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GDP/EPC-BID-S/09-10/029 (F)
June 8, 2009
GPD/SDE/HPCL/08-09/045
September 12, 2008
Technical Specifications
Prepared For
June, 2009
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GDP/EPC-BID-S/09-10/029 (F)
June 8, 2009
GPD/SDE/HPCL/08-09/045
September 12, 2008
Title
Intent of Specifications
Project information
Design Basis, Scope of Supply, Services & Terminal
Points
Design Basis
Scope of Supply
Services
Terminal Points
Technical Specifications
Cane un-loading / loading
Weigh Bridges
Cane Un-loading & Handling
Cane Preparation
Cane Stabilizer & Density Enhancer
Cane Cutter
Swing Hammer Type Heavy Duty Cane Fibrizor
Rake Cane Carrier
Auto Cane Feed Control System
DSM Screens for RJ
Cane Diffusion
De-watering Mills
Rake Type Intermediate Carrier (RIC) after Diffuser
Mill Auxiliary System
Cane Diffuser
Bagasse Elevator
Mass Flow Meters
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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
Doc No.
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GDP/EPC-BID-S/09-10/029 (F)
June 8, 2009
GPD/SDE/HPCL/08-09/045
September 12, 2008
Title
Sugar Process House
Juice Heating & Clarification
Sulphur Furnace
Air Blower Fans
Juice Sulphiter & Auto pH Control System
Syrup Sulphitation
Milk of Lime Preparation
Juice Clarifier
Rotary Vacuum Filter
Juice Evaporator Station
Online Conductivity Measurement
Syrup & Molasses Storage Tanks
Molasses Conditioning Units
Automatic Brix & Temperature Control Equipment,
Molasses Conditioners
Batch Type Vacuum Pans
Seed & Vacuum Crystalizers
Condensers
Injection & Spray Water Pumps
Spray Nozzles & Pond
Cooling, Curing & Grading Plant
Centrifugal Machines
Pug Mills, Magma Mixers & Transient Heaters
Air Compressor & Magma Pumps
Sugar Melter, DSM Screen & Dry Seed Conveyor
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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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GDP/EPC-BID-S/09-10/029 (F)
June 8, 2009
GPD/SDE/HPCL/08-09/045
September 12, 2008
Title
Automatic Brix & Temperature Control Equipment, Sugar
Melter
Grass Hoppers, Sugar Elevator, Sugar Grader & Dust
Catcher
Fully Automatic Sugar Silo & Weighing Machines
Molasses weighing, Final Molasses Tanks & Water Tanks
Sugar Go-downs
Water Conservation & Circulation
Miscellaneous Equipment
Supporting Structure & Material Specifications
Other General Design Criteria
Interface Piping
Energy Efficiency Improvement
Steam Consumption
Power Consumption
Electrical Distribution System
General Design Basis
Scope of Work
Diesel Generating Set
Control & Instrumentation System
Introduction
Statutory Requirements
DCS based Automation
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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
Doc No.
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GDP/EPC-BID-S/09-10/029 (F)
June 8, 2009
GPD/SDE/HPCL/08-09/045
September 12, 2008
Title
Civil Works
General
Design Philosophy & Criteria
Buildings & Civil Works
Important & Common Notes
Spares
Inspection & Testing
Drawings, Data & Information
Guaranteed Performance Parameters
Cane Preparation, Milling & Diffusion
Clarification
Evaporation & Boiling Section
Cooling, Curing & Grading of Massecuite
Reduced Boiling House Recovery
Steam Consumption
Power Consumption
Performance Trial Period
Input & Output Flow Rates
Performance Parameters for Bank Guarantee
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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
Doc No.
Date
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GDP/EPC-BID-S/09-10/029 (F)
June 8, 2009
GPD/SDE/HPCL/08-09/045
September 12, 2008
LIST OF APPENDICES
Appendix No.
