarifier, evaporator set, syrup and molasses storage and
supply tanks, vacuum pans, crystallizers, centrifugal machines, hoppers, grader
and sugar silo systems for designed crushing rates. A clear working platform of
atleast 2.50 m width shall be provided in working front of pans and evaporator
bodi es . Moving space between pans shall be 1000 mm and in between
evaporator bodies a distance of 1000 mm minimum shall be provided. In case of
other units a clear working platform of atleast 1.50 m width shall be provided.
All statutory requirement regarding staging platform staircases, safety devices
etc shall be observed at the design stage.
General Material Specifications have been indicated below:
Gun metal used for bushes and bearings shall conform to IS: 318-1965.
Phosphor bronze castings shall conform to IS: 28-1975.
The mill drive pinions shall be made of cast steel as per IS: 2708-1973 B
Grade III and gear wheels as per IS: 2708-1973 Grade II.
Cast iron flexible couplings shall conform to IS: 2693-1964.
70
Glass wool for vessels and piping shall conform to IS: 3690-1974
type 2. Mineral wool shall conform to IS: 5696-1970. The thickness
shall be to suit the temperature and diameter of pipes.
Sheet rubber shall conform to type 8 of IS: 638-1965 Grades to suit the
nature of work.
Compressed asbestos fibre shall conform to IS: 2712-1971.
Cast iron sluice valves shall conform to IS: 780-1969.
Gun metal valves shall be of heavy duty and shall conform to IS: 778-
1971.
Plummer blocks used for roller bearings shall conform to IS: 4773-1968.
The slide rails for electric motors, if of grey cast iron conform to grade 15
of IS: 210-1962. The slide rails shall be as per IS: 2968-1964.
Stirrer shaft for crystallizers, pug mills, magma mixers, lime tanks,
sugar melter, juice sulphiter, molasses dilution tank etc. shall conform
to 30 C8 of I S: 1570-1979, except when mild steel fabricated pipes are
used.
Mild steel plates shall conform to IS: 2062-1969 in case of fabricated
base plates, gear beds, for mill drive and all fabricated parts subjected to
steam pressure higher than 1.5 kg/sq.cm.g.
Structural steel and mild steel plates conforming to IS: 226-1975 shall
be used for the fabrication of rest of the machinery and equipment.
Stability Certification Of Staging & Structure
I t is necessar y to check, ver ify and get cer tified the str ength and designs of
proposed staging and structure used for equipment and machinery for both the
proposed crushing rates.
4.5 Other General Design Criteria
In designing factory building and engineering layout criterion should be attached
to local wind direction mainly during crushing season to ensure the following.
General layout of plant and machinery shall show equipment for 3500 TCD at
juice extraction diffusion process and 1750 to 1925 TCD crushing capacity at
sugar process house.
The specifications of plant and machinery, wherever not mentioned in these
specifications for 3500 TCD, shall be according to the guide line specifications
designed and finalized by the technical committee of Government of India in
November 2003 and 1987 and should incorporate the following:
71
1) In designing factory building and engineering layout criterion should be attached
to local wind direction to ensure the following. General layout of plant and
machinery shall show equipment for 3500 tcd.
1) Effective natural ventilation of Mill, Diffusion and Sugar Boiling Houses.
2) Non contamination of circulating waters by acidic agents.
3) Statutory requirements of pollution preventions.
2) The factory floor levels as well as injection channels and cooling spray pond
levels shall be decided to suit the topography at the Sugar Plant site. All floors
shall be well designed and given sufficient slopes to keep factory clean and neat.
All gutters shall be well sealed and kept under ground levels. All pumps shall be
provided with SS pots grouted under ground near pumps to collect all leaked
sugar liquids and fill up again in the same source.
3) Plant and machinery to confirm to all State and Central Govt laws.
4) All the cranes in the Sugar Plant (including cane unloader) should have box type
bridge girders (and not lattice type). All the gear boxes installed on the cranes
should be helical high efficiency type having hardened and ground teeth.
5) The 4-sets of manufacturing design drawings, 4-sets O & M manuals, 4- sets of
drawings, 4-sets of detailed specifications etc should be supplied by the Seller to
the Purchaser 4 months before the scheduled date of commissioning of the Sugar
Plant and should also include the following:
i) List of Ball/Roller bearings fitted in the Sugar Plant (equipment wise
stating bearing Nos.)
ii) List of all electric motors installed in the Sugar Plant (equipment wise
stating motor type, H.P., RPM etc.).
iii) List of all Reduction gear boxes installed in the Sugar Plant (equipment
wise stating gear box type, ratio, H.P., rating, service factor etc.)
iv) List of pumps installed in the Sugar Plant (pump type, duty, discharge,
total head etc.)
v) List of all coupling bushes, oil seals, vee belts etc fitted in the Sugar Plant
(stating size wise quantity and equipment name where the part is fitted).
72
6) The venders shall not make the use of building columns and trusses for lifting
weights of machinery during erection. Factory building structure should not be
used as staging for any items of machinery and equipment (except mill house
cranes & piping).
7) All the Grit catchers in the Sugar Boiling Process Plant should be 800 mm dia x
1000 mm height shell 8 mm thick, bottom 10 mm thick, cover plates 20 mm
thick. Covers should be hinged and cover holding bolts should be 25 mm dia.
The bucket screens should be made of 3 mm thick, AISI 304 quality S.S. and
should have sturdy handles for lifting.
8) Condensate outlet pipes from various units to have sight glasses at eye level in
addition to sight glasses in extr acting columns. Test cocks should also be
provided for taking out all condensate samples.
9) Test cocks should be provided in condensate outlets of all units individually for
testing water for sugar traces. All the condensate pumps delivery lines should
have 50 mm NB connection with a valve to let out the water in the drain, as and
when sugar traces are found in the condensate.
10) Size of Condensate Receivers for J uice heaters and Evaporators should be 400
mm dia x 1200 mm height Shell 8 mm thick, bottom 10 mm thick.
11) The speed of the motors of the condensate extraction pumps should be not more
than 1440 RPM.
12) Heating surfaces of juice heaters, direct contact juice heaters, evaporator bodies,
pans and all other heat exchangers shall be calculated on the basis of mean dia
and effective tube length with contact of heating fluid.
13) All the pumps of juice, lime and syrup should be provided with suitable grit and
sand catchers in the suction side. Also, juice delivery lines should be provided
with non-return valves.
14) All the centrifugal pumps should have stop and non-return valves in the delivery
pipes.
15) Centrifugal pumps: The service water pumps, injection and spray water pumps,
syr up pumps, melt pumps should be br onze fitted wher ever not mentioned,
otherwise these and other (except at mill house and diffuser) centrifugal pumps
should conform to IS-5659 and IS-5120 specifications.
73
16) All the vapour line of the pans and last bodies of the evaporator set should be
provided with manhole to enable accessibility inside the vapour lines for cleaning
and chemical resistance painting purposes. One 100 m dia x 150 mm long nipple
should be welded in the vapour pipe along with a blind flange to enable water
filling of the vapour line.
17) The diameter of the pipes for filling water into bodies and calandr ias of
evaporator and pans should be not less than 100 mm size.
18) All the gate valves for massecuite and magma lines should be of rising spindle
type only.
19) The sluice/right angle valves used in exhaust steam and vapour pipelines should
have stainless steel internals and S.S. spindles.
20) Suitable capacity float ball type steam traps should be provided in the exhaust line
for the outlet of the condensate for quality condensate recovery.
21) Steam flow meters of indicating, integrating and recording type shall be provided
for exhaust steam and for PRDS.
22) Temper atur e r ecor der s for r aw, sulphited juice, evapor ator exhaust steam,
injection outlet/inlet water and vacuum recorder for last body of evaporator shall
be provided at appropriate place.
23) For lagging the equipments, pipes and fittings, juice heaters, evaporator bodies,
vacuum pans, headers, valve bodies, flanges, drain pipes etc of the sugar plant as
per specifications the Sellers scope of supply should be as follows:
All the equipments and pipelines (including fittings as defined under Clause 6 of
IS: 7413 specifications), surfaces in the sugar plant above 55
o
C. temperature
should be effectively lagged (except where heat dissipation is desirable and the
surfaces which become hot intermittently such as steam traps and relief valve
outlet pipes, vents, pipes etc.)
74
Specifications of Lagging Material to be used:
i) F or lagging: F actor y made mattr esses of Bonded Glass wool/Rock
wool/Mineral wool as per IS: 8183 (latest issue) specifications. The
bulk density of the material should be:
a) 50 kg/m
3
for hot surface temperatures up to 250
o
C.
(As per clause 3.2 of IS: 8183 (latest issue) specifications)
The thickness of the lagging should be such that the difference
bet ween t emper a t u r e mea su r ed ( a t a n y t i me du r i n g t h e
maintenance warranty period as per clause of the draft agreement)
at any point on the outer sur face of the lagging cladding (i.e.
protective finish) and the ambient temperature at that time should
not exceed 10
o
C.
ii) For protective finish:
Material for cladding of all lagging in the sugar plant should be cotton
canvas (as per IS: 7413 standard specifications) (except as follows).
a) The valves and flanges (including the flanges of the equipment) to
be lagged and shall be provided with openable lagging boxes for
valves and fittings of the LP exhaust steam lines, openable boxes
shall be out of 18 SWG thick aluminum sheets as per I S: 737
designation 31000 condition H3.
b) All the lagging should be provided with boxes of 3.20 mm thick
Aluminum sheets. Lifting blocks should be pr ovided for these
boxes.
c) Balance materials (not specified above) should be as per IS: 7413
specifications.
Application and finishing of the lagging materials, protective coverings etc
should be ca r r ied out by the Seller a s per I S: 7413 (la test issue)
specifications.
24) All maintenance tools, special tools, tube expanders etc shall be supplied by the
Seller to the Purchaser as per scope of supply stipulated under this Agreement
should be brand new and should not be those used by the Seller for erection and
commissioning of the Sugar Plant.
25) All nuts and bolts and non-return valves should be as per ISI specifications.
26) In cases tensile strength or solidity has been mentioned the supplier shall submit a
suitable certificate of the same from original manufacturer/Govt. approved testing
laboratories/Govt. Engineering Colleges.
75
27) Suitable arrangements shall be provided for continuous sampling of following
a) Primary juice
b) Diffuser juices
c) Last mill juice
d) Mixed juice
e) Clear juice
f) Un-sulphited syrup
g) Sulphited syrup
4.6 Interface Piping
All hot and cold water , juice, syr up, magma, molasses, massecuite and bled
vapors, reduced pressure and exhaust steam pipe lines and headers shall be
suitable for processing mixed juice of 3500 TCD at juice extraction diffusion
process and 1750 to 1925 TCD crushing capacity at sugar process house.
Var ious pipelines shall be designed so that velocities given below ar e not
exceeded:
Material Velocities m/s
Water and juice Suction 1.0 m/second, Delivery 1.20 m/second
Condensate Suction 1.0 m/second, Delivery 1.20 m/second
Syrup Suction 0.5 m/second, Delivery 1.00 m/second.
Molasses Suction 0.3 m/second, Delivery 0.50 m/second.
Massecuite-Magma Suction 0.1 m/second, Delivery 0.15 m/second
Super heated & Satur ated
steam
30.00 m/second
Exhaust steam 30.00 m/second
Bled vapours 30.00 m/second.
Compressed air- SO
2
20.00 m/second
All common headers, pipelines, valves etc shall be designed for 3500 TCD juice
extraction diffusion process and 1750 to 1925 TCD crushing capacity at sugar
process house.
Safety valves shall be provided in the exhaust steam pipe lines wherever
necessary. Blow off pipes shall extend beyond the roof to be taken out from the
sides of walls and partitions. There should not be a single venting line vertically
in the top roof of the factory buildings. All vents shall be provided in the side
walls or partitions.
Safety valves in the exhaust and reduced pressure lines shall be dead weight type
and additional hand lever operated.
76
Suitable drains, valves, steam traps etc shall be provided in all steam lines, where
ever necessary. All the steam traps shall be of ball float type.
The condensates coming out from the entire ball float type traps from exhaust
steam and vapour lines under pressure shall be collected in suitable tanks and as
such no condensate should be allowed to drain in the gutters of the sugar plant.
The quality condensates shall be sent directly to the steam boiler of cogen plant.
The pipes shall conform to specifications given below:
(i) Cast Iron Pipes and Fittings:
The pipes shall be class ' B' and shall conform to IS: 1537-1976 specifications
and integrally cast flanged joints or spun pipes with screwed ends on flanges as
per IS: 1536-1976 shall be used.
The pipe fittings shall be class ' B' and shall conform to IS: 1538 (part I to XXIII) -
1976 specifications. Only flanged joints shall be used. One side of the flanges
shall be machined in case all pipe fittings.
