Mill

J P Mukherji & Associates Pvt Ltd
WSSF-USI TECHNICAL SPECIFICATIONS Section – VI-D

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CONTRACT DOCUMENT FOR
JUICE EXTRACTION PLANT
Table of Contents
Table of Contents
0100 CANE WEIGHMENT.................................................................................................3

0101 Electronic weighbridge for truck.............................................................................3
0102 Electronic weighbridges for general purpose.........................................................4
0200 CANE UNLOADING.................................................................................................4
0201 Hilo type unloaders...............................................................................................4
0202 Drag type feed table..............................................................................................4
0202-1 AC-VFD for feed table..................................................................................5
0202-2 Cane kicker for feed table............................................................................6
0202-3 Rotary drum type stone catcher for feed table.............................................7
0202-4 Belt conveyor for rotary drum stone catcher................................................8
0202-5 Auxiliary cane carrier (for feed table)...........................................................9
0202-6 Drive for auxiliary cane carrier (for feed table)...........................................10
0202-7 Cane kicker for auxiliary cane carrier (for feed table).................................12
0203 Truck tipper (Optional).........................................................................................13
0203-1 Auxiliary cane carrier for truck tipper (Optional).........................................13
0203-2 Drive for auxiliary cane carrier (Optional)...................................................14
0203-3 Cane kicker for auxiliary cane carrier (Optional)........................................17
0300 CANE HANDLING & PREPARATION....................................................................17
0301 Feed cane carrier.................................................................................................17
0302 Secondary cane conveyor (Belt type).................................................................21
0303 Cane chopper......................................................................................................24
0303-1 Drive for cane chopper...............................................................................24
0304 Cane leveller........................................................................................................27
0304-1 Drive for cane leveller.................................................................................27
0305 Cane fibrizor.........................................................................................................29
0305-1 Drive for cane fibrizor.................................................................................30
0305-2 Pusher for cane fibrizor..............................................................................32
0306 Cane equalizer.....................................................................................................33
0306-1 Drive for cane equalizer.............................................................................33
0307 Magnetic tramp iron separator.............................................................................33
0308 Automation for cane feeding devices, mills and intercarriers...............................34
0400 JUICE EXTRACTION PLANT.................................................................................35
0401 Donnelly chutes...................................................................................................35
0402 Three roller mill with UFR.....................................................................................35
0402-1 Under feed roller........................................................................................38
0403 AC Variable Speed Drives (AC VFD) for mills......................................................38
0404 Gearing system....................................................................................................39
0404-1 Enclosed gear box.....................................................................................39
0405 Rope coupling for mills........................................................................................40
0406 Rake type intermediate carrier.............................................................................40
0407 Juice gutters........................................................................................................ 41
0408 Imbibition tanks and piping..................................................................................41
0408-1 Juice tank for mill # I & II...........................................................................41
0408-2 Juice tanks for mill # III, IV & V.................................................................41
WSSF-USI TECHNICAL SPECIFICATIONS Section – VI-D

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Table of Contents
0408-3 Imbibition piping.........................................................................................42

0409 Imbibition juice pumps.........................................................................................42
0410 Unscreened juice pumps....................................................................................42
0410-1 Unscreened juice pumps for mill # I..........................................................42
0410-2 Unscreened juice pumps for mill # II.........................................................43
0411 Rotary juice screen..............................................................................................44
0412 Screened juice tank.............................................................................................45
0413 Screened juice pumps.........................................................................................45
0414 Imbibition water tank............................................................................................46
0415 Imbibition water pumps......................................................................................46
0416 Water flow meter..................................................................................................47
0417 Mill house crane...................................................................................................47
0418 Mill roller lathe......................................................................................................48
WSSF-USI TECHNICAL SPECIFICATIONS Section VI – D

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SECTION – VI-D
TECHNICAL SPECIFICATIONS
1st Stream machinery specifications for 6250 TCD Plant.
0100 CANE WEIGHMENT
0101 Electronic weighbridge for truck
Quantity: 1 No.
Weighbridge shall be electronic load cell type with automatic computerized weight
recording with printing facility. The computerized system shall be included with
accounting, up to date crushing status report generation, fast access and analysis,
PC based supervisory station, relevant software for report generation, including
identification of customer/farmer, field, transporters/trailer or tractor No., cane
variety, plant cane/ratoon, etc. shall be tailored to customer requirements.
The detailed specification of weighbridge is as under:
Capacity 40 t
Type of platform Pitless or surface mounted
Type of weidgebridge Electronic load cell type
Platform size 3000 mm x 16000 mm
Load cell details:
Type Compression
Sealing Hermetically Sealed IP 68
Safe Overload 150%
Ultimate overload 400%
Output 2 mV/V  0.1%
Temperature range -40 to 65 ºC
Non-linearity  0.02%
Accuracy 5 kg
Details of Electronics Microprocessor based suitable to hook
(PC based or Microprocessor based or up to DCS system
dedicated system)
Display of weight Digital LED
Spike arrester Provided
UPS with batteries 2 KVA with one hour backup shall be
provided
* Supplier to specify