Title
II
III
IV
VI
VII
VIII
IX
XI
XII
List of Spares
XIII
XIV
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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 Lauriya in West 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 commercially proven diffusion process for optimum juice extraction, for
diversion of 50% juice to ethanol plant and balance to sugar process 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)
(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 driven 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 works at the project site (Refer
Appendix I).
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
Chapter 2
Project Information
Name and Address
Project Title
EPC Consultant
Products
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
Project overview
: Zone IV
Relative Humidity
: 70% (average)
Climatic Conditions
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
: 32 0 C
:
: 20
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
Chapter 3
Design Basis
3.1.1
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
3.1.5
Automatic juice proportioning device for screened mixed juice at the outlet of the
diffusion process to transfer 45-50% of Mixed Juice (MJ) to sugar process house
and balance 50-55% to the Ethanol Plant.
3.1.6
3.1.7
3.1.8
High efficiency evaporators and vacuum filters, with optimum no. of pumps in
operation and gravitational discharge of press mud (for direct loading in the
trailers from the vacuum filters).
3.1.9
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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 provision to transfer 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 fibrizor motors, 660 V for thyristor controlled DC motor for dewatering 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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 derived through Phase &
Neutral for single phase power consumer
3.2
Scope of Supply
3.2.1
General
The scope of work 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
will also need to complete all associated electrical, mechanical and
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 providing the appropriate
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)
(b)
Providing all labourers, materials and equipment for testing at shop / site,
as required.
(c)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
(d)
Spare parts required for two (2) years of trouble free operation
(e)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
(b)
(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 process equipment, perforations on fixed bottom screens,
loosening screws for moving bagasse mat, counter current extraction, unscreened & 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
remaceration juice pumps, lagging & cladding, drives for various
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 control system, milk of lime
preparation, clarifier and vacuum filters, juice evaporator station with
quintuple effect evaporator 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 crystallizers,
condensers, injection and spray water pumps, spray nozzles and pond, etc.
(e)
(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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
3.2.3
(g)
(h)
All steam and power consumption reduction equipment for achieving the
related guaranteed performance parameters.
(i)
3.2.4
3.2.5
Civil Works
All necessary civil works including foundations, structural, earth work, etc.
required for installation of the proposed 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
(b)
Preparation of BOQ
(c)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
10
(d)
(e)
3.3.3
3.3.4
(a)
(b)
(c)
Pre-commissioning checks.
(d)
(e)
Statutory Approvals
(a)
(b)
(c)
Making the arrangements for periodical and final inspection of all major
equipment at own or sub-contractors works.
(b)
3.4
Terminal Points
3.4.1
Sugarcane
At the weigh bridge inlet of the cane carrier
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
11
3.4.2
Raw water
At the specified intake point at the nearby Gandak river
(Contractors scope coverssuitable water lifting scheme, pumps, pipelines, valves
/ fittings, ground water reservoir, common distribution header, raw 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
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.
(Contractors 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 switchboard in cogen plant 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 contractors scope).
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
12
3.4.6
Compressed air
Necessary size compressor & accessories, distribution header & pipelines, valves,
fittings, etc. required for the sugar plant included in the contractors scope.
3.4.7
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 nursery plantation area, treated effluent meeting the
BSPCB norms.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
13
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
14
Chapter 4
Technical Specifications
4.1
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.
1
2
3
Capacity, MT
50
30
5
Platform Size, m x m
16 X 3
16 X 3
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
Cane Un-loading Bridge
Cane Un-loading Gantry
Remarks
2-motion type
According to local situation
Cane Un-loading
trolleys
Lifting crane
bar / grab
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
15
Type of motor
Squirrel cage
Squirrel cage
Slip ring
Slip ring
kW
20
20
7.5
4.0
Rating
1 hr.
1 hr.
hr.
hr.
Duty
S4
S4
S4
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
Hoisting
Holding
Long Travel
Cross Travel
Speed
12 meters/minute
12 meters/minute
15 meters/minute
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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
16
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 supported on steel structure 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.