(ii) Mild Steel Pipes
All mild steel pipes and pipe fittings used for conveying of air, cold water, to
water (except boiler feed water) oil (except oil for hydraulic accumulators),
molasses, massecuite, juice, lime, syrup, noxious gases etc. shall conform to IS:
1239(part I)-1976 and IS: 1239 (part II)-1982 specifications. All juice and
syrup piping including imbibition juice piping shall be class `C' (heavy) and
rest of the piping shall be class `B' (medium). The thickness of mild steel pipes
having diameter more than 200 mm shall be 8 mm.
I n case of all piping above 25 mm NB only flanged joints shall be used. All
flanges to be as per IS: 6392-1971.
(iii) Exhaust steam piping:
These shall conform to IBR wherever applicable. The thickness of exhaust and
vapor steam piping shall be minimum 8 mm in case of 300 mm dia. and above.
The distance between two flanges in straight portion of pipes shall not exceed 6
meters except steam, vapor pipe. In case of bends, flanges shall be provided at
least at one end. All steam expansion bellows shall be of stainless steel tested at
1.5 times the exhaust steam pressure.
77
Valves shall be pr ovided in each br anch line of juice heater ,, r educed
pressure steam lines, water separator, drain, steam trap etc.
All delivery lines of juice, water and syrup of centrifugal pumps shall have non-
return valves except in case of unstrained re-maceration juice pump, lime and
Mud pumps. Water connections shall be provided at each station for cleaning.
All exhaust steam valves for evaporator and pans shall be of right angle type
valves with suitable leak proof seats.
(iv) Bearing cooling piping:
All bearing and oil cooling water shall be collected in a masonry tank which shall
not be more than 15 meters away from the factory building.
78
Chapter 5
Energy Efficiency Improvement
5.1 Steam Consumption
The Tendererss to evaluate and provide following specific proven steam economy
measur es for a chi evi ng gua r a nt eed per for ma nce pa r a met er s for st ea m
consumption of 22% on cane. Additional possible measures for the purpose or
even for lower steam consumption than to be guar anteed may be separ ately
quoted.
i) I nstalling full automation system fo r t h e entir e sugar plant, a n d
par ticular ly for sugar pr ocess house t o r educe st ea m a nd power
consumptions.
ii) Avoiding medium pr essur e stea m of 5-7 bar entir ely, during normal
operation of the sugar plant.
iii) Making use of dynamic, vapour line and direct contact juice heaters.
iv) Using waste exothermic heat of SO
2
gas for melting sulphur powder.
v) Heating of clear juice CJ-1 by using flash heat from clarifier
vi) Utilization of condensate flash heat energy at evaporator station.
vii) Ar r anging Quintuple set and evaporator bodies for extensive vapour
bleeding and minimizing condenser vapour load near to zero.
viii) Heating of sulphited juice in two stages.
ix) Using noxious gases back to immediate low pr essur e vapor lines to
recover the waste heat.
x) Use of third body vapors for special melter for B-seed.
xi) Pan body washing with second effect vapours.
xii) Intensifying pan circulation by using less height calandrias of 750 mm.
xiii) Controlling movement water in vacuum pans by using flow meters.
xiv) Using all second body vapours at pans and minimizing the use of first
body vapors.
xv) Super heating wash water at centrifugal machines by exhaust condensates
xvi) Using vapor condensate heat for heating air at sugar hoppers.
xvii) Sugar melting by syrup, pan condensate water and non condensable gases
under vacuum.
xviii) Using non-condensable gas s heat for molasses conditioners, syrup and
filtrate heating.
xix) Using waste heat of blow down water using heat exchangers at boiler
79
5.2 Power Consumption
The Tendererss to evaluate and provide following specific proven power economy
measur es for a chieving gua r a nteed per for ma nce pa r a meter s for power
consumption of 23 KW / MT at 150 TCH. Additional possible measures for the
purpose or even for lower steam consumption than to be guaranteed may be
separately quoted.
i) Providing star connection instead of delta for motors with constant low loads
up to 35%, such as final molasses pump, C-light molasses pump, sugar
melter, sugar elevators, weighed molasses transfer pump, B-continuous grain
pumps, sugar melter screw pump, belt conveyor and all crystallizers.
ii) Providing adequate size motors for various applications and providing star
delta controllers for dr ive motor s expected to operate at less than 50%
capacities and where fluctuating loads are envisaged for applications like
magma pumps, dr y seed pumps and mixtures, molasses conditioners and
milk of lime stirrers.
iii) Providing energy efficient electrical motors having efficiencies more than
90%.
iv) Providing bigger sized equipment and machinery to minimize number of
machinery, such as at A, B and C massecuite centrifugal machines.
v) Providing variable speed drives (VFD) for variable speed and different flow
applications like cane carrier drive and other motors at variable flow rate
pumps such as raw juice, sulphited juice, imbibition, injection, condensate
and service water pumps, rake cane carriers and inter carriers, magma pumps
and super heated wash water pumps.
vi) Providing voltage controllers in the circuit of general lighting applications
for reduction of voltage to 210 V instead of 230-240 Volts, without affecting
luminous intensity.
vii) Providing high efficiency planetar y gear dr ives at crystallizers, magma
mixers, vacuum and seed crystallizers and pug mills.
viii) Pr oviding high efficiency helical gear units at all car r ier s, cane yar d
equipment, magma and massecuite and molasses pumps, milk of lime
equipments, molasses conditioners etc.
ix) Elimination of power dr ives by using gr avitational for ce at cush-cush
conveyor s under DSM and for filter cake conveying by using gr avity
discharge chutes.
x) Providing capacitor banks of adequate sizes at MCCs, to reduce cable losses.
xi) Providing level controller switches for juice and sugar dust collector tanks
xii) Providing automation of massecuite feeding to continuous centrifugal
machines and Sugar plant automation by DCS / MPBA (micro processor
based control automation) at ACFC, Auto power factor controls, condensers,
vacuum pans etc and interlocking of machinery and equipment.
80
xiii) Providing of high voltage (11 kV) AC motors for heavy duty higher power
machinery like fibrizer, where constant speed is desired.
xiv) Providing anti friction roller bearings instead of bush-journal bearings at mill
gearing, cane carriers, rake inter carriers, crystallizers, pug mills, magma
mixers etc.
81
Chapter 6
Electrical Distribution System
6.1 General Design Basis
6.1.1 Design Criteria in Equipments / Power Distribution
a. All Busbars shall be Air insulated and of ALUMINIUM. Busbar size shall
be selected based on Temperature limit of 85 C at Busbar for the rated
current.
b. Power Cables (HV & LV) shall be XLPE ar mour ed ALUMI NI UM
conductors above and including 6 sq. mm. size. Power cables including
and less than 4 sq. mm. shall be copper conductor.
c. Squirrel Cage Motors up to 15 KW shall have automatic DOL Starter
suitable for operating from MCC, DCS and PB Station near Motors.
d. Motor rating above 15 KW up to 200KW shall be with Automatic Star
Delta Starter suitable for operating from MCC, DCS and PB Station
near Motors.
e. Motor rating above 200KW shall be operated with Soft Starter suitable for
operating from starter, DCS and PB Station near Motors. Starter shall have
bypass contactor with AC3 rating.
f. VFD shall be provided as per the functional requirement.
g. Following spare feeders shall be considered in Power Distribution
- In 11 KV Switchboard - 1 No. Transformer feeder
- In Cogen Aux. L. T. Panel - As per SLD
- Panels in other areas including PCC / MCC / DB - 1 No. of Each
Rating
h. MCC shall be floor mounted self supporting, dust and vermin proof, fixed
type construction.
i. Power Control Center (PCC) shall have Switch Disconnector Fuse up to
630A and above 800A these shall have Manually operated Draw Out
(MDO) type ACB. ON indication shall be provided on outgoing feeders.
82
j. Motor Control Center (MCC) shall have Switch Disconnector Fuse unit,
Contactor and Bimetallic Over Load (O/L) relay for starters. Starters on
MCCs shall have ON & TRIP indication. The selection of switchgear
components shall be minimum with one stage higher than Type II
co ordination as per IS 13947
k. Motor protection shall be provided in ACVF Drives & Soft Starters, as
inbuilt protection functions.
l. Rating of Switchboard incomer ACB/SDF shall be 1.2 times the operating
load current. Protection & Indication (For HV Switch board)
m. Flameproof equipments such as Push Button Stations, junction boxes,
Lighting Switches, L lighting Fixtures etc shall be considered with
hazardous area classification in Ethanol plant.
n. Push Button Station with Shr ouded type actuator for ON push
button, Lockable Mushroom type actuator for OFF Push button with
Aluminum die cast enclosure shall be provided. Push Button Station
for Motor s above 15KW r ating shall be pr ovided with suppressed
scale Ammeter . Push Button Station for VFD shall have Speed
Setting Potentiometer and speed indicator in addition to Push Buttons
and Ammeter
6.1.2 Power & Distribution Transformer
The following criteria shall be applicable for the sizing of Transformer
a) Total Connected Load shall be calculated based on Motor List.
b) Oper ating Load shall be calculated excluding Standby Loads and
equipment for maintenance such as Crane.
c) Load Factors shall be considered on Operating Loads according to
Load Factor to consider shall be as below:
- Motor Loads with DOL / S/D Starter / Soft Starters :
0.85
- Motor Loads with VFDs 0.75
- Lighting Loads : 1.0
- Utility Plug Sockets : 0.5
- Cranes, winches etc. : 0.1
d) Average Power Factor 0.8 shall be considered to arrive at KVA.
e) Equipment Efficiency shall be considered 90% as average.
f) On such Calculated load + 20% Margin shall be considered.
g) If necessary percentage impedance shall be increased more than the
impedance indicated in IS to limit 415 V side Fault Level to 50KA for
1 sec.
83
6.1.3 Power Factor Improvement
a) Plant PF shall be required to improve above 0.95
b) This is achieved by providing:
Capacitors across HV Motors as per recommendation of manufacturer.
Provide Automatic Power Correction Panel with required no. of APP
type capacitor banks in 415V PCC in Cogen Plant, Sugar Plant and
Distiller y plant. I n Sugar Plant fixed type capacitor s can be
connected additionally near MCC with appropriate capacitor duty
contactor and FSU feeder in MCC.
c) To determine number of capacitors following consideration be given
Operating KW & Average operating P.F.
Drive with VFD shall maintain P.F. above 0.95. These loads shall not
to be considered for deciding capacitor rating.
6.1.4 LV Power Control Centre (PCC)
The following points shall be considered while designing and selection of
components.
a) TYPE OF FEEDERS:
Incomers : D.O. 3-Pole ACB
Emer gen cy Power
Supply Feeder
: D.O. 4-Pole ACB
Outgoing Feeders : SDF up to 630 A
: MDO Type ACB Above 800A
b) BUSBARS Color Coded Sleeved Aluminum
Bus bar Size shall be selected as per following
norms:
Continuous current carrying capacity as per the
Rated Current of Incomer
Temperature Rise Limit
Short Circuit Withstand Capacity
6.1.5 Motor Control Centre (MCC) :
The following points shall be consider ed while designing & selecting
components.
a) Incomer
Feeder
- MDO ACB above 800 A up to 2000 A
Fixed Switch Fuse Disconnector up to 630 A
84
b) Outgoing
Starter
Feeder
Feeders shall be comprising of:
Switch Fuse Disconnector
Contactors
Thermal Overload Relay
Timer in case of Star Delta Starters
Push Buttons
Indicating Lamps
c) Bus bar Above 125A rating
d) Control
Logic
- Plant shall be capable of operation from MCC, DCS
located at Centr al Contr ol Room or locally fr om
Push Button Station near motor.
- I t will be possible to start the Motor locally through
enable command from PLC.
- P. F . a n d KW pa r a met er of I n comer sh a l l be
communicated to PLC.
- ON/ OFF Status of the Motor shall be communicated to
PLC.
e) Provision
of Spa r e
feeders
I n MCC t ot a l 10% spar e feeder s shall be pr ovided,
depending on feeder ratings in MCC following feeders
shall be provided.
6.1.6 LV Bus Ducting
Bus duct up to 3200A shall be CRCA enclosure with color coded sleeved
Aluminum bus bar. Short circuit rating shall be 50KA, 1 sec.
6.1.7 Battery & Battery Charger
a) BATTERY: - VRLA Maintenance Free
- Capacity shall be determined by total operating load
& 20% margin
- AH shall be determined for 8 hour backup time
b) BATTARY :
CHARGER
Float and Float cum Boost with 20% capacity
c) DCDB : Built in with Batter y char ger panel with I ncomer as
MCCB & Outgoing as MCB
85
6.1.8 Grounding / Earthing System & Lightening Protection
a) Earthing shall be done according to IS 3043 1987.
b) Earthing shall be carried out by G.I. Strips & Wires. Earth Electrodes
shall be G.I . Plate type & Pipe type as per r equir ement. However,
Transformer Neutral will be connected to G.I.Earth Electrode through
Copper Strip.
c) Total Resistance of Earthing system shall be Less than one ohm.
d) Plant shall be protected against lightning according to IS 2309-1989.