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0102 Electronic weighbridges for general purpose
Quantity: 1 No.
Capacity 60 t
Type of platform Pitless or surface mounted
Type of weidgebridge Electronic load cell type
Platform size 3000 mm x 16000 mm
Load cell details:
Type Compression
Sealing Hermetically Sealed IP 68
Safe Overload 150%
Ultimate overload 400%
Output 2 mV/V  0.1%
Temperature range -40 to 65 ºC
Non-linearity  0.02%
Accuracy 0.5 kg
Details of Electronics Microprocessor based suitable to hook
(PC based or Microprocessor based or up to DCS system
dedicated system)
Display of weight Digital LED
Spike arrester Provided
UPS with batteries 2 KVA with one hour backup shall be
provided
0200 CANE UNLOADING
0201 Hilo type unloaders
Quantity: 2 Nos.
Hilo type cane unloaders of mobile/stationary type shall be provided. Hilo dumping
crane shall be used to unload the cane from trailers on feed table. Capacity of each
hilo unloader shall be 20 tons and shall be capable of 20 cane unloading cycles per
hour. Vertical travel shall be 12.5 m minimum and lifting speed shall be 25 m/min.
Width of unloader is to suit the feed carrier. The hilo unloader shall be complete with
chain net, operators cabin and hydraulic power pack system.
0202 Drag type feed table
Quantity: 2 Nos.
Feed table shall be of 8 m wide and approx. 21.5 m horizontal length between
sprocket centres and shall be installed at right angle to the feed cane carrier. Feed
tables shall be suitable to handle both whole stick cane as well as chopped cane.
The inclination of feed table shall not be more than 15 0.

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Chain shall be drag type, 12 strands 150 mm pitch having minimum 40,000 kg
breaking strength with stainless steel pin. Sprocket shall be of cast steel with
minimum 12 Nos. of machine cut teeth. Head and tail shaft bearing to be roller type
antifriction bearings. The feed table shall be suitably supported on steel structure
designed to withstand heavy shocks.
Operators cabin with control console at suitable height shall be provided to have a
clear view of the loading of feed table/auxiliary carrier to the feed cane carrier.
Suitable staircase with operating platform shall be provided on both sides.
Feed table shall be provided with rock removal system and belt conveyor as per
requirement.
0202-1 AC-VFD for feed table
Quantity: 2 Nos.
The feed table shall be driven by 45 kW TEFC sq. cage induction motor with
variable frequency controller, directly coupled to planetary gearbox. Feed table
speed range required 1 m/min to 5 m/min. Power rating of spur gear shall conform
to IS 4460-1967 and helical gearbox service factor shall be 1.7 minimum as per
AGMA Standard.
Speed variation shall be through AC-VFD drive with DOL bypass.
Power Output required : 45 kW

Input parameters :
a) Voltage : 400 V  10%, AC 3 Phase.
b) Frequency : 50  5%.
Type of Enclosure : Dust, water and vermin proof, vertical free

standing IP 51 protection. No separate air
conditioning shall be provided. Enclosures
provided with forced ventilation, in order to
achieve specific current ratings, are not
acceptable.
Ambient temperature : 40 ºC
Altitude : 1580 m above MSL.
Application : Speed control in the range of 40-100% of rated

speed of 45 kW squirrel cage induction motor
for Sugar Mill.
Overload current rating : 150 % for 120 seconds.

200 % for 10 seconds.

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Continuous output : 100 % of full load.
Output torque rating : Full load torque between 40 - 100% speed

variation.
Efficiency : Min. 97 %
Control Method : Frequency control (V/F), Vector Control, *
Switching Frequency : *
Rectifier system : 12 pulse, 4 Quandrant Operation.
Harmonic filter : *
Type of control : *
Motor reversal : Reversing facility at lower speed to be provided.
Motor Data : Three Phase sq. cage, TEFC, 400 V, 50 Hz,

1500 rpm.
Protective Functions : Under Voltage, Over Voltage, Earth Fault,

Single Phasing Prevention, Motor Stall
protection.
0202-2 Cane kicker for feed table
Quantity: 2 Nos.
Located on inclined portion of feed table to suit 8000 mm wide feed table. Reversed
rotation to cane flow having approx. 52 fabricated curved arms having 300 mm
pitch secured on hollow pipe having outside diameter 600 mm. Pipe shall be made
of min. 16 mm thick plate conforming to IS: 2062. Diameter over the tip of arm
shall be 1500 mm.
Shaft shall be supported on 160 mm bore, heavy duty cooper roller bearing in cast
steel plummer blocks.
Clearance between the arm tip and top of feed table shall be approx. 750 mm.
Clearance should be adjustable within ± 50 mm. Suitable supporting structure,
attendance platform with hand railing and access staircase shall be provided.
Drive for cane kicker
45 kW/1500 rpm, TEFC foot mounted slip ring induction motor directly coupled to
suitable helical reduction gear box with service factor 2. Kicker speed shall be