Operators 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
Cane carrier-1
Cane carrier-2
KW rating
40
40
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
17
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
18
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 renewable 10 x 65 mm thick
spring steel wear pads would be bolted on the top side of the cross pieces to
support the cane carrier chain rollers. The distance between the adjacent
supporting columns should not exceed 3.50 meters. The runners 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 running 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
19
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 800 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 tramp iron 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
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
20
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 doors at top of the hood to suit reverse
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
row spherical roller bearings 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 grade FG 260, IS - 210 duly machined and well
balanced shall be provided at the outer end of the shaft.
Cane cutter set shall be driven by a continuously rated drip proof / screen
protected slip ring 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. It shall be directly coupled by geared
coupling, having service factory of 2.00, capable of transmitting 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 from 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
21
4.2.3
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
22
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 Fibrizer shall be driven 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
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
23
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 run in minimum 120 mm size spherical roller
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
Speed of Rake cane carrier
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
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
24
Control Action:
The system should be provided with two control actions i.e. proportional and ONOFF control actions. Proportional control shall be as per the diffuser load. ONOFF 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
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
25
4.2.6
DSM Screens RJ
Specifications
Qty.
3-Numbers
Each screen shall be of stainless steel stationary wedge bar type having 450 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
discharge of juice and wet cush-cush and shall be provided with attendant
platform. 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%. Broad specifications are given in the following paragraphs.
However, the Tendererss are free to make minor changes in the specifications to
achieve guaranteed performance parameters, based on the proven performance
a c h i e v e d b y t h e i r t e c h n o l o g y / e q u i p m e n t s u p p l i e r s h a v i 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 (36x72), 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.
1.
2.
3.
4.
5.
Element
Total carbon
Manganese
Silicon
Phosphorus
Sulphur
% composition
3.20 to 3.60%
2.20 to 3.20%
1.20 to 2.20%
0.50% Max
0.15% Max
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
26
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 770 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 roller. The bearings 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. Scrapers 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
27
The mill shall be provided with hydraulic loading system, consisting of hydropneumatic 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 hydraulic system shall be designed for oil pressure 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
control panel pressure gauges and audio/visual alarm with suitable timer
arrangement for controlling pump operations.
Juice 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. Joint 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 t y p e GRPF (Grooved, Pressure Feed Rollers, one set for dewatering mill)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
28
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 dewatering mill. Level sensing device shall have on off control of
intermediate carrier and shall have sequence inter lock.
4.3.2
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
29
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 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 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 run in minimum 120 mm size spherical roller
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 repump 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
30
4.3.3
Specifications
Continuous
1
750 kW, 1000 rpm, Class V & Duty S1
V
660 V
220 V
IP 23 SPDP(force cooled with air filters)
F, Temp. rise limited to class B at continuous
rating
Horizontal foot mounted
50 o C
The motor shall be designed for variable speed operations, controlled 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
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
31
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 relays, mounted on passivated plates; the cubicle will
conform to IP-30 protection.
All necessary indications, annunciations, controls will be neatly arranged on
cubicle front door with neoprene gaskets on all edges of panel. Ventilation
openings shall be provided at the top of panel and on side covers by louvers
suitably covered by fine wire mesh.
The thyristor drive panel shall be as per following specifications:
Armature converter
Particulars
Specifications
Torque rating
Type of Thyristor bridge
Voltage grade of thyristor
660 V
11KV / 440 V, 3 phase, 50 Hz
(11KV / 660 V through converter transformer)
100% continuous, 150% for 2 hours and 200%
for 1 min, class V, constant for rated full speed
3 ph, 6 pulse, fully controlled non regenerative
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 annunciators will be provided. 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
32
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
33
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
Grooving pitch mm
Dewatering Mill
35 mm
Description
Grooving Angle0 F, T, D for 2-mills
Hard facing of Rollers
Hard facing of trashplates &
scrapers
Messchaert grooves
Chevron grooves
Specifications
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
34
Specifications
+ or - 0.0005 gm/cc
0.001 % of nominal flow rate per0 c
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
35
Power supply
Housing
85-230 V AC
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.
1.
Equipment
Controller
2.