6.1.9 Cables
The following consideration shall be given for Cable Sizing and Selection on
Nominal Current Capacity
a) Ambient Temperature in Air/Ground
b) Continuous Load Current
c) Short Circuit Withstand Capacity
d) Voltage Drop at the Starting of Motor limited to 15% & 5% at Steady
state up to motor terminals.
e) Deration Factor due to type of Laying & Grouping.
f) Generally Power and Control cables shall be stranded.
g) XLPE insulated cables upto & including 4 sq.mm shall be with stranded
copper conductors. Cables of 6 sq.mm & above size shall be with Al.
conductor
6.1.10 Cable Trays, Accessories & Support
a) Generally Cable trays shall be prefabricated Hot Dip Galvanized Iron
b) Cable Trays shall be run in Vertical formation as far as possible.
c) HV & LV Power Cables shall have separating distance of 300mm
d) Separ ating distance between Power and Contr ol cable shall be
300mm.
e) Instrument cables & screened shall run on perforated cable tray having
300 mm separating distance of 300 mm.
6.1.11 Illumination System
a) The Lux Level in various indoor areas shall be as per IS. In plant
areas, the lighting shall be provided as per functional requirement.
86
b) HPMV Well Glass with integral control gear box fittings (IP55)
shall be provided in plant areas. Industrial FL. Lamp fittings will
be pr ovided in sub station and other indoor areas. Mirror Optic
fixtur es shall be pr ovided in CCR. I n outdoor ar eas HPSV Lamp
fixtures (IP 55) shall be provided.
c) The lighting shall be catered by Main Lighting DB. LDB & SLDB
connected by Al. conductor cables. The Emer gency power supply
from 415V DG set will be made available to lighting transformer in
case of failure of power
6.1.12 HV & LV Motors
Motors shall be as per IS 325. LV motors shall be IP 55 degree of protection
and for HV motors the degree of protection shall be IP 55 (CACA). Motors
shall have insulation of class F and temperature rise limit of class B. Motors
shall be designed with 50 C ambient. F lame pr oof Enclosur e shall be
provided for motors where ever required.
6.2 Scope of Work
In line with the overall battery limits for the sugar plant and particularly for the
electrical power, the Tenderers will have to consider following in the scope of
work for electrical distribution system:
11 KV Cables (2 sets.) from cogen power plant 11 KV distribution board, up to
sugar plant 11 KV panel.
11 KV panel compr ising of VCB, CTs / PTs, meter s, protective relays,
required cables and terminations, etc.
11 KV cables from 11 KV panel in the sugar plant, up to 11 KV motors like
fibrizor and cutter
11 KV / 433 V distribution transformers of adequate size along with all
necessary incoming and out going cables / bus bars, protection system, safety
devices, fire fighting system, etc.
Lightening protection for buildings in sugar plant area as per IS 2309.
87
415 V distribution network within the sugar plant including main distribution
panel, incoming / out going cables / bus bars, CTs / PTs, protection relays,
annunciator, indicating lamps, push buttons, DCDB, battery & charger, safety
devices, distribution boards, incoming / outgoing cables, indicating lamps,
push buttons, etc. for all drives.
High mast lighting fixtur e with 30 m high tower including cradle, motor
operated mechanism, 8 nos. 400 W, metal halide lamps total 4 nos. to be
installed at designated places as advised by Owner with all electr ical
connections.
11 KV / 690 V conver ter tr ansfor mer of adequate size along with all
necessary incoming and out going cables, bus bars, protections, panels, ACBs,
safety devices, fire fighting system, etc. for driving DC motor
415V supply feeder suitable for 100 KW for providing power to colony and
other miscellaneous areas within the entire integrated complex.
6.3 Diesel Generating Set For Emergency Electrical Power Supply
One No: 250 kW and one no. of 50 kW rating diesel sets each with 0.80 power
factor shall be installed for the sugar plant.
The diesel generating set shall be continuously rated comprising multiple
cylinder diesel engine having necessary protections such as low lube oil
pressure trip, high engine temperature trip, over speed trip etc. and shall be
fitted with speed control knob speedometer, hour meter battery charging meter,
oil pressure and temperature gauges, radiator etc.
The diesel engine shall be coupled with suitable alternator capable of
developing continuously the rated power at 3 phase, 4 wire, 50 Hz at normal
voltage of 440 V AC. Alternator to be suitable for voltage range of 440 V AC
and conforming to IS-4722 specifications. The alternator shall be fitted with
minimum one ETD in each phase for ther mo pr otection of the alter nator
windings. The alternator shall be designed for an ambient temperature of 45
o
C.
The alternator shall be self excited and self regulated.
The diesel set shall be complete with base fr ame, couplings, one M.S.
fabricated, diesel service tank of 15 HL capacity, inter-connecting piping, D.C.
storage battery and self starting mechanism for starting of engine.
88
One 2 mm thick for the back side and 1.6 mm thick for the other sides cold
rolled sheet steel fabricated floor mounted, dust and vermin proof panel for the
diesel set shall be provided. The panel shall be fitted with air circuit breaker,
over current relay, earth fault relay, reverse power relay, over voltage relay, reed
type frequency meter, neutral isolating switch, three phase 4 wire unbalanced
energy meters, kW meter, 3 phase power factor meter, 3 nos. ampere meters,
one no voltmeter with selector switch, ON-OFF indicting lamps.
The panel shall have neutral and phase bus bars of electric grade (EC-91E)
aluminum and shall be designed to withstand symmetrical short circuit current
of 35 KA (RMS) for one second. The panel shall be designed for an ambient
temperature of 45
o
C the operating temperature of the bus bars shall not exceed
85
o
C. All the meters shall be class 1.50 per cent accuracy and shall conform to
IS-1248 specifications. All the meters shall be square type of 100 mm sq. with 90
per cent deflection Inter connecting electrical cable 3 cores from the diesel set to
the main distribution panel and to the auxiliary panel changeover switch shall be
provided.
89
Chapter 7
Control & Instrumentation System
7.1 Introduction
I t is essential to have full automation of the sugar plant along with required
instr umentation and systems at var ious equipment / locations, as well as a
centralized DCS system. The details of automation, of ACFC, imbibition water,
diffuser, mass flow meters, pH control system, on line conductivity measurement
of condensates, br ix & temper atur e contr ol of juice sulphiter and molasses
conditioners, all batch vacuum pans, sugar melter and sugar silo system, etc. have
alr eady been specified in the pr evious chapter s under each equipment and
machinery.
The Tendererss may provide the control & instrumentation system according to
these specifications and / or provide additional systems for achieving guaranteed
performance parameters for the sugar plant operation, as well as for reducing the
manpower requirement. Additional systems may be quoted separately.
7.2 Statutory Requirements
7.2.1 Online Mass Flow meters:
1) Depending upon the plant conditions like size, flow rate, specific gravity,
viscosity the vendor shall furnish detailed sizing calculations showing mass
flow rate accuracy, pressure drop, velocities at 10 operating steps.
2) Weights and measures certification and stamping from regional Weights and
Measures authority shall be provided.
3) Manufacturer shall have facility for weight calibration of mass flow meter in
the flow laboratory as per NIST standards.
7.2.2 Automatic pH Control for Juice/Syrup Sulphitation:
Well designed and fabricated sampling system for cooling the juice at 40
o
C for
effective online pH measurement.
7.2.3 Online Brix Indicators
1) Brix measurement shall be independent of changes in the other process
parameters like pressure, temperature additives etc.
90
2) I nstr ument shall be fully configur ed, oper ated and maintained using
operators' interface. It shall have large backlit digital display, soft push
buttons and easy to operate menu driven screen.
7.2.4 Online Conductivity Measurement of condensate water
1) To ensure the compatibility the sensor and transmitter shall be of same
make.
2) Well designed and fabr icated sampling system for each line shall be
provided.
7.2.5 Instrumentation Panel
The entire panel mounted instruments which are integral part of the following
control and measurement systems shall be housed in a well designed, fabricated
and wired instrumentation panel.
1) Auto Cane Feed Control System
2) Automatic Imbibition Water Flow and Temperature Control System
3) Online Mass Flow Meter for mixed juice and water [existing]
4) Automatic pH Control System for J uice Sulphitation
5) Online Brix Indicators
6) Automatic pH Control System for Syrup Sulphitation
7) Automatic Brix and Temperature Control of Molasses Conditioner & melter
8) Online conductivity measurement of condensate water
9) Automatic massecuite level control in pug mill
10) Massecuite feed control for continuous centrifugal machine.
7.2.6 DCS-Based Automation
For recording various process parameters like pressure, temperature, flow level
etc at various equipments in the boiling house two numbers -p based 32 channels
data loggers specifications with inkjet printer having following specifications
shall be provided: one at evaporator floor and the other at pan floor.
Specifications
For recording various process parameters like pressure, temperature, flow level
etc. at various equipments in the boiling house two numbers p based 32 channels
data loggers specifications with 80 column dot matrix printer/132 column dot
matrix printer/inkjet printer having following specifications shall be provided: one
at evaporator floor and the other at pan floor.
91
Sr.
No.
1. Input Universal
a) Thermocouple as per DIN 43710
(other than standard on request)
(J,K.E,R,S,T,N,B grounded or ungrounded)
Input resistance 1 M
b) RTD PT - 100 as per DIN 43760
(Excitation current 2.5 mA)
c) Electrical signal (0/4-20 mA, 0/1-5 V.DC)
Input resistance 250 for current input
Input resistance 500 K for voltage i/p
2. D i s p l a y &
I nter nal Scan
Time
a) 3 digits, " , 7 segment LED display for process
var iable; 2 digits, " , 7 segments LED display for
channel no.
b) 16 x 2/20 x 2 backlit LCD
c) 50 m sec. per channel
3. R a n g e &
Accuracy
Keyboard configurable for each channel separately with
reading accuracy of 0.25% of F.S.
4. Alarms
Facilities
2 settings (HI & LO) per channel over entire range, alarm
output (NC/NO), programmable alarm acknowledgement
& alarm status (bi-colour LEDs) for each channel shall
be provided.
5. Broken Sensor Indicated by displaying error message on display
6. C.M.R.R. 120 db
7. Memory It shall be possible to retain the user interaction memory
for more than six months in case of power failure
8. Operating
Temperature
0 to 50
o
c with maximum 0.015% /
o
c drift
9. Mains supply a) 230 V AC, 10%, 50 Hz, single phase (Standard)
b) 110 V AC, 10%, 50 Hz, single phase (Optional)
10. Communication
Port
a) RS 232 or RS 485 with Modbus RTU protocol for PC
communication
b) Centronic parallel port for printer (log & print interval
shall be user configur able with differ ent pr int
options)
92
7.2.7 Drawings, Design Details & Documentation
The following documents shall be sent to the Owner and copy to the Consultant
for approval.
1) Instrumentation hookup diagram.
2) P & I diagram.
3) Specification of instruments i.e. Range, make etc.
4) Orifice plate design calculation data sheet as per BS 1042 for flow meters.
5) Control valve sizing and CV calculations.
6) Instrument control panel cutout, foundation and panel wiring drawing.
7) List and specification of erection material.
* Impulse tubing shall be of SS 316/304 15 NB SCH 40 pipe with SS isolating
and drain valves.
* Instrument cables from field transmitters to panel shall be 1.5 mm x 2 core Cu
conductor armoured cable.
The following documents shall be submitted in triplicate along with instruments
to the end user:
1) Erection drawing and instrumentation calibration and test reports.
2) Operation and servicing manuals.
7.2.8 Central Data Acquisition System
It shall be possible to connect all the data loggers to the centralized PC based data
acquisition system
7.2.9 Instrumentation Control Rooms
To achieve the desir ed wor king per for mance of var ious instr umentation
measurements and control system even under extreme conditions like shock,
vibrations, humidity, electrical interference installation of instrumentation panel
shall be done in well designed and constr ucted r ooms as per the standar d
instrumentation practices. Rooms shall be constructed by the vender as per his
r equir ements. Air Conditioner s sha ll be insta lled by vender a s per his
requirements to satisfy performance of equipment, machinery and instruments.
Full automation of entire sugar plant shall be done to achieve 15 workers per shift
in phase-I and 20 total workers per shift in phase-II.
93
7.3 DCS Based Automation
Sr.
No.
CONTROL
BASE
STATION WISE AUTOMATION
1 MPBA Cane carrier automation, ACFC
2 MPBA Di gi t a l & Mech a n i ca l dewater ing Mill-r oller lift
indication
3 MPBA Dewatering mill and inter carriers speed control by
mounting bagasse level sensors in Donnelly chutes
4 MPBA/ABA Imbibition water control automation by monitoring last
dewatering mill juice brix and load
5 MPBA J uice flow stabilization
6 MPBA J uice tip jumbo display digital type unit
7 MPBA El ect r oni c st a t i c t ype j ui ce wei ghi ng sca l es a nd
molasses weighing scale
8 MPBA Automatic juice pH control system
9 MPBA Automation of evapor ator station to contr ol level of
liquid in individual bodies and brix of syrup
10 MPBA Pressure reducing and de-superheating station
11 MPBA Automation of molasses conditioners
12 MPBA Automation of sugar melter
13 MPBA Automation of super heating of wash water system
14 MPBA Automation of centrifugal machines
15 MPBA Automation of Batch & Continuous vacuum pans
16 MPBA Automation of condenser s, cooling and condensing
systems
94
Chapter 8
Civil Works
8.1 The existing buildings and structure at the site location need to be dismantled /
demolished completely, to make the available plot clear for construction of sugar
plant, as well as associated cogen power plant and ethanol plant. The appointed
EPC contractor will have to take up this responsibility entirely and the relevant
cost and time schedule to be indicated in the EPC bid. Appendix - I gives the list
of identified existing buildings and structure to be demolished by the select EPC
contractor.