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approx. 36 rpm. Suitable strong supporting structure, attendance platform with

hand railing and access stairs are to be provided.
0202-3 Rotary drum type stone catcher for feed table
Quantity: 2 Nos.
The drum shall be located at the front side below the head end of feed table to
collect the sand/stones received from the feed table. The drum shall be fabricated
from 16 mm thick carbon steel plates. The outside drum diameter shall be 1500 mm.
Spikes shall be welded on drums in staggered manner. The pitch of spike shall not
more than 300 mm. The diameter over the tip of arms shall be 2250 mm and drum
length shall be suitable to feed table width of 8000 mm. The drum shall be
supported by 160 mm spherical roller bearing in cast steel plummer block/cooper
roller bearing and shall be supported from feed table structure.
Drive for rotary drum stone catcher
The stone catcher shall be driven by 15 kW / 1500 rpm TEFC squrrel cage induction
motor directly coupled to planetary gearbox, having AGMA service factor 2. The
drum speed range required is 3 to 10 rpm.
Input parameters :
a) Voltage : 400 V  10%, AC 3 Phase
b) Frequency : 50  5%

acceptable.

for Sugar Mill.
Overload current rating : 150 % for 120 seconds.

200 % for 10 seconds.

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Output torque rating : Full load torque between 40 - 100% speed

variation.
Rectifier system : 12 pulse, 4 Quandrant Operation.
Harmonic filter : *
Type of control : *

1500 rpm.

protection.
0202-4 Belt conveyor for rotary drum stone catcher
Quantity: 2 Nos.
The belt conveyor shall be provided below rotary drum stone catcher to collect the
stones, sand, dirt etc., from discharge chute of rotary drum and delivered outside
the feed table. The belt conveyor shall be general duty trough type and 600 mm
wide. The length of belt conveyor shall be 12 m. The belt conveyor shall be provided
with suitable headend, tailend and tension pulleys. The headend and tailend shaft
bearings shall be spherical roller type.
Other details of belt conveyor are:
- Idler spacing maximum 1000 mm on carrying side and 2000 mm on

return side.
- Joining of belt shall be by vulcanising. Provision is to made for tensioning

belt after initial run in period.
- Suitable side skirting shall be provided to avoid spill over the material
received from stone catcher.

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- Belt conveyor shall be provided with suitable supporting structure and

attendance platform at drive end.
Drive for belt conveyor
The belt conveyor shall be driven by 7.5 kW/1500 rpm TEFC squirrel cage induction
motor directly coupled to shaft mounted planetary gearbox having AGMA service
factor 1.7 with anti runback device. The belt speed shall be 40 m/min.
0202-5 Auxiliary cane carrier (for feed table)
Quantity: 1 No.
Apron type, 2300 mm wide. Overall length of the carrier is to suit layout
requirements.The main requirements of layout are as follows:
- Horizontal sprocket center distance will be approx. 40 m.
-
Inclination with horizontal will be 15.
-
Depth of carrier should be suitable for the final factory capacity of 261 tch
plus 10 % based on density of cane 150 kg/m 3
The horizontal cross section of the carrier shall have the inclined sides suitable to
feeder table arrangement.
Carrier chains shall be lubricated roller type, 4 strands, 200 mm pitch and minimum
60,000 kg breaking strength.
Slats are to be 8 mm thick conforming to IS: 8236-1976 and fixed to the chains by
bolts and nyloc nuts.
The carrier structure shall be of steel construction with minimum 8 mm thick side
plates. The side plates shall be adequately stiffened with angle irons.
Support columns are to be rolled steel channels 250 mm x 80 mm size or equivalent

section with base plate and gusset plates. Foundation bolts are to be supplied. The
bearing centres shall not be less than 3500 mm.
Columns at the cane kicker location shall be 250 mm x 80 mm double channels or

equivalent section. All columns shall be adequately braced with angles. Column
spacing is to be not more than 3000 mm. The walkway of 800 mm width shall be
provided along the auxiliary cane carrier from drive end side and suitable platform;
railing and staircase at kicker drive.
Chain runners are to be minimum 150 mm ISMB with 8 mm thick mild steel
renewable wear pads. The runners are to have a downward curve at the entry and
exit points of the chains. 6 mm thick x 75 mm flat iron wear pad is to be tack welded

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on the side plates of the auxiliary cane carrier to protect the side plates from the
carrier slats. The return apron of the carrier is to be supported on the angle
runners, minimum 75 x 75 x 10 mm with 6 mm thick wear pad. Slats are to be
provided with renewable wear pads.
Sprockets are to be of cast steel, with minimum 18 at headend & 12 at tailend

machine cut teeth.
Head shaft is to be of 45C8 forged steel or equivalent quality steel, minimum

diameter 280 mm at centre. Head shaft bearings are to be minimum 220 mm
diameter anti-friction split type roller bearings / cooper roller bearings. The shaft
shall be designed for drive from both ends. Columns under the head shaft and
carrier drive shall be extra heavy section to withstand vibrations.
Tail shaft is to be 45C8 forged steel, 200 