Control Valve
3.
AC Variable Drive
Specifications
Microprocessor based multi loop PID
controller.
It shall be suitable for controlling the flow of
imbibition water continuously
with
proportional control.
Suitable for controlling the speed of the
electric motor employed for imbibition water
pump.
Specifications
Suitable RTD PT 100
Two wire electronic analogue type with 4-2 0 m A D C
output
Microprocessor based single loop indicating type
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).
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
37
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 rake type bagasse elevator of all steel construction 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 breaking strength 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 sprockets 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 surface facing the bagasse elevator. Platform 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
38
4.3.6
1)
2)
Capacity,
m3/hr &
Head, m
100, 60
100, 60
for
Numbers
2
4
(2 in operation & 2
stand by)
Each Juice flow measuring system shall have computerized, instantaneous and
integrated system, to be installed in screened mixed juice line with check
weighment arrangement. Beam scale of suitable capacity to be provided 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.
Description
Type
2.
Wetted Parts
and connection
3.
4.
7.
Accuracy
Ambient Temp
Effect
Repeatability
Inaccuracy in
Current output
Core processor
8.
Outputs
9.
Power Supply
5.
6.
Specifications
Coriolis Dual U Tube design or single full bore
straight tube design.
Tube, Manifold, and Process flanges in 316 SS
welded design, enclosure in SS 304 and should
fulfill NACE standard.
0.10% of mass flow rate
0.001 % of Nominal flow rate per0c
0.05% of rate
None
It should be microprocessor based with digital
communication having meter diagnostic capabilities
and multivariable measurement with 4 wire system
between the sensor and transmitter.
i) 4-20 mA for mass flow rate
ii) 0-1000 Hz frequency for mass flow rate
iii) Digital HART for remote configuration
85-250 V AC / 24 V DC
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
39
Sr.
No.
10.
11.
12.
13.
14.
Description
Specifications
Electrical
Connection
Electrical
Housing
Temperature
Limits
Indication
facilities
inch NPT
Communication
Ports
NEMA 4X
0 to 1000 C
Flow rate in TPH; Current hour flow in tones; Last
hour flow in tones Separate display for measured
liquid during check weighment.
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
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
40
Description
Dynamic juice heater
Vapor line juice heater
Direct contact juice heater
Clear juice heater
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
condensates from the respective evaporator bodies to minimize steam
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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
41
Dynamic and Vapour Line juice heaters will be made suitable for two vapour
passes.
Juice 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
temperature rise expected to achieve minimum steam consumption for juice
heating.
4.4.2 Sulphur Burning Furnace
Equipment
Sulphur furnaces (2 working, 1 spare)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
42
4.4.3
4.4.4
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
43
Sr.
No.
1.
Equipment
Specifications
Other Arrangements
Sensor
Ruggedized industrial
grade combined pH
electrode with
automatic temperature
compensation. It shall
be field repairable
type.
Microprocessor based
design with LCD
display for pH and
temperature value with
following facilities:
2.
pH
Analyzer
3.
Controller
4.
Control
Valve
5.
Recorder
Microprocessor based
multi loop controller
with
following main
facilities:
Suitable for
controlling the flow of
lime and SO2
continuously with
proportional control
shall be provided.
Suitable recorder shall
be provided.
Output : 4 -2 0 m A 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 features feature
shall be provided
Electronic failure
Electrode coating
Electrode breakage
Cascade control and self
tuning Communication port RS
232 or RS 485 for PC
communication Centronic
Parallel port for printer
44
SO2 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); grit catchers and one
sulphited syrup receiver of suitable capacity with sight and light glasses, inlet,
outlet, and equalizing connections shall be provided.
4.4.6
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 provided up to juice sulphitation with return
piping and to mud overflow tank and to condenser outlet.
4.4.7
Juice Clarifier
Equipment
Clarifier
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
45
The clarifier shall be made of mild steel plates having following minimum
thicknesses:
Sr. No.
1.
2.
3.
4.
5.
6.