8.2 Design philosophy and criteria for civil and structural construction at the project
site has been indicated in the ensuing paragraphs.
8.2.1 Major Civil Works
1. Dismantling/ demolishing of all existing buildings & structures within
the entire area & removal of debris from the entire site area about 65-70
acres.
2. Contour sur vey, soil testing, tests for ascer taining the soil bear ing
capacity, water tables at site, wind direction etc.
3. Back filling and levelling, if required
4. Chain link/barbed wire fencing, gates, entrance arches etc., for sugar
plant and other non-plant buildings etc.
5. Cane / marshalling yard and nursery
6. Foundations for 3500 TCD sugar plant and machinery
7. Foundations for cooling systems for sugar plant
8. Foundations for bagasse handling equipments
9. Main Factory building and auxiliary structures for sugar plant
10. Suga r Go-downs/War ehouses/Machine Shop/Stor e building/ lime,
sulphur and gunny bags go-downs, Excise offices, Workers rest rooms,
panel rooms, worker s rest room, first aidfacility, fire fighting facilities
including sheds for fire tenders, foundations for fire fighting equipments,
pipe lines for fire fighting/fire hydrants etc. and other auxiliary buildings
11. Non plant buildings such as canteen, laboratories, toilet blocks, effluent
disposal schemes, etc.
12. Wa ter supply scheme including gr a vity/r ising ma ins, ja ckwell,
percolation galleries, pipelines, pumping machinery etc.
13. Water reservoir of minimum 7 days capacity
14. Foundations for large tanks, pumps, fuel conveyors, pipe racks, electrical
equipment, pipe / cable racks, water treatment equipment and all other
equipments
95
15. Panel rooms, sheds for equipments, sheds for DG sets
16. All internal roads to be of RCC and RCC approach roads within the
sugar plant area to be pr ovided for all building / structures including
green areas, road side drains, culverts, pipelines and other provisions for
street lighting, yard lighting, area lighting etc.
17. Drainage channels, storm water drains within sugar plant area
18. Underground cable & bus ducts, trench for CW piping, etc.
19. Earthing pits and earthing mats
20. Required plumbing and sanitary fittings & equipments.
21. Rain water harvesting, ETP, sewage treatment plant and green belt
22. Pile foundation to be provided, if required, based on soil investigation
23. Landscaping for the sugar plant area
24. All building and civil wor k commencement cer tificates, building
completion certificates, stability certificates, any other certificates as per
statutory requirements of the Bihar and the Central Government, NOC of
the BPCB, NOC of Airport Authority etc., all necessary permissions
from the statutory authorities.
25. All electrification and lighting
26. Fire fighting
8.2.2 Design data:
The following basic design criteria are used in the designs of various structures.
Soil bearing capacity (to be verified : 12 ton/m at 2 m from NGL
by Tenderers, prior to civil design)
Min grade of concrete for RCC works : M20
Grade of reinforcement steel : IS : 1786
Type of Cement : 43 grade Portland cement
All structural steel members : As per IS 800
Seismic zone of factory area : As per IS 1893-2002
Wind velocity & direction : Velocity : As per IS : 875
South-West (May- Sep),
North East (Oct Apr)
96
8.2.3 System Description and Specifications
a) Site Grading and Levelling
The site clearance and grading work has been considered only of the area
for the plant. The grading work will be done by cutting-filling balance
method and no earth will be transported from outside. All excavation and
back filling shall be in Contractor s scope. The contour survey and all
necessary surveys of the total area for the integrated plant shall be carried
out by the EPC Contractor.
b) Plant Internal Roads And Culverts
Internal roads within the plant boundary and roads for access to equipment
and buildings will have to be provided. Layout of the roads will be based
on Plot Plan. Adequate turning space for vehicles will have to be provided
and bend r adii will be set accor ding to maximum vehicle speed of
20km/hour. Roads to be as short and straight as possible. All internal
roads shall be well designed RCC roads. All roads shall be designed as per
IEC 58. Wherever drains or other underground facilities cross the roads,
concrete pipe culverts class NP2 or NP 3 as required or RCC box culverts
shall be provided. Roads shall be provided with kerb stones and the same
shall be painted as per specification.
All plant roads will be constructed so as to permit transportation of all
heavy equipment. Internal roads will be minimum 6.0m wide.
c) Soil Investigation
Soil investigation will be done by EPC Contractor for the determination of
safe bearing capacities for the design of foundations for various structural
elements. Earth resistivity will be determined. If required and necessary,
pile foundation design shall be adopted for the major and cr itical
foundations.
8.2.4 Design Criteria
The design cr iter ia for var ious str uctur es and str uctur al elements will be as
follows:
a) Steel Framed Structures
The design of steel framed structures will be done by linear elastic method
as per the provision of IS: 800.
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b) Reinforced Concrete Framed Structures
All reinforced concrete structures will be moment resisting frames along
both longitudinal & transverse directions. The suspended slab will be
considered as continuous over secondary beam and will not form part of
the framing system. However it will be considered to be transferring the
shear to the framing system. RCC structures/members will be designed as
per IS:-456 using limit state method.
8.2.5 Foundations
Introduction
All main plant structures i.e. Sugar Plant Buildings, including Silos, Transformer
Foundations, buildings and foundations, all plant and non-plant buildings for the
integrated plant and other Misc. Buildings will be supported on RCC foundation -
isolated, combined or raft and/or pile foundations. Machine foundations for
Compressors, BFP and misc. pumps and equipment foundations will be supported
on RCC foundations - Isolated or Block foundations and/or pile foundations. Pile
foundations will be provided, if required, by the soil investigation report.
Design
The foundations will be designed for the most critical combination of forces and
moments, resulting from all the possible combinations of the various loading from
the str uctur al system. The effect of water table will be consider ed and the
foundation will be checked for overturning for minimum and maximum vertical
loads. Ther e should be no uplift under any portion of the foundation for any
loading condition. The foundation sections will be sized and r einfor ced
adequately for bending moments and shear stresses. A levelling course of plain
cement concrete will be provided before casting the foundation.
8.2.6 Machine Foundations
Introduction
This section outlines the design philosophy & construction aspect for foundations
for large equipment as follows:
a) Diffuser foundation, fibrizor foundation
b) All major and minor foundations for the sugar plant
c) Compressor foundations
d) All Miscellaneous machine foundations
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General
A necessary requirement for all rotating machinery is that it should be properly
suppor ted. Thus the foundation becomes an impor tant element of machine
installation. It has to resist both static and dynamic forces exerted by the machine
and transmit these to the ground. In doing so, it is responsible for smooth running
of the machine by ensur ing that amplitudes ar e limited to values that ar e
permissible for the machine and for local environment, including structures and
people. The foundation must have sufficient structural strength to withstand all
applicable forces and most severe combination of individual load cases that result
in the maximum foundation loading for any conceivable set of nor mal or
abnormal circumstances. Spring supported foundation shall be provided for low
fr equ en cy ma ch i n es, wh er ever t h e sa me a r e r equ i r ed fr om t ech n i ca l
consideration.
Design Parameters
The data required for the analysis and design of machine foundations may be
listed as under:
a) Loading diagram showing static and dynamic loads on the foundations, points
of application of loads, area over which these loads will be distributed etc.
b) Operating speed of the machine.
c) Capacity or rated output of machine.
d) Critical speeds of the machine.
e) Geometric limitation.
f) Opening limitations, depressions, projections etc.
g) Details including sizes and locations of anchor bolts, pipe sleeves, inserts,
embedded parts etc.
h) Layout and distribution of pipe lines, ducts etc. and their supporting details.
i) Temperatures in various areas during operation.
j) Mass moment of inertia.
k) Allowable amplitudes at the machine bearing points, etc.
l) Tolerance in bearing and clearances of various components.
Loads
The loads to be considered for analysis and design are:
a. Static loads of the stationary components of the entire assembly along with the
static weight of rotating parts.
b. Dynamic loads from start-up torque.
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c. Loads on foundation resulting from admissible forces and moments of pump
nozzles.
d. Loads on pedestal top due to installation and maintenance.
e. Any other for ces/loa ds which equipment EPC Contr a ctor consider s
applicable.
Analysis And Design
The analysis and design of machine foundations will be carried out to ensure the
following:
a) Compliance with the manufacturer s requirements.
b) No resonance phenomenon of a disturbing nature to machine operation should
exist at the normal running speed.
c) Calculations to be performed for dynamic as well as static cases for reinforced
concrete block type pedestal.
Foundation Sizing
The outline plan dimensions of foundations will be given by the machine EPC
Contr a ctor . The height of founda tion will be selected a fter ta king into
consideration soil strata and operating level of the machine. The eccentricity of
common CG of machine and foundation with respect to the centroid of base
area/pile group should not exceed 3% of the corresponding base dimensions of the
foundation.
In order to reduce the horizontal amplitudes, the height of foundation should be
selected as small as possible. A larger base dimension should be selected in the
direction of rocking moment, if any, acting on the foundation.
Compressor Foundation
The Compressor is a machine of reciprocating type. This is a low speed machine
and pr oduces unbalance for ces dur ing oper ation, causing vibr ation in the
foundation. Excessive foundation vibrations may cause settlement or damage to
the foundation-machine system and also a feeling of discomfort and uneasiness to
the personnel. Compressor foundation shall be isolated from the close slab and
other foundations
Vibrations are also transmitted through the ground. Ground vibrations may be
minimized by providing trenches all around the foundation up to a suitable depth.
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Miscellaneous Machine Foundations
For the large variety of other types of machines there are numerous foundation
designs and the most suitable one will depend on the particular application.
Foundations for pumps, etc. are usually in the form of solid block foundations,
resting on the undisturbed strata.
At machine supports supported on the finished floors, floor may be thickened and
extra reinforcements provided. Also, the machines, which are almost vibration
fr ee and ar e ver y light to moder ately heavy, may be suppor ted in the above
manner . Rubber or neopr ene pads may have to be used under some of these
machines to reduce transmission of vibrations to the supporting floor.
8.2.7 General Design Considerations
The design of various civil and structural works will be done as per relevant
I ndian Standar d and sound engineer ing pr actices to meet the system and
functional requirements.
Design Loads: Design loads for all structures will be determined according to the
criteria described below.
Dead Loads: - Dead loads will consist of the weights of the structure and all
equipment of a permanent or semi-permanent nature including tanks, wall panels,
partitions, roofing, piping, drains, electrical trays, bus-ducts. Dead loads will be
determined using the weight from IS-875 (Part -1).
Live Loads:- Live loads will consist of uniform live loads and equipment live
loads. Uniform live loads are assumed unit loads which are sufficient to provide
for movable and tr ansitor y loads, such as the weight of people, por table
equipment and tools, equipment, or parts which may be moved over or placed on
floor s dur ing maintenance oper ations. These unifor m live loads will not be
considered on floor areas which will be permanently covered with equipment.
Equipment live loads are calculated loads based upon the actual weight and size
of the equipment and par ts to be placed on floor s dur ing dismantling and
maintenance or to be tempor ar ily placed on or moved over floor s dur ing
installation. Floor s a nd suppor ting member s which a r e subject to hea vy
equipment live loads will be designed on the basis of the weight of the equipment
in addition to a uniform load of 500 kg/m, or specifically defined live loads,
whichever is greater. Each member in the floor which may carry these loads will
be designed for the heaviest piece or pieces of equipment arranged in the most
critical position.
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F or loa ds ca used by moving equipment over the floor for insta lla tion,
consideration will be given to the shoring of beams and floor from floors below.
When moving equipment over floor s for installations ar e consider ed, str ess
increases of 25 percent are permitted in beams and columns.
Wind Speed: The design wind speed will be based on IS: 875 (Part - 3). This
design wind speed will be used to determine wind loads for all structures.
Seismic Zone: As per IS: 1893-2002
Design Loads
Dead Loads
Dead load will comprise of the following and will be computed as per IS: 875
(Part-1). Following will be considered for evaluation of dead loads:
i) An uniform 150/200 mm thick RCC slab wherever concrete floors are
provided
ii) An uniform floor finish of 50 mm laid over RCC slab
iii) Other area flooring will consist of removable grating/chequered plate
or 50 IPS.
iv) Beams & columns as per actual size
v) Wall/cladding loads
vi) Self weight of supporting structure/facilities
Imposed Loads
Imposed loads will include minor equipment loads, cable trays, small pipe racks /
hangers (not exceeding 250 Kg/m) and also loads during erection, operation &
maintenance.
