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Mechanical Maintenance Manual
Mechanical Maintenance Manual
Mechanical Maintenance Manual
FINCHA
PREPARED BY
SHREE RENUKA SUGARS LTD
INDIA
MAINTENANCE MANUAL
FOR
CANE HANDLING, CANE PREPARATION, MILLINGPLANT, STEAM AND
POWER GENERATING PLANT
1. Equipment Description
2. On Season Maintenance Procedure
This Manual is drafted in such a way that this single document which will
cater the need of Engineers, Chemists, Operators and the Workers as far as
maintenance of Sugar Mill Machinery and Equipment is concerned.
TABLE OF CONTENTS
1 Cane Tippler 5
2 Feeder Table 9
3 Cane Loader 12
2 Cane Cutter 22
3 Fibroses 25
1 Mills 29
2 Prime Movers 38
1 Boiler 43
2 Economizer 52
3 Air Heater 52
4 ESP 53
6 ID Fans 60
7 Traval Grate 61
VI ANNEXURE 107
3 Fasteners 119
MAINTENANCE MANUAL
FOR
CANE HANDLING & FEEDING ARRANGEMENT
Cane handling is a most important activity of a Sugar Mill. Following are the
main tools usually used for handling of sugar cane. In some places Railways are
the main conveyance for cane transportation and Trolley Tippler, but fading
away with passage of time.
2. FEEDER TABLE
3. CANE LOADER
Equipment Description
Feeder Table is a cane feeding equipment which helps in feeding the cane
into the cane carrier as and when required and also fills up gaps left over
by other cane handling and feeding devices. The cane is unloaded over
the table first by the cane un-loader or suitable mechanism and then fed
into cane carrier .The drive for feeder table is generally a variable speed
type, may be either VFD or Eddy current coupling. The controlled
quantity of cane is fed to cane carrier with the assistance of variable
speed drives.
3. CANE UNLOADER
Two motion Cane un-loaders are normally sling type. In each lift while
grab lifts 2.5 tonnes of cane, sling type un-loader lifts 5 tonnes of cane.
Drives are heavy duty and suitable for continuous outdoor type. The
operator’s cabin is attached to Trolley for both types of cane un-loaders.
All electric Motors are Crane duty, TEFC (Totally enclosed fan cooled)
enclosures suitable for 300 operations/ hour, having following
specifications:
All gear boxes are totally enclosed, dust proof and helical type gears. Gear
boxes have a service factor of normally 1.7. All couplings are either gear
type or centrifugal Type. Brakes are Electro-hydraulic thyruster operated
type.
Figure: General Arrangement of Cane Unloader
Main Components of a Cane Un-loader are:
a. Steel construction columns having base plates and extension 3 meters.
b. Gantry having steel channel over top and rail.
c. Un-loader end girders with wheels.
d. Un-loader Bridge.
e. Un-loader trolley with moving control cabin.
f. Steel wire ropes having fastening devices.
g. Mechanical or hydraulic grab.
h. Electric motors for long& cross travel, hoist and hold.
i. Reduction gear boxes
j. Hydraulic system.
Main cane carrier if wider than the width of Mills, facilitates better
preparation and less power consumption in preparatory devices. The
inclination of main cane carrier is 18 degree for a leveller with a minimum
length of 8 meters, and for Fibrizer is around 8 degree. The horizontal
length of cane carrier is kept below the ground level in such a way that
the top of the sloping sides of the carrier is 300 mm above the ground
level.
Normally three strands of chains are installed having 150 mm pitch and
Breaking load 40 tons.( for 915x1830mm Milling Tandem).Main Cane
Carrier is made up of all steel construction, slats 6 mm thick. Three
longitudinal ISMB150 with renewable 8x65 thick spring steel wear pads
are provided as runners for chain rollers.
a. Dismantle chain in pieces two meter long each and detach the slats
from the chain by opening the fasters.
b. Check the elongation of chain if exceed 5mm/meter, dismantled the
Chain into pieces. ( dismantle pin, bushes, link plate and rollers)
c. Cleaning all the pin, bushes & links.
d. Check the wear and tear of pin, bushes & the links.
e. Assemble the all spares, i.e. pin, bushes links.
f. Lying of chain and slats.
g. Inspect all bearings of the driving and tail end shafts. Repair or
replace need based.
h. Sprocket teeth pitch to be checked any deviation, reclaimed and set
right by welding, grinding or machining.
i. Align Drives with Driving shaft coupling.
j. Worn-out runners and side plates of carrier be replaced as required.
k. For runners spring steel flats to bes used.
l. Welding electrode of grade-312 or equivalent be used for welding of
spring steel flat joints and be followed by grinding to ensure levelling
of wear strips.
m. Preferably NY lock nut may be used for tightening the slats .
n. Check the gear box any repair or replacements be done.
MAINTENANCE MANUAL
FOR
Cane preparatory devices mainly used in Sugar Industry are cane chopper,
Cane Leveller, Cane Cutter, Fibrizer or Shredder. A better cane preparation not
only saves power on mills but improves milling results.
Cane Chopper of all steel construction with raised sides plates 8mm thick
and 10 mm thick deflector plate at the top is mounted on first cane carrier.
The cane chopper / Cane levellers are provided with hard faced 45 to 48
HRC cutting knives which are mounted on Cast steel hubs of IS:1030
grade and Forged Steel shaft 40C8 quality. The diameter over the tips of
knives is normally 1600mm.
The chopper generally has less no. of knives and more cane bed clearances,
while leveller has more no. of cane knives and less clearance (800mm for
Chopper and 300 to 350 mm for Cutter) with respect to cane carrier slats.