Part
Bottom
Shell
Tray (intermediate)
Tray (Top)
Top Cover
Flocculating Compartment
Thickness, mm
8
6 (with stiffeners)
8
6
6
6
The continuous clarifier shall be complete with mild steel flash tank and
withdrawal 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
bronze fittings complete with drive motor shall be provided. 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
Equipment
Vacuum Filter
Two rotary vacuum filters shall be installed, each of 2.44 m dia x 4.88 m long
drum (8x16
) having filtering area of 36 sq. m each.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
46
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 bronze valve body, bronze 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 mixture, 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 way valve fitted with manually operated flap door, two mud
circulation non clog centrifugal pumps each of 25 cu.m/hr capacity at 20 meter
discharge head complete with motor drive, 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.
Equipment
Evaporator
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
47
The heating surfaces given for quintuple effect evaporator are indicative. The
Tendererss m a y w o r k o u t heating surfaces so as to provide guaranteed
performance parameters.
Item
Distribution of
Heating Surface
A -set: Cap 150 tch x
32 = 4800 sq.m
B-set standby
Extensive Vapour
Bleeding:
Total
1
30%
2
35%
3
18%
4
10%
5
7%
100%
720
840
433
240
167
2400 sq.m
720
840
433
240
167
2400 sq.m
CLJ-3
SJ-2
SJ-1
RJ-3
RJ-1
RJ-2 By
condensate
heater
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
48
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 evaporator sets shall be complete in every respect 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
arrangement from each body shall also be provided. 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 recovery 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 extraction columns. The sample cocks shall be
provided at all units individually for testing condensate for sugar traces 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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 evaporator bodies with recirculation arrangement 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 1st and 2nd 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:
Alarm :
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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The wash out connection of each tanks shall be connected by a pipe to juice
check weighment tank with proper 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 provided, for respective 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
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
51
Sr.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Control
System
Brix Control
System
Sensor
Specifications
Brix Control System
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
52
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 (m2 ) to volume (m3 ) 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 atmosphere venting. Hot water meter cum recorder capable of
measuring 15 m3 /hr of hot water shall be provided. Panometer with automatic
feed control system and pneumatically operated discharge valves shall be
provided.
The condensate extraction system shall consist of two closed cylindrical
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 from low grade pans could go to either of these tanks whereas
condensate from high grade pans could go to vapour condensate receiver.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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The condensate pipes in these receivers 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 m3/hour capacity and one pump of 15 m3 /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. Control loop should consist of conductivity electrodes (self cleaning
type) conductivity monitor, micro processor based PID controllers, IP
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 regulate 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
54
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
55
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 platform with railings, access
staircase for inspection, repair etc. of the condenser shall be provided. Jet & 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 m3 /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 ring induction motor with suitable starter for
continuous working. Priming pumps for injection and spray 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 provided. Each pump shall have
isolating & NRV in delivery line and 2 Nos. drain connection of 100 mm dia with
blind shall be provided.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
56
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 centre 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
A- AC (air cooled)
B-WC (water cooled)
C&R
C-WC-MVC
(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 crystallizer of 45 tones capacity as receiver 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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 recycling with a separate 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 control box and indicated by different 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 temperature on sensing through ETDs of the motors. 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
B & C-massecuite
Transient heaters
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 cured.
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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
59
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.
Operators push button panel shall have provision for operating 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 provided having stirring arrangement, driven by electric
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 provided for C after and B machines. All the fore
-workers and low
grade massecuite afterworker machines to discharge directly into the
corresponding magma mixer of suitable capacity and design. The shell of the
magma mixers 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
60
One continuous sugar melter of 15 MT/hour capacity for melting sugar lumps
and magma sugars and one melt pump of 20 m3 /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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
61
Transmitter
Controller
Control
valve
Recorder:
Recorder:
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
62
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 42 C 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
capable to sieve mini m u m 4 MT of sugar of any grade and shall 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
provided. The screens 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
65
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
66
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
67
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
68
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
69
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: 7781971.