Actual plant loads coming on the floor area occupied by the equipment will be
calculated and compared with the superimposed loads given above. Higher of the
two will be adopted for analysis and design.
Steam Piping Load
As per static/dynamic analysis for steam piping, the loads super imposed on
structure by piping hangers and at the restraint points will be considered as
a dvised by piping Contr a ctor . However , pipe dyna mic for ces a t ha nger
location/restraint points will be considered not to act simultaneously with seismic
forces in that plane.
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Crane Loads
The frames will be analyzed for the maximum wheel loads when the lifted weight
is nearest to A row in one case and B row in another load case. The impact
factor for ver tical load will be 25% for cr ane gir der and 10% for columns /
foundations as per provision of IS: 875 and lateral crane surge of 10% of lifted
weight and trolley weight will be considered in the analysis of the frame. The
longitudinal surge will be 5% of the static wheel load. Each of the crane girders
will be analyzed for the moving loads and for half the total surge loads on each
gantry girder.
Wind Loads
The basic wind pressure will be taken as IS: 875(Part-III) and combination of
wind loads with other types of loading will be done according to provision of
IS:875 (Part-V). The basic wind speed of 50m/sec. up to height of 10metres above
ground level.
Earthquake Load
As per IS: 1893, the seismic zone and basic horizontal seismic coefficient for this
plant location will be decided. The importance factor of not less than 1.50 will be
used to calculate base shear coefficient. The coefficient of soil-foundation
interaction will be not less than 1.0. Reduction in live loads is to be considered for
analysis accor ding to I S: 875. I n view of the asymmetr ical natur e of main
powerhouse, response spectrum method will be used for analysis.
Temperature Loads
The effect of temperature loads will be considered for design of the structural
frames. For temperature loading calculation the total temperature variation will be
considered as 2/3
rd
of the average annual variation in temperature. The structure
will be designed to withstand str esses due to 50% of the total temper atur e
variation. The structures will also be analyzed/checked for temperature effects in
the areas where the temperature rise is expected to be high.
Load Combinations
The following load combinations will be considered for finding out the critical
forces, moments and torsion on the structural elements.
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i) DL + LL
ii) DL + LL + CLA + DLC CS
iii) DL + LL + CLB + DLC CS
iv) DL + LL + CLA + DLC CS TL
v) DL + LL + CLB + DLC CS TL
vi) DL + 0.5LL + K1(DLC) + K2(CLA)
vii) DL + 0.5LL + K1(DLC) + K2(CLB) + EL TL
vii) DL +LL + DLC + K3(CLA) K3(CS)+ WL1+TL
viii) DL +LL + DLC + K3(CLB) K3 (CS)+WL1+TL
ix) DL +LL + DLC + K3 (CLA) K3 (CS) WL2+TL
x) DL +LL + DLC + K3(CLB) K3(CS) WL2 TL
xi) DL +LL WL1 TL
xii) DL + LL WL2 TL
The following load combinations will be used for getting max. tension at column
base which will be used for the design of holding down bolts
i) 0.9DL EL
ii) 0.9DL WL1
iii) 0.9DL WL2
Nomenclature
DL Dead load (comprising of only dead weight of structural members,
side cladding etc.)
LL Live load (including imposed load, plant loads & equipment loads)
TL Temperature load
DLC Dead load of crane bridge with impact
CLA Crane trolley + lifted weight nearest to A row column with impact
CLB Crane trolley + lifted weight nearest to B row column with impact.
CS Crane surge
EL Earthquake load
WL1 Wind load with internal suction of 0.2p
WL2 Wind load with internal pressure of 0.2p
K1 (DLC)Dead load of crane bridge without impact
K2 (CLA)Crane trolley without lifted weight with impact or (CLB)
K3(CLA) Crane trolley + lifted weight with impact or (CLB)
K3(CS) Crane surge for lifted weight.
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Permissible Stresses
The permissible stresses will be as per relevant IS Code. An increase of 33.3% in
permissible stresses will be made wherever wind or earthquake load has been
considered with dead load and appropriate amount of live load. For secondary
effects without wind or earthquake load, permissible stress will be increased by
not more than 25%.
8.2.8 Design Of Miscellaneous Items
a) Cable Trenches
The cable tr enches and pr e-cast r emovable RCC cover (with lifting
arrangement) will be constructed using RCC/Masonry work. The cable
trench walls will be designed for the following loads:
1. Dead load of 155 Kg/m length of cable support and 75 Kg on one tier
at the end.
2. Triangular earth pressure + uniform surcharge pressure of 2T/m.
3. Cable trench covers will be designed for self-weight of top slab and
concentrated load of 200 Kg at center of span on each panel.
4. Cable trench cr ossing the r oad/r ails will be designed for class AA
loading of IRC/relevant IS code and should be checked for transformer
loading.
Suitable drainage arrangement will be provided to drain water from cable
trenches. Cable trenches will not be used as storm water drains. The top of
tr enches will be kept at least 50mm above the finished gr ound level.
Trench wall will not foul with the foundation. Suitable clear gap will be
provided.
A clear (vertical) space of at least 200-mm will be available for each tier
in cable trench. From trench bed to lowest tier, a minimum clearance of
150 mm will be available. The trench bed will have a slope of 1/500 along
the run and 1/250 perpendicular to the run. All the construction joints of
cable trenches i.e. between base slab to base slab, the junction of vertical
wall to base slab, from vertical wall to wall and all the expansion joints
will be provided with approved quality PVC water stops of approx. 230 x
5 mm size for those sections where the ground water table is expected to
rise above the junction of base slab and vertical wall of cable trenches.
Cable trenches will be blocked at the ends if required with brick masonry
in cement sand mor tar 1: 6 plaster with 12mm thick 1: 5 cement sand
mortar.
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b) Drains
Adequate surface drainage system will be provided within the plant area.
Design will be done with obtained r ainfall data and the stor m water
drainage system designed, (Culverts, ditches, drains etc.) to accommodate
the most intense rainfall that is likely to occur over the catchments area in
one hour period on an average of once per ten year. The surface of the site
will be sloped to prevent the ponding of water.
The maximum velocity for pipe drains and open drains will be limited to
2.4m/ sec and 1.8m/ sec r espectively. However , minimum non-silting
velocity of 0.6 m/sec will be ensured. Longitudinal bed slope will not be
milder than 1 in 1000.
Invert of the drainage system will be decided in such a way that the water
can easily be dischar ged above the High F lood Level (HFL) outside
substation boundary at suitable location and approved by Owner. Pumps
for drainage of water (if required) will be provided.
8.2.9 Architectural Concepts And Design
An Architectural Design Basis Report will be submitted to the Owner including
proposals for the following scheme components: shape, form, color, and basic
mater ials for inter ior and exter ior ar chitectur e along with an appr opr iate
landscaping scheme. All schemes will be supported by architectural statement
explaining the factors considered in the design.
EXTERIOR ARCHITECTURE : Gener al design cr iter ia for the exter ior
architectural systems will be as follows:
a) Wall / Cladding System
All external walls of the building shall be 230 mm thick brick walls and
internal walls 230/115 mm thick brick walls as per requirement in CM 1:5.
Internal plastering shall be 12 mm thick using CM 1:4 and external wall
with CM 1: 4., 20/25 mm thick and/or sand faced plaster or any other
special finish if required, 115 wall shall be plastered with CM 1:3, 12 mm
thick. Ceiling plastering shall be 6 mm thick with CM 1: 3. Damp proof
cour se 40 mm thick in PCC 1: 2: 4 using 6 mm down stone shall be
provided in the external brick walls at grade level.
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I n or der to quickly er ect / complete the Sugar Plant buildings, wall
cladding with Galvalume sheets may be examined above 5.0 m fr om
gr ound level and up to 5.0 m br ick wor k can be adopted. Wher e ever
advised, self supported galvalume roofing could also be provided for the
main plant buildings and other non-plant buildings.
b) Roof
As per details given in relevant sections.
c) Flooring & Floor Finish
The floor slabs will be designed as cast-in-situ RCC slabs with removable
shuttering unless mentioned otherwise. The nominal thickness of RCC
slabs will be 150/200 mm.
Floor finish of 50mm thickness will be provided over the RCC Slab as per
finish schedule wherever applicable. Type of floor finish will be as per the
functional requirements of different areas and facilities.
d) Roof Water Proofing Treatment Above RCC Roofs
Over the cast-in-situ roof slab, 50mm thick screed concrete (blended with
water-proofing admixture) will be laid. The final treatment will be heavy-
duty type with bitumen felts. For the provision of handling of equipment
on the roof and movement of personnel, tiles will be provided in place of
pea gravel.
Roof slope of 1 in 75 will be provided in one direction in A-B bay and
sloping towards A-r ow. For other bays, r oof slope of 1 in 100 will be
provided in two directions.
For r ainwater down comer s, heavy duty UPVC pipes will be used.
Number and sizing will be as per the relevant Indian Standard.
e) Windows, Ventilators
Window and Ventilator frames will be made of extruded aluminium, steel,
or other tr ied and pr oven mater ial as per the schedule given ear lier .
Frames will have a minimum depth of 38 mm and a minimum thickness of
3 mm. Ventilation sections will be compatible with the frames providing a
weather tight seal.
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All aluminium windows shall be pr ovided with MS gr ills of approved
design and all glazed windows to be provided with sun control film. All
steel windows to be provided with 12mm sq MS safety bars of 100 mm
c/c.
All windows will be fully flushed and sealed for weather tightness.
f) Doors:
Pressed steel door s/ Aluminium door s will be pr ovided as per the
schedule given earlier. Steel doors will be the hollow metal type, flush, 46
mm thick, insulated, with formed hollow metal frames. The doors will be
constr ucted fr om 1.3 mm steel with an inter nally r einforced, insulated
core. Frames will be constructed of 1.6-mm steel, welded, and ground
smooth. Both doors and frames will be factory galvanized or field painted.
Doors will have a glazed vision panel when required by door function.
Glazing will consist of tempered safety glass or wired glass.
Fire barrier doors, if any, shall be specifically designed steel doors with
required fire rating. The door, frame, and hardware will bear a certification
label for the class of opening and r ating. Door s for fir e exits will be
secured with panic bars.
Solid core flush doors with both side veneer finish to be provided for
housing and other non-plant buildings as advised and specified.
g) Equipment Access Doors:-
Large access exterior doors will be vertical lift rolling shutter type, with
weather seals and windsocks. Components will be formed from galvanized
steel, factory primed, and field painted. Doors at high traffic areas will be
motor-oper ated. Door s will be manually oper ated wher e access is
infrequent.
INTERIOR ARCHITECTURE: I nter ior ar chitectur al systems will
conform to the following general design criteria. Fire rated architectural
system will be pr ovided when r equir ed by building or fir e codes. All
normal occupied areas will be finished areas.
108
h) Painting:
Inside masonry walls and ceilings of all buildings will be provided with
white wash, color wash, oil bound distemper, acrylic emulsion paint as per
schedule given ear lier . Steel str uctur es, door s, windows, steel r olling
shutters, gangways, stairways railing, grating rain water pipes etc. will be
painted with synthetic enamel paint.
i) Lighting:
Lighting fittings and fixtures will be provided for proper illumination in
all buildings as per good engineering practice.
j) Sanitary Facilities:
Toilet and shower facilities will be provided for personnel in finished
areas of all major buildings and in other areas as determined by project
requirements. Sanitary facilities fixture types will be so selected to provide
a balance of local and Western fixtures. Towel and waste receptacles will
be recessed to the extent possible. J anitor closets and cleaning material
storage areas will be provided in finished areas of all major buildings. The
sewage fr om var ious locations will be collected in septic tank. The
capacity of the sewerage system, septic tank, required gutters, air vents,
PVC piping, etc. will be calculated based on manpower deployment of
500 personnel per shift.
All Architectural, Structural and RCC drawings and design calculations, shall be
supplied in triplicate to the Client and their Consultants, minimum 15 days prior
to construction of works at site, for approval purposes and only after approval, the
works shall be taken up at site. A soft copy of all such drawings and designs,
either by E-mail or by CD/DVD, shall also be pr ovided along with the har d
copies.
8.2.10 Construction
a) Concrete:
Reinforced concrete structures will be designed in accordance with the
latest ver sion of I S: 456 Code of Pr actice for Plain and Reinfor ced
Concrete.
Water r etaining RCC Str uctur es will be designed in accor dance to
I S: 3370: Code of pr actice for concr ete str uctur es for the stor age of
liquids.
109
The grade of concrete for various structures will be as follows:
PCC below Foundations/Plinth Beams 1:4:8
PCC in base slabs for drains, water retaining structure etc. 1:3:6
PCC/RCC in grade slabs, pavements, plinth protection, etc M20
RCC in foundations and super structures M20
RCC for liquid retaining structures M25
RCC for T. G. Foundation M20
Minimum cement content shall be as follows:
M15 : 324 kg/m
M20 : 360 kg/m
M25 : 400 kg/m
1:3:6 : 216 kg/m
1:4:8 : 216 kg/m
1:5:10 : 130 kg/m
Grouting :
Non-shrink flowable grout shall be used for grouting below base plate of
columns. For grouting of base of machine foundation high flowable
strength ready mixed non shrink grout shall be sued.