The leveller/chopper is installed just before the inclined portion of cane
carrier. Suitable Fly Wheels of C.I. Grade 20 duly machined both for
Chopper and Cutter are provided. The Knife set is totally enclosed by a
suitably enforced hood of minimum 10/12mm thick mild steel plate
attached to the cane carrier frame work and provided with suitable swing
flaps and bolted doors at the top of the hood.
For a 915x1830mm Mill 30 knives confirming to IS: 8461-1977 are
provided for Cane Chopper and 40 for Cane Cutter. The knife shaft 230mm
diameter is supported on 200 bore, heavy duty self-aligning, double row
spherical roller bearings with adopter or with-drawl sleeve in cast steel
Plummer blocks.
3. FIBRIZER
Fibrizer of all steel construction is located at the head end of cane carrier.
Fibrizer fiberizes the cane into long fibres.
Two types of Fibrizers are in use in sugar Industry. Fixed Hammer Fibrizer
and Swing Hammer type Fibrizer. Swing type Fibrizer is commonly used
having edge over Fixed Hammer Type Fibrizer and imparts better cane
preparation/ higher Preparatory Index.
Weight of each hammer is normally 18-20 kg or as per design by the
manufacturer. The no of hammers are decided as per crushing capacity.
Rotor shaft is heavy duty minimum 400mm diameter at the hubs and
260mm at the at the bearing journal of 40C8 quality.
The hammer shank is minimum 65mm thick having 600BHN hardness.
The Hammers are secured in 50mm thick Forged or Fabricated MS Hubs.
Fibrizer discs and hammer shanks have G M bushes to suit SS pins. The
Domite tips made of special alloy steel are fitted in Hammers and are
detachable.
The Deflector plate is normally 25mm thick and Anvil 75mm thick while
chute plate is 16mm with 2.5mm thick having Stainless Steel lining. Rotor
is supported on two heavy self-aligning double row spherical roller bearings
with adopter/with-drawl sleeve.
The diameter over the Tips of Hammers is 1800mm when running at
750rpm. A matching Fly Wheel is fitted at both ends of the shaft duly
machined and balanced to reduce the peak load to 150% of full load. Rotor
bearing Plummer blocks are of cast steel double jacketed for cooling water
.External pressure lubricating system is provided with standby
arrangement to ensure uninterrupted lubrication of bearings.
Anvil plate is another important construction part and is of pocketed type
having wrap angle 90 Deg or 120 Deg or may be higher as required. It is
completely covered by reinforced steel fabricated hood and attached to cane
carrier frame and is provided with deflector plate, fixed or oscillating type.
Drive for Fibrizer may be LT & HT electric motor directly coupled or steam
turbine coupled through reduction gear box. Fibrizer speed is in range of
700-800RPM.
1 MILLS
Milling is a mechanical process used for extracting cane juice from cane.
Mainly number of Mills and combination of rollers are responsible for
better juice extraction from cane. The number of mills and size of roller
depend on capacity and efficiency of plant. In one tandem four or five mills
and several combinations of mills as detailed below are popular in
common practice.
GROOVING
The grooved rollers rupture the bagasse more completely and thus facilitate the
extraction of Juice. The grooves of Rollers in a Mill are arranged in such a way
that teeth of top roller, mesh with two bottom rollers. The size of grooves
generally decreases from 1st to last mill. This is because of bagasse becomes
finer and finer as it proceeds from 1st to last mill. The types of grooving
generally provided are as under:
Circumferential grooving
Messcheart grooving
Circumferential grooving
Circumferential grooving are made along the length of the roller and round the
circumference. The depth of groove is slightly less than the pitch of the grooves.
Depending upon the size these grooves are termed as Fine, Medium and Coarse
grooves. Differential Grooving is also in common use having differential angles
to the tune of 3 to 5 degree in Top, Feed and Discharge rollers.
Messcheart grooving
Deep circumferential grooves in between or in alternate circumferential groove
is universally adopted as is termed as Messcheart Groove. Special scrapers are
required for cleaning Grooves and are called as Masscheart Knives. These type
of grooving provide extra drainage area and help in avoiding juice re-
absorption.
Mill Roller
Rollers are made up of a shaft 40C8 Forged steel confirming to IS:1570-1979
and Shell of coarse grain Cast Iron material confirming to IS 11201:1985 and
hardness 180-210 BHN. All shafts have square ends approximately 420mm or
more to have inter-changeability with other rollers.
These are gravity pressure feeding devices to increase the feed ability of
cane blanket. The level is maintained in Donnelly chutes which are
controlled by mill control system which helps to achieve the performance
.Stainless Steel lining in side facilitates cane feeding to the Mills.
Scrapper
The use of scrapper is to clean the bagasse from roller grooving so that
roller rows are clear and extracted juice does not get re-absorbed. Top roller
scraper is floating type. Scrapers for Top and Discharge rollers have
renewable Cast Iron tips.
Scrapper
Trash beam of cast steel material is fitted in between head stocks. For
achieving Trash Plate settings a tilting mechanism is provided for tilting the
Trash Plate and Beam assembly. Trash Plate has matching teeth to fit
closely with feed roller teeth.
Hydraulic accumulators:
2. PRIME MOVERS
Following are the prime movers which are in use as Mill Drives:
A. Steam turbine.
B. Electric Drives . . DC motors/AC Motors With VFDs
C. Hydraulic drive.
Quite a few Hydraulic drives have been installed in some Sugar Mills but
are not popular even few advantages have been noticed:
Since Hydraulic Drives are not installed in the factories hence not
described while Electric drives have been explained in “Electricals”.