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 IS: 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
It is necessary to check, verify and get certified the strength and designs of
proposed staging and structure used for equipment and machinery for both the
proposed crushing rates.
4.5
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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1)
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)
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).
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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 extracting 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 Juice 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,
syrup pumps, melt pumps should be bronze fitted wherever not mentioned,
otherwise these and other (except at mill house and diffuser) centrifugal pumps
should conform to IS-5659 and IS-5120 specifications.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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 calandrias 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)
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.)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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ii)
b)
c)
25)
26)
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.
All nuts and bolts and non-return valves should be as per ISI specifications.
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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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27)
4.6
Velocities m/s
Suction 1.0 m/second, Delivery 1.20 m/second
Suction 1.0 m/second, Delivery 1.20 m/second
Suction 0.5 m/second, Delivery 1.00 m/second.
Suction 0.3 m/second, Delivery 0.50 m/second.
Suction 0.1 m/second, Delivery 0.15 m/second
30.00 m/second
30.00 m/second
30.00 m/second.
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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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.
In 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.
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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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Chapter 5
Steam Consumption
The Tendererss to evaluate and provide following specific proven steam economy
measures for achieving guaranteed performance parameters for steam
consumption of 22% on cane. Additional possible measures for the purpose or
even for lower steam consumption than to be guaranteed may be separately
quoted.
i)
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5.2
Power Consumption
The Tendererss to evaluate and provide following specific proven power economy
measures for achieving guaranteed performance parameters 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)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
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.
Providing adequate size motors for various applications and providing star
delta controllers for drive motors expected to operate at less than 50%
capacities and where fluctuating loads are envisaged for applications like
magma pumps, dry seed pumps and mixtures, molasses conditioners and
milk of lime stirrers.
Providing energy efficient electrical motors having efficiencies more than
90%.
Providing bigger sized equipment and machinery to minimize number of
machinery, such as at A, B and C massecuite centrifugal machines.
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.
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.
Providing high efficiency planetary gear drives at crystallizers, magma
mixers, vacuum and seed crystallizers and pug mills.
Providing high efficiency helical gear units at all carriers, cane yard
equipment, magma and massecuite and molasses pumps, milk of lime
equipments, molasses conditioners etc.
Elimination of power drives by using gravitational force at cush-cush
conveyors under DSM and for filter cake conveying by using gravity
discharge chutes.
Providing capacitor banks of adequate sizes at MCCs, to reduce cable losses.
Providing level controller switches for juice and sugar dust collector tanks
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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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Chapter 6
6.1.1
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.
c.
d.
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.
g.
h.
MCC shall be floor mounted self supporting, dust and vermin proof, fixed
type construction.
i.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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6.1.2
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.
l.
m.
n.
d)
e)
f)
g)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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6.1.3
c)
6.1.4
6.1.5
a)
TYPE OF FEEDERS:
Incomers
: D.O. 3-Pole ACB
Emer g e n c y P o w e r : D.O. 4-Pole ACB
Supply Feeder
Outgoing Feeders
: SDF up to 630 A
: MDO Type ACB Above 800A
b)
BUSBARS
Incomer
Feeder
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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6.1.6
b)
Outgoing
Starter
Feeder
c)
Bus bar
d)
Control
Logic
e)
Provision
of Spare
feeders
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
b) BATTARY :
CHARGER
c) DCDB
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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6.1.8
c)
d)
6.1.9
Cables
The following consideration shall be given for Cable Sizing and Selection on
Nominal Current Capacity
a)
b)
c)
d)
e)
f)
g)
6.1.10
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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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6.1.12
b)
c)
The lighting shall be catered by Main Lighting DB. LDB & SLDB
connected by Al. conductor cables. The Emergency power supply
from 415V DG set will be made available to lighting transformer in
case of failure of power
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. Flame proof Enclosure 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.
1 1 K V panel comprising of VCB, CTs / PTs, meters, 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
1 1 K V / 4 33 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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 fixture 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 electrical
connections.
11 KV / 690 V converter transformer 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
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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.
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Chapter 7
Introduction
It is essential to have full automation of the sugar plant along with required
instrumentation and systems at various 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, brix & temperature control of juice sulphiter and molasses
conditioners, all batch vacuum pans, sugar melter and sugar silo system, etc. have
already been specified in the previous chapters 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
7.2.3
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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2)
7.2.4
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 Juice 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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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Sr.
No.
1.
Description
Input
2.
Display &
Internal Scan
Time
3.
Range
Accuracy
Alarms
Facilities
4.
&
5.
6.
7.
Broken Sensor
C.M.R.R.
Memory
8.
Operating
Temperature
Mains supply
9.
10.
Specifications
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
a) 3 digits, ", 7 segment LED display for
process
variable; 2 digits, ", 7 segments LED display for
channel no.
b) 16 x 2/20 x 2 backlit LCD
c) 50 m sec. per channel
Keyboard configurable for each channel separately with
reading accuracy of 0.25% of F.S.
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.
Indicated by displaying error message on display
120 db
It shall be possible to retain the user interaction memory
for more than six months in case of power failure
0 to 50oc with maximum 0.015% / oc drift
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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7.2.7
7.2.9
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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7.3
CONTROL
BASE
MPBA
MPBA
MPBA
MPBA/ABA
5
6
7
MPBA
MPBA
MPBA
8
9
MPBA
MPBA
10
11
12
13
14
15
16
MPBA
MPBA
MPBA
MPBA
MPBA
MPBA
MPBA
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
:
:
:
:
:
:
M20
IS : 1786
43 grade Portland cement
As per IS 800
As per IS 1893-2002
Velocity : As per IS : 875
South-West (May- Sep),
North East (Oct Apr)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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b)
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 critical
foundations.
8.2.4
Design Criteria
The design criteria for various structures and structural elements will be as
follows:
a)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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b)
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 structural system. The effect of water table will be considered and the
foundation will be checked for overturning for minimum and maximum vertical
loads. There should be no uplift under any portion of the foundation for any
loading condition. The foundation sections will be sized and reinforced
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
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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General
A necessary requirement for all rotating machinery is that it should be properly
supported. Thus the foundation becomes an important 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 ensuring that amplitudes are limited to values that are
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 normal or
abnormal circumstances. Spring supported foundation shall be provided for low
frequency machines, wherever the same are required from technical
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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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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For loads caused by moving equipment over the floor for installation,
consideration will be given to the shoring of beams and floor from floors below.
When moving equipment over floors for installations are considered, stress
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)
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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 vertical load will be 25% for crane girder 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 according to IS: 875. In view of the asymmetrical nature 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 2/3rd of the average annual variation in temperature. The structure
will be designed to withstand stresses due to 50% of the total temperature
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.
EPC Bid Document for Sugar Plant at Lauriya, Dist. West Champaran, Bihar, Technical Specifications
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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
Cable Trenches
The cable trenches and pre-cast removable 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 crossing the road/rails 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
trenches will be kept at least 50mm above the finished ground 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 mortar 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 rainfall data and the storm 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 respectively. 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 discharged above the High Flood 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
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Roof
As per details given in relevant sections.
c)
d)
e)
Windows, Ventilators
Window and Ventilator frames will be made of extruded aluminium, steel,
or other tried and proven material as per the schedule given earlier.
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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Doors:
Pressed steel doors/ Aluminium doors will be provided 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
constructed from 1.3 mm steel with an internally reinforced, 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 rating. Doors for fire 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-operated. Doors will be manually operated where access is
infrequent.
INTERIOR ARCHITECTURE: Interior architectural systems will
conform to the following general design criteria. Fire rated architectural
system will be provided when required by building or fire codes. All
normal occupied areas will be finished areas.
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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 earlier. Steel structures, doors, windows, steel rolling
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. Janitor closets and cleaning material
storage areas will be provided in finished areas of all major buildings. The
sewage from various 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 provided along with the hard
copies.
8.2.10 Construction
a)
Concrete:
Reinforced concrete structures will be designed in accordance with the
latest version of IS: 456 Code of Practice for Plain and Reinforced
Concrete.
Water retaining RCC Structures will be designed in accordance to
IS:3370: Code of practice for concrete structures for the storage of
liquids.
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1:4:8
1:3:6
M20
M20
M25
M20
: 324 kg/m
: 360 kg/m
: 400 kg/m
: 216 kg/m
: 216 kg/m
: 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 grouting 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.
ii.
iii.
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Admixtures:
i)
ii)
iii)
iv)
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
provided with 150 mm of boulder soling or brick aggregates,
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.
2.
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 rubbed. Rubbing will produce a smooth, uniform
surface free of marks, voids, surface 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.
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.
Structural Elements :
Minimum thickness of structural element to be as follows:
Suspended flow slab / roof s l a b /
walkways / canopy slabs, etc
Ground floor slab (non-suspended)
Water retaining slab / walls
Cable / Pipe Trenches / Under ground pit
/ Launder walls and base slab
All footing (including raft foundation)
Tapered footing
100 mm
:
:
:
150 mm
150 mm
100 mm
:
:
Parapets / Chajjas
Pre-cast louvers / fins
Pre-cast trench cover slabs / floor slabs /
louvers
Paving
Basement walls and base slab
:
:
:
250 mm
150 mm
(Min. at
edges)
75 mm
50 mm
75 mm
:
:
150 mm
150 mm
Curing:
1.
2.
Concrete will be protected from loss of moisture for not less than 7
days after the concrete is placed. Trowelled surfaces, except those
that receive a separate finish or coating, will be cured with a
membrane curing compound. Float finished surfaces, except those
that receive a separate finish, may be cured with either a
membrane-curing compound or with water. Only water curing will
be used if the surface receives a separate finish.
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.
4.
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 conform to IS:-1367. Connections will
conform to the latest version of the Specification for Structural Joints.
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 provided at yield stresses 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
Equipment in open area
Equipment in covered area
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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
Covered
c)
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d)
8.2.11
8.3
8.3.1
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8.3.2
8.3.3
8.3.4
8.3.5
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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.
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
(vertical/horizontal as required) 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. 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 personnel can walk from the
equipment to the electrical equipment room 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
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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
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. 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 workers rest room, 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.
The EPC Contractor shall also include in his bid erection of proper
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 officers, 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 visitors and
guests to the plant area.
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RCC slab with brick/block masonry 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.
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
(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 officers, 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 proof and doors and windows of proper grade and
specification shall be used for the building.
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Chapter 9
Spares
The spares required for erection & 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
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Chapter 11
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Chapter 12
12.2 Clarification
(1750 TCD to 1925 TCD on 24 hr basis)
Juice heaters:
1)
2)
3)
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Vacuum Filter
Vacuum filter efficiency (mud solids retention) should be not less than 75% based
on the average of 6 samples taken under regular working 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
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 oC.
Spray Pond
Minimum drop of 13 o C or within 7 o C of wet bulb temperature for injection
water cooling during season.
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12.4
(ii)
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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
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) Operating electrical power consumption of the entire cane preparation,
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
Item
Crushing rate
Fibre % cane
Pol % cane
Mixed Juice Purity, %
Value
150 TCH or 3500 TCD on 24
hr basis
Not more than 17
Not less than 11.5
Not less than 80
Performance trials to be carried out for the continuous period of 10 days, during
the period of January and February.
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12.9
Material
Sugar cane:
Imbibition water:
3.
4.
5.
Steam % cane:
Electrical Power:
G. S. Water:
Outputs:
Sr. No.
1.
Material
Screened &
measured
mixed juice
2.
Bagasse
3.
5.
High quality
exhaust
condensate
Plantation
white Sugar
Molasses
6.
Filter cake
7.
Effluent water
discharge
4.
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Value
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.
Steam consumption %
cane
Power consumption in
the fully electrically
driven sugar plant
Automation,
Interlocking &
Instrumentation
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