Type and grade of grouting for structural columns and equipment base
shall be as indicated. Crushing strength of the grout shall generally be one
grade higher than the base concrete. Minimum grade of grout shall be
M30.
Nominal thickness of gr outing shall be at least 50 mm for building
columns and pedestals of major equipments. For secondary posts, stair &
ladder base, etc, grouting shall not be less than 25 mm thick
Reinforcing Steel:-
i. Reinfor cing steel will be High, Yield Str ength Defor med bar s
conforming to IS-1786 (Grade Fe 415).
ii. Cement:- Cement used in all concrete mixes will be Ordinary Portland
cement/ Por tland Slag cement 43-Grade unless design requires a
different type.
iii. Aggr egates: Fine aggr egates will be clean natur al sand. Coar se
aggregates will be crushed gravel or stone. All aggregates will meet
the requirements of IS:383 - 1970.
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Admixtures:
i) Plasticizers and retarders will be used to control setting time and to
obtain optimum workability, if required.
ii) Water : Clean water of potable quality will be used in all concr ete
mixes.
iii) Mixes: A table will be supplied with the Design Intent Memorandum,
which classifies the proposed mixes into a general range of classes.
The minimum cement provided in concrete mixes will be as per the
stipulations laid down in IS: 456.
iv) Secondary reinforcement : Polyester fibres will be used in cement
mortar, PCC, RCC, etc. to enhance / impr ove the per for mance of
mortar / PCC / RCC
Design Mix Tests:
1. Two sets of compression test samples, three samples per set, will be
made from each proposed concrete mix. One set of three samples will
be tested at an age of 7 days, and the other set will be tested at an age
of 28 days. Tests will be in conformity with IS:4031-1968.
2. Grade Slab: The existing earth fill will be thoroughly compacted, and
pr ovided with 150 mm of boulder soling or br ick a ggr ega tes,
interstices filled with small stones and sand. Floor paving will be of
100/150 mm thick in M-20 grade laid over the prepared surface.
Finishing Formed Surfaces:
1. Fins and other surface projections will be removed from all formed
surfaces except exterior surfaces that will be covered with earth
back fill. Exterior surfaces that will be exposed above grade and all
interior surfaces, except those not usually exposed to view, will be
cleaned and r ubbed. Rubbing will pr oduce a smooth, unifor m
sur face fr ee of mar ks, voids, sur face glaze, and discoloration.
Rubbing will be done by hand with a carborandum stone using
only the mortar produced by the rubbing action and the application
of water.
2. Projecting ends of all form ties will be removed. The resulting
recesses will be cleaned, wetted, and filled with patching mortar.
Patches on rubbed surfaces will match the texture of the adjacent
concrete.
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3. Plinth Protection: All buildings will be provided with 1000 mm
wide and 100 mm thick plain cement concrete paving all around on
the outside. The plinth protection will be laid over prepared sub-
gr ade and base for med with br oken br icks or r ubble laid to a
thickness of 75 mm.
Structural Elements :
Minimum thickness of structural element to be as follows:
Su s pen ded f l ow s l a b / r oof s l a b /
walkways / canopy slabs, etc
: 100 mm
Ground floor slab (non-suspended) : 150 mm
Water retaining slab / walls : 150 mm
Cable / Pipe Trenches / Under ground pit
/ Launder walls and base slab
: 100 mm
All footing (including raft foundation) : 250 mm
Tapered footing : 150 mm
(Min. at
edges)
Parapets / Chajjas : 75 mm
Pre-cast louvers / fins : 50 mm
Pre-cast trench cover slabs / floor slabs /
louvers
: 75 mm
Paving : 150 mm
Basement walls and base slab : 150 mm
Curing:
1. Concrete will be protected from loss of moisture for not less than 7
days after the concrete is placed. Trowelled surfaces, except those
that r eceive a separ ate finish or coating, will be cur ed with a
membrane curing compound. Float finished surfaces, except those
t ha t r ecei ve a sepa r a te finish, ma y be cur ed with either a
membrane-curing compound or with water. Only water curing will
be used if the surface receives a separate finish.
2. Water Curing: Water saturation of concrete surfaces will begin as
quickly as possible after initial set of the concrete. Water curing
will begin within 12 hours in dry weather and within 24 hours in
damp weather. The rate of water application will be regulated to
provide complete surface coverage with a minimum of runoff The
application of water may be interrupted for surface rubbing. The
concrete surface will not be permitted to dry.
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3. Damp proofing: Damp proof course in a thickness of 40mm and
consisting of cement concrete 1: 2: 4 with admixture of approved
water pr oofing compound, will be pr ovided at plinth level for
masonry walls in super structure.
4. Wa ter pr oofing: A wa ter pr oofing sea l will be pr ovided for
structures where applicable. Water-proofing will be carried out by
a system duly approved by the Owner/Engineer.
b) Steel
Structural Steel:-
Steel framed structures will be designed in accordance with IS:-800- Code
of Practice for Construction in steel adopting allowable stress design and
plastic design. In addition steel framed structures will be designed in
accordance with the criteria discussed in the following subsections.
Materials:
Structural steel shapes, plates, and appurtenances for general use will
conform to Indian Standards IS:800 with a minimum yield strength of 250
MPa. Connection bolts will confor m to I S: -1367. Connections will
conform to the latest version of the Specification for Structural J oints.
Welding electrodes will be as specified by the AWS.
Tests:
Mill test reports or reports of tests made by the fabricator will be required
certifying that all material is in conformance with the applicable standards
and specifications. In addition, the fabricator will provide an affidavit
stating that all steel specified has been pr ovided at yield str esses in
accordance with the drawings and the specification.
Minimum Heights for pedestals of Steel Columns :
Top of RCC foundation (pedestals) shall normally be kept at a height of
300 mm above the floor level.
Other Pedestals and Foundations
Stairs and ladder pedestal : 200 mm above the finished floor
level
Equipment in open area : As required (300 mm min.)
Equipment in covered area : As required (150 mm min.)
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Structures / Equipment supplied : As per vendor s data subject to
minimum as specified above
In case the top of pedestal is kept at a lower level so that the column base
plates together with gussets and stiffener remains below finished floor
level (FFL), the column base as well as column section shall be encashed
in concrete above FFL as below:
Open area : 300 mm above FPL / FGL, whichever is higher
Covered : 150 mm above the FFL
c) Miscellaneous Metal Items
Steel Grating:
Steel gratings will be pressure locked grating manufactured with 40mmx
5mm MS strips as longitudinal bearing strips (spanning the supports) and
25mm x 3mm strips in transverse direction. The grating will be provided
with a 40mm x 5mm band all-round. The grating will be designed for
500kg/m2 loading and spans up to 1500mm. Stair treads will also be made
of steel grating with nosing.
Guard rail /Handrail:
Guard rail will be a two-rail system with the top rail 1000 mm above the
walkway surface and the intermediate rail 500 mm below the top rail.
Guard rail post spacing will be proportioned to the length of the protected
horizontal opening, but will not exceed 1200mm centre-to-centre of posts.
Guard rail will be shop fabricated for specific locations and field welded
or bolted to the erected structural steel. Steel pipe will conform to IS-1151,
Medium grade.
Anchor Bolts and Embedded Shapes:
Anchor bolts will conform to IS:-5624. Embedded shapes and plates will
be galvanized where required. Anchor bolt assemblies will be galvanized
where required. Steel, which is not galvanized and will remain exposed,
will be primed with a primer paint.
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d) Data to be submitted by Contractor with the bid
The Contractor to submit the integrated sugar plant layout and sections,
cross-section, elevation, GA, layout for the housing areas, all plant and
non-plant buildings, layouts for the cooling systems, designs for the water
supply schemes etc., layout and sections for the effluent disposal and the
schemes for the same, areas designated for the marshalling and cane yards,
nursery, the bagasse handling system schemes etc. Contractor to also
reflect water collection schemes, water harvesting schemes, collection
systems etc. Landscaping details shall also be reflected by the Contractor
on the layout. Contractor shall also reflect provisions for future expansion
for all sections. The Contractor to also submit the sizes considered for all
buildings in the scope.
8.2.11 Effluent Treatment Plant
The sugar project will have its own effluent treatment plant. Effluent will be
discharged by the Contractor at identified exits of the integrated plant area. The
discharged effluent will be oil free and meet or better the BPCB norms. Part of
the treated effluent will be pumped back to the Contractor to be utilized for ash
quenching and gardening in the integrated plant area. The ETP will include the
required storage area, aerators, dosing systems, sludge drying beds, etc. based on
the expected effluent quality and BPCB norms. The expected quantity of effluent
is to be detailed by the Contractor.
8.3 Buildings & Civil Works
8.3.1 Cane Yard, Marshalling Yard
The cane and marshalling yard for required number of vehicles shall be properly
devel oped for t he hea vy t r a ffi c expect ed. Ca ne Ya r d sha l l be concr et e
topped/paved and the marshalling yard shall be leveled and shall be properly
planned for pr oper and easy movement of the vehicles, bullock car ts etc.
Provision of area for housing the seasonal labor shall be made in the marshalling
yard along with provisions for providing the numbering slips etc.
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8.3.2 Internal Roads & Culverts
Internal roads in sugar plant area shall be concrete/bitumen topped of sufficient
widths as required, one way/two way with proper street lighting arrangements and
green zone/plantation in the centre/ along the sides, with proper road side drains,
culver ts, pr ovision of pipes/ducts to car r y stor m water in separ ate ducts and
cables/pipes in separate ducts. Crossings, cul-de-sacs and dead ends shall be
properly planned for and provided. No roads shall be less than 6m in width. Roads
shall follow the specifications provided with the tender documents. The joining of
internal roads with common roads and roads within other plants will be suitably
co-ordinated.
8.3.3 Fencing & Gates
Fencing for the sugar factory and non plant buildings shall be as required for the
excisable limits with openings as required by excise norms. Fencing shall be
masonry wall up to 600mm above NGL with bar bed wir e/chain link fencing
above and of a minimum height of 2.1m above NGL. Y shaped angles with
barbed wire rounds shall be provided at the top of the fencing necessarily. Gates
to be sliding type electrically operated and all gates to have provision of man
gates within the gates. Gates shall be minimum 2m height. Gates shall be of
various widths as per requirement, however not less than 6m in width.
8.3.4 Culverts, Side Drains, Storm Water Drains
Drains and culverts shall be designed as per requirements and as specified in the
other sections. Side water drains and storm water drains shall be connected to the
water harvesting scheme. Proper provisions shall be carried out especially at
crossings, cable crossings etc. Drains shall as far as possible be trough type RCC,
with sufficient depths and proper slopes in conjunction with the total scheme
worked out for the site. Pipes for drains could also be used with provision for
proper inspection and maintenance at regular intervals. As far as possible, drains
and cable trenches shall not be planned side by side. The hook ups for storm
drains with common drains and drains within other plant areas will be suitably co-
ordinated.
8.3.5 Diffusion Juice Extraction Plant
The Diffusion Extraction Plant/building (only if necessary) is approximately 25.0
meter s wide x 50.00 meter s long x 15.0 eaves height with sloped r oof. The
building (if required) is designed to be a structural frame building with no interior
building column and the exterior wall columns shall also serve as crane columns
for the overhead traveling crane in the building. Crane beams and crane rails
shall be installed on the wall columns. The roof shall either be either of truss or
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single beam rafter construction. Adequate bracing is to be provided on all sides
and roof of the building for wind and equipment loads.
The building will have metallic siding for the roof and walls and translucent
fiberglass panels shall be provided as sky lights in the roof and a light band
(ver tical/hor izontal as r equir ed) ar ound the per imeter of the building. The
metallic siding shall extend down to within 5 meters of grade and the remaining 5
meters shall be brick masonry/concrete block with louver panels installed. The
roof is to be provided with a 2 meter wide gravity vent to insure adequate natural
ventilation of the building during operation and in the out of crop season.
A brick masonry/concrete block electrical equipment room shall be built on the
side of the Building on which the electric motor drive controls are installed. The
floor height of the building shall be such that per sonnel can walk fr om the
equipment to the electr ical equipment r oom without having to go up or
downstairs. The room shall be air conditioned.
Flooring shall be checkered plate for all working platforms and rcc/pcc flooring
vaccum dewatering system.
8.3.6 Boiling House Building
The Boiling House Building will house the following process areas:
Evaporator and Heaters 30m x 60m x 23m Ht.
Vacuum Pans, Centrifugals 60m x 60m x 27m Ht.
Sugar Dryer, Sugar Silos, Sugar Bagging 30m x 42m x 30m Ht.
Tool and Spare Parts Room, Panel Room
Time Keeper s Office, Central Control Panel RoomArea as required
Overall, the Boiling House Building is approximately as dimensioned above with
eave height with sloped roof. The building is designed to be a structural frame
building with no interior building columns. Equipment inside the building shall
be supported on independent structural columns that are connected to the side
wall columns but do not extend to the roof. The roof shall either be either of truss
or single beam rafter construction. Adequate bracing is to be provided on all
sides and roof of the building for wind and equipment loads.
(vertical/horizontal as required) around the perimeter of the building. Where
possible the side wall panels will align with those of the Diffusion Plant Building.
The metallic siding shall extend down to within 5 meter s of gr ade and the
remaining 5 meters shall be brick masonry/concrete block with louver panels
117
installed. The roof is to be provided with a 2 meter wide gravity vent to insure
adequate natural ventilation of the building during operation and in the out of crop
season.
Flooring shall be checkered plate for all working platforms and rcc/pcc flooring
vaccum dewatering system.
A b r ick ma sonr y/concr ete block wa ll sha ll be insta lled to sepa r a te the
Evaporator/Vacuum Pan area of the building from the Dry Sugar Handling area,
Sugar Drying and Bagging areas, to reduce contamination of sugar from dust
emanating from the Building and to contain sugar dust in one area which will
make it easier to reclaim sugar. In the event of a sugar dust explosion, the wall
should mitigate the blast wave into the rest of the Boiling House Building.
A brick masonry/concrete block with RCC slab, Electrical Equipment Room shall
be incorporated into the building to house the drives and motor starters for the
A , B and C centrifugals, which will be air conditioned.
8.3.7 Clarifier & Filter Building
The Clarifier building shall be approximately 16.0 meters wide x 60.0 meters long
x 17.0 meter eave height, the Vaccum Filter building 18m x 36m x 17m eave
height, the sulphur burner building 12m x 24m x 17m eave height, the lime station
18m x 24m x 17m eave height, sulphitors building 6m x 24m x 17m height, and
all buildings shall be structural framed building with metallic roofing and partial
siding. The Clarified Juice Tank, Sulphited Juice and Syrup Tanks and associated
pumps, and Lime Pr epar ation Equipment shall be installed at gr ade or on
intermediate structures. Sulphur Burners shall be installed at the 8,000 MM
elevation on one side of the building and shall be separated from the Rotary
Vacuum Filters and Juice/Syrup Sulphitation equipment by a concrete block wall.
A concrete floor shall be provided for the sulphur burners. This area shall be
covered by the roof but siding will not be installed around the burners or the lime
preparation equipment below. Siding will be carried to within 5 meters of grade
on the side of the building that encloses the juice pumps and storage tanks. The
remaining 5 meters shall be brick masonry/concrete block with louvers. That
portion of the building, approximately 50%, housing the sulphur burners and lime
preparation equipment will not be sided. Elevated flooring around the Filter
Station shall be checkered plate Columns on one end of the building and shall be
designed to support half the load of the Mud Storage Bin.
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8.3.8 Chemical Stores Building
The Chemical Storage Building shall be a concrete block building approximately
7.0 meters wide x 18.0 meters long x 5.0 meter eave height with sloping metallic
roof. The building shall be divided into three separate storage areas, one each for
bagged sulphur, bagged or drummed caustic soda and bulk burnt limestone.
Manual rollup doors will be provided for the two storage areas for sulphur and
caustic soda, the limestone storage area will have a full width opening. Brick
Masonry/Concrete block walls shall extend up to the roof in each area and a
gravity vent shall extend the length of the apex of the roof.
8.3.9 Sugar Godown / Bagged Sugar Warehouse
The Bagged Sugar Warehouses shall be a free span portal frame of rigid frame
design building with no internal columns with approximate dimensions of 70
meters wide x 90 meters long x 8.00 meter eave height and a sloping/curved roof.
The buildings shall be designed to store 15000 tons of 50 kg bags of sugar with
ample allowance for aisles and stand off from walls. Two end bays on one side of
the building shall be reserved for unloading bags from the two bagged sugar
conveyors. The building will have metallic siding for the roof or self supporting
galvalume sheet roofing and walls and translucent fiberglass panels shall be
provided as sky lights in the roof and a light band around the perimeter of the
building. Where possible, the translucent side wall panels will align with those of
the Diffusion Plant Building and Boiling House. The metallic siding shall extend
down to within 5 meter s of gr ade and the r emaining 5 meters shall be brick
masonry/concrete block. The roof is to be provided with a 2 meter wide gravity
vent to ensure adequate natural ventilation of the building during operation and in
the out of crop season.
The building shall be provided with six rollup doors, manual operated, 4.5 meters
x 4.5 meters and six man doors with locks and emergency exit bars. Three meter
canopies shall be provided over each rollup door.
8.3.10 Machine Shop Building
Shall be approximately 20 meters wide x 25 meters long x 8 meter eave height
with sloped roof. The building could be adjacent to the sugar plant. The building
is designed to be a structural frame building with one line of interior columns that
shall serve as a crane column for the 20 meter span overhead traveling crane on
the building. Crane beams and crane rails shall be installed on wall columns. The
roof shall be either of truss or single beam rafter construction. Adequate bracing
is to be provided on all sides and roof of the building for wind and equipment
loads.
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around the perimeter of the building. The metallic siding shall extend down to
within 5 met er s of gr a de a n d t h e r ema i n i n g 5 met er s sh a l l be br i ck
masonry/concrete block with louver panels installed. The roof is to be provided
with a 2 meter wide gravity vent to ensure adequate natural ventilation of the
building during operation and in the out of crop season.
The building shall have inbuilt racks for storage of materials, files etc. and a
closed room for the In-Charge with slab at 3m lvl. for the closed room.
Two roll up doors, 4.5 meters x 4.5 meters, manually operated shall be provided
at locations to be determined during the design phase. A minimum of two man
doors shall also be provided with emergency hardware.
8.3.11 Security, Time, Excise & Allied Offices, Ambulance Room, Fire Fighting
Tender Shed Etc.
The security cabin at the entrance shall be RCC roof with brick/block masonry
walls and an ambulance room along with the shed for the fire fighting tender shall
be provided at the entrance. Time, excise and allied offices shall however be
provided near the common control panel room area in the boiling house along
with the wor ker s r est r oom, toilet facilities etc. The building shall have
aluminium doors and windows, spartek or equivalent flooring and good finishes
on the exterior and interiors. The rooms may be air conditioned. The building and
the rooms shall be sound proof if provided within the factory building area and
proper doors and windows shall be planned for the same.
Th e EPC Con t r a ct or sh a l l a l so i n cl u de i n h i s bi d er ect i on of pr oper
security/inspection turrets in RCC/Structural Steel at all corners of the plot and as
identified by the Client/Client Consultant for security and watch. All such turrets
shall have provision of protection from rains, wind and heat and facility for proper
inspection.
8.3.12 Canteen Building
Proper canteen and facilities shall be provided for the management, workers and
the staff of the integrated plant. Proper segregation for the officer s, the workers,
the labor and others shall also be planned for in the canteen building and the
canteen building may be placed at any suitable location. Canteen shall cater to all
the personnel connected with the integrated plant including the visitor s and
guests to the plant area.
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RCC slab with br ick/block masonr y building with minimum 3m height with
cooking and washing facilities shall also be planned in the canteen area. Canteen
shall also have proper storage facilities such as toilets, wash hand basins, drinking
water facilities etc.
8.3.13 Store Building
Stores Building shall be approximately 15.0 meters wide x 125.0 meters long x
8.0 meter eave height with sloped roof. The building shall be designed as a portal
frame or rigid frame structure with no interior columns.
fiberglass panels shall be pr ovided as sky lights in the r oof and a light band
(vertical/horizontal) around the perimeter of the building. The metallic siding
shall extend down to within 5 meters of grade and the remaining 5 meters shall be
brick masonry/concrete block with louver panels installed. Heavy gauge wire
mesh shall cover the louvers on the inside surface. The roof is to be provided
with a 2 meter wide gravity vent to insure adequate natural ventilation of the
building during operation and in the out of crop season.
A brick/concrete block office approximately 5 meters wide x 5 meters long x 4
meter roof height shall be provided in the building. The room shall be lockable
type with RCC slab on top and good finishes for the walls and floorings.
One roll up door, 3.5 meters x 3.5 meters, manually operated shall be provided at
a location to be determined during the design phase. A minimum of two man
doors shall also be provided with emergency hardware.
The building shall have inbuilt racks for storage of materials, nuts bolts etc.
8.3.14 Laboratory, Manufacturing & Engineering Offices
The laboratory, manufacturing and engineering offices shall be housed inside the
boiling house but shall be air conditioned. The building shall be adjacent to the
central control panel room to be provided in the boiling house. This shall also
house the crusher room, the dark room, toilets for the officer s, meeting room,
drafting section, computer room beside the other engineering and manufacturing
staff offices. The building shall be RCC of 3m ht. with good internal and external
finishes and vetrified tiles for flooring. Walls shall be brick/block masonry. The
building shall be sound pr oof and door s and windows of pr oper gr ade and
specification shall be used for the building.
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8.3.15 Weigh Bridge Cabins
Weigh bridge cabin each of size 5m x 5m x 3m shall be provided at the cane
entrance near the weigh bridges. The structure shall be RCC slab, brick/block
masonry, aluminium doors and windows, industrial flooring, inbuilt rack facilities
for record storage, ease of operation for recording and issuing necessary slips etc.
A separate cabin shall be provided for each weigh bridge, which shall however be
connected by networking facilities to each other. Sufficient storage space for
records shall be provided.
8.3.16 Toilet Blocks
Proper sanitary facilities as per factory norms shall be provided inside the fenced
area for the workers, the staff and the management. The scope shall cover all the
plumbing, sanitation etc. required for the toilet blocks at all locations. Separate
toilet facilities shall be provided for male and female both. Toilet blocks shall be
RCC slab, brick/block masonry structure with glazed tile flooring and dado upto
the ceiling levels, with proper ventilated areas, W.C s, wash hand basins, shower
areas, urinals, bidets etc. All sanitary and plumbing shall be concealed type and of
1
st
quality only.
8.3.17 Spray Pond, Water Channels & Pump House
Spray Pond of required size and capacity shall be provided for the integrated
plant. The str uctur e could be masonr y/r cc str uctur e including for the water
channels. Required pump house with gantry facilities shall be provided adjacent
to the spray pond/cooling tower. Epoxy waterproofing shall be adopted for the
water holding areas and the structures shall be made fully water-proof. Spray
pond/cooling tower shall be designed for minimum dead water storage and if the
site permits, table top spray pond design shall be adopted. Proper levels and
slopes shall be maintained at all locations. Location and orientation of the spray
pond shall be such as to provide maximum contact with wind or to provide proper
natural aeration.
8.3.18 All Machinery & Other Equipment etc. Foundations
Machinery foundations suitable for the machinery equipment loadings suitable for
the 3500 TCD capacity plant and machiner y including all major and minor
foundations shall be included in the offer of the EPC Contractor. The foundations
could broadly be identified as :-
Diffusion Plant foundations
Cane handling foundations
Boiling house foundations
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Sugar house foundations
Clarification house foundations
All major and minor foundations for 3500 TCD plant and machinery
All pumps, compressors, d.g.set foundations
Injection Condensate water channels
Weigh bridge foundations
Machine shop lathe etc. foundations
Bagasse carrier, elevators etc. foundations
8.3.19 Cable Trenches/Water Drains Etc.
Cable trenches will be rectangular reinforced concrete structures of approx. 1m
width and 1m depth (sizes may vary as per sections and houses). They will be
covered either by pre-cast concrete covers or by chequered plate covers. Cable
pull pits of approx. 1x1x2m deep will be provided at suitable locations.
All paved and unpaved surface in the power plant area will be adequately drained
with drainage system for rain water/ fire water/ washing water. Open surface
drains will be provided with bricks of class designation 50 or locally good quality
brick in cement mortar 1:4 including 100 mm thick bed concrete of grade 1:3:6
and 12 mm thick cement plaster 1:4 with a floating coat of neat cement inside the
drains without any cover. Manholes will be made of reinforced concrete and
contain silt traps. Storm water drains will collect all surface water from roofs of
the buildings and from paved and unpaved areas as applicable. The drains from
proposed plant area will be connected to the main drains running all along the
roads.
8.3.20 Effluent Treatment Plant
Effluent treatment plant of suitable capacity for the integrated plant comprising of
baby and oil trap, oil and grease trap, aeration tanks, primary and secondary
clar ifier s, equilisation tanks, holding tanks, sand filter s, flocculation tank,
cleaning day tank, sludge drying beds including all pipes lines in UPVC/HDPE
and/or structures as required as per the effluent disposal systems could be in
masonry/rcc structure. Details of the scheme shall be submitted along with the bid
proposal. Effluent treatment plant location and disposal of treated effluent will be
as laid down in other parts of the specifications.
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8.3.21 Ground Water/Process Water Reservoir
This will consist of a partly underground/partly above ground water reservoir (1
no. approximately 45000 m wor king capacity including 3000 m fir e water
stor age). The water r eser voir will be of RCC or masonr y constr uction with
adequate waterproofing & strength. PCC (1:3:6) paving will be provided in water
treatment area all around 1m. The raw water reservoir will have a partition for
fire water storage. Capacity of the water storage tank shall be finally confirmed
before construction as per the requirements for the integrated plant. The water
reservoir shall be designed as a common reservoir for the sugar, co-generation
and the ethanol plant and the capacity for the same shall be confirmed for the
various plants. The water reservoir shall be designed for at least 4 days capacity.
8.3.22 Water Supply Scheme
Water supply scheme from the water resources as identified by the Client/ its
consultants and the EPC Contractor shall broadly consist of :-
Jackwell in masonry/rcc, at the water source
Percolation galleries in the water source (if required)
Gravity/Rising main for the water supply scheme from the water source to
the water reservoir at site
D.G.Set/Electrical connection and panels for pumping
All pumping machinery for the water supply scheme
Panel room, pump room etc.
All non-return valves/air valves/scour valves etc.
Reservoir and relevant arrangements for two stage pumping (if required)
Elevated Service Reservoir for Domestic Use
The EPC Contractor shall carry out all the surveys including availability of
sufficient water at the water source, including the L section etc. and acquire all
t he per mi ssi ons for l i ft i ng of wa t er fr om the local/government/statutory
authorities.
The EPC Contractor shall also consider and include the requirement for domestic
use of water and if required water filtration plant shall be put up for potable water
for use for domestic pur poses. An over head water tank (ESR) of adequate
capacity shall be put up at a suitable location for gravity flow of water at all
locations and at all times. Proper systems for the water supply including pump
house, filtration plants, pumping machinery, sanitation lines, all valves etc. are to
be included in the scope of the EPC Contractor.
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8.3.23 Control Panel, Centrifugal Panel etc. Rooms
A brick masonry/concrete block with RCC slab, Electrical Equipment Room shall
be incorporated into the building to house the drives and motor starters for the
A , B and C centrifugals, which will be air conditioned.
EPC Contractor shall also consider all other control panel rooms required for the
3500 TCD integrated sugar plant.
8.3.24 Lighting & Electrification
All cane yard, marshalling yard, other areas lighting and electrification shall be
considered within the EPC Contract. Electrification and lighting for the sugar
plant, all areas covered under the sugar plant including street lighting are to be
included. Lighting and electrification shall be as per proper accepted norms of
illumination and as per IS.
8.3.25 Fire Fighting
EPC Contractor shall include all provisions for fire fighting including providing
the water lines (preferably along the roads and in the bagasse/fuel yards, the
marshalling yard, cane yard etc.) as per proper norms and as required by the
Factory Inspector. This shall include all provisions required for the same.
8.4 Important & Common Notes
The sizes of buildings and areas are tentative and may vary as per the final
engineer ing and machiner y layouts and r equir ements of the EPC
Contr actor , which shall be got appr oved fr om the Client and their
Consultants prior taking up any work at site.
Landscaping details shall be submitted along with the layouts and got
approved from the Client and their Consultants prior taking up any work at
site.
EPC Contractor to verify availability of land as per the records of the
Client and carry out their independent surveys for the land as per the Land
records statement.
The FFL/Plinth levels shall be verified by the EPC Contractor and shall
necessarily be above the HFL at site.
Water harvesting details and scheme shall be worked out and approved
from the Client and their Consultants for all sections and shall necessarily
be incorporated in the integrated plant.
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Sites in possession of the Archeological department shall be identified and
shall be protected and maintained in proper manner as per the Statutory
norms of the Archeological Department.
Places of wor ship within the site need to be identified and shall be
properly protected and maintained at all locations. The layout shall reflect
all such locations and the means of protection to be adopted for these
locations.
8.5 The construction specifications have been given in Appendix - XI.
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Chapter 9
Spares
The spar es r equir ed for er ection & commissioning will be made available by the
appointed EPC contractor. Essential spares required for 2 years of operation as per
Appendix - XII will be provided in the EPC bid price.
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Chapter 10
Inspection & Testing
The Contractor will submit Quality Assurance Plan (QAP) and inspection schedule for
the equipment covered in this bid for approval, within 15 days of Letter of Intent (LoI).
The Owner or r epr esentatives of the Owner will attend these inspections at the
Contractor s or sub-contractor s works and / or give waiver.
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Chapter 11
Drawings, Data & Information
The Contractor will submit list of documents, data & drawings to the Owner for the
equipment covered under this section, defining the category like approval or information,
within 15 days of LoI. The Owner or representatives will approve the list accordingly.
129
Chapter 12
Guaranteed Performance Parameters
The guaranteed performance parameters for different sections and equipment of the
proposed 3500 TCD cane diffusion based sugar plant will be as follows:
12.1 Cane Preparation, Milling & Diffusion
i) The cane preparatory index shall be 92 - 94%. The preparatory index shall be
deter mined by Aldr ich / Rayner s CCR Austr alian method, a t 150 TCH
crushing rate and fibre of 16.5% on cane.
ii) Whole Reduced Extraction (Mittal) shall be 98.5%+ at 350% imbibition water
addition on fibre, for cane crushing of 150 TCH.
iii) Down time of primary mill shall be nil.
iv) Bagasse moisture of 48 - 49%.
v) Steam consumption at Diffuser shall not exceed 2.5% on cane
12.2 Clarification
(1750 TCD to 1925 TCD on 24 hr basis)
Juice heaters:
1) Raw juice heating from 20
o
C to 70
o
C in three stages, by using dynamic,
vapour line and condensate juice heaters.
2) Sulphited juice heating fr om 65
o
C t o 103
o
C in three stages, by using
vertical and direct contact juice heaters.
3) Clear juice heating to 115
o
C in three stages, by available vapors, noxious
gases and flash heat of clarifier.
Milk of Lime preparation, Juice Sulphiter and Clarifier
The clear juice obtained fr om clar ifier should be fr ee fr om suspended mud
particles and thick mud should be obtained. In a sample of one liter muddy juice
drawn from the clarifier, minimum 50 grams of dry insoluble solid should be
obtained.
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Vacuum Filter
Vacuum filter efficiency (mud solids retention) should be not less than 75% based
on the aver age of 6 samples taken under r egular wor king conditions. The
bagacillo should be available at the rate of 9.00 Kgs per tone of cane per hour; pol
% filter cake should be not more than 1.00% at wash water of 100% on cake.
12.3 Evaporation & Boiling Section
(1750 TCD to 1925 TCD on 24 hr basis)
Evaporator
(i) Minimum vacuum at the last body of evaporator 600-635 mm.
(ii) The evaporator set to give up to 85% + evaporation.
(iii) Two separate sets to achieve non-stop season throughout run.
Syrup Sulphiter
The syrup sulphiter capable of sulphiting the syrup of 5 pH.
Vacuum Pan
(i) Minimum vacuum at the pan body of 625-635 mm.
(ii) Total cycle time (with full strike level) not more than the following:
A massecuite pan - 2.5 hours to 3.00
B massecuite pan - 4.0 hours
C massecuite pan - 8.0 hours after footing and C massecuite brix 101 deg.
Condensers
(i) Minimum vacuum in the body of the condenser of 650 mm. The water to
vapour ratio of 26 average and 30 max.
(ii) Temperature difference between vapours to be condensed and tail pipe water
temperature less than 10
o
C.
Spray Pond
Minimum dr op of 13
o
C or within 7
o
C of wet bulb temperature for injection
water cooling during season.
131
12.4 Cooling, Curing & Grading of Massecuite
Crystallizers
(i) Minimum purity drop in C crystallizers of 4 units, reckoned from C pan
dropping massecuite to over flow of C MV Continuous crystallizers.
(ii) B Massecuite cooled from 65
o
C to 50
o
C in 8 hours, when supplied with
cooling water at 33
o
C.
(iii) C Massecuite cooled from 65
o
C to 40
o
C in 15 hours, when supplied with
cooling water at 33
o
C.
Rapid Transient Reheating Equipment
The cooled C massecuite reheated rapidly from 40
o
C to 50
o
C and the final
temperature not to exceed more than 52
o
C.
Batch & Continuous Centrifugal Machines
1) B massecuite brix 94-96, purity not exceeding 70.0
2) C massecuite brix 100-102, purity not exceeding 57.0
All Centrifugal machines:
(i) Purity of single cured C sugar not less than 80.
(ii) Purity of double cured C sugar not less than 92
(iii) Purity increase between Nutsch molasses purity (C massecuite fed to C
fore workers) and final molasses purity from C fore worker machines not
more than 1.50.
(iv) Purity of B single cured sugar not less than 95.
(v) Capacity of A batch machine judged for average cycles during continuous
four hour s wor king and for continuous machines also for four hour s
continuous working for successive 7 days respectively.
(vi) Exhaustion of massecuite minimum 60%.
Sugar Melter
The brix of the melt not less than 55 deg. and melt free from sugar crystals (to be
installed for 1750-1925 TCD).
132
Grass Hopper
The temperature of the sugar at the end of the last hopper not more than 42
o
C
and moisture not more than 0.03%, when the ambient temperature is below 36C.
12.5 Reduced Boiling House Recovery
The reduced boiling house recovery not less than 91.5% by Gundu Rao formula.
12.6 Steam Consumption
Steam consumption of the entire sugar plant not more than 22% on cane. Medium
pressure steam not to be used for any purposes in the operating sugar plant, but
kept as standby provision for start up purposes.
12.7 Power Consumption
1) Oper ating electr ical power consumption of the entir e cane pr epar ation,
diffusion section and sugar boiling process house not to exceed 19 kWh/TCH
x 150 TCH or 2850 kW.
2) The power factor of the electrical system not less than 0.95;
3) The performance of all electrical equipments as per existing IS: codes.
12.8 Performance Trial Period
At the time of performance trials, the HPCL management should, besides giving
assistance as per agreement, also arrange adequate supply of clean, sufficient and
continuous cane of 3500 TCD or 150 TCH for 10-days period, conforming to the
following specifications so that the performance trials get completed smoothly:
Sr. No. Item Value
1. Crushing rate 150 TCH or 3500 TCD on 24
hr basis
2. Fibre % cane Not more than 17
3. Pol % cane Not less than 11.5
4. Mixed Juice Purity, % Not less than 80
Performance trials to be carried out for the continuous period of 10 days, during
the period of January and February.
133
12.9 Input & out put flow rates
(50-55% mixed juice to be sent to ethanol plant and remaining 45-50% mixed
juice to be sent to Sugar Processing House)
Inputs:
Sr. No. Material Flow Rate, for 150 TCH
1. Sugar cane: 3500 TCD or 150 TCH
2. Imbibition water: 40-50% cane or 1400-1750 MT/day or 60-88
MT/hour
3. Steam % cane: 22 or 792 MT/ day or 33 MT/ hour
4. Electrical Power: 19 kWh/TCH or 2850 KW
5. G. S. Water: 1800 cu.m /day or 75 cu.m /hr
Outputs:
Sr. No. Material Flow Rate, for 150 TCH
1. Screened &
measured
mixed juice
110% on cane or 3850 MT/day or 165 MT/hour.
(50% mixed juice to be sent dir ectly to Ethanol
plant or 1925 MT/day or 82 MT/hr and 50% mixed
juice to be sent to Sugar plant or 1925 MT/day or 83
MT/hr)
2. Bagasse Moisture 48 to 49% and pol 1-1.25%, the bagasse
shall be sent to cogeneration power plant, at 3500
TCD x 33-34% bagasse on cane or 1155-1190
MT/day
3. High quality
exhaust
condensate
To cogen power plant at 576 MT/day or 24 MT/hr
4. Plantation
white Sugar
10% recovery on cane x 1750 TCD or 175 MT /day
or 7.50 MT/hour
5. Molasses 4.85% on cane x 1750 TCD or 85 MT/day or 3.55
MT/ hour, to be sent to the Ethanol plant
6. Filter cake 2.5-3% on cane x 1750 TCD or 44 MT/day or 1.825
MT/hr, t o be sent for composting of spent wash
from ethanol plant
7. Effluent water
discharge
Nominal, near to zero
134
12.10 Performance Parameters for Bank Guarantee
Section Value
Cane handling, cane
preparation &
Diffusion
Preparatory Index : 92-94%
Reduced Mill Extraction : 98.5%+ at 150 TCH
Bagasse Moisture : 48% at crushing rate of 3500 TCD
on 24 hr basis
Time utilization efficiency: 98%
Electrical power consumption : 19 kWh/TCH in cane
handling, cane preparation, diffusion and boiling
house at 150 TCH.
Sugar process house Reduced Boiling House Extraction : 91.50%
Time utilization efficiency : 98%
Plantation white sugar : ICUMSA 60-65
Steam consumption %
cane
22% on cane for the entire sugar plant
Power consumption in
the fully electrically
driven sugar plant
19 kW/TCH for the entire sugar plant x 150 TCH or
2850 KW
Automation,
Interlocking &
Instrumentation
Staff-workers 15/shift in the cane handling, diffusion
& boiling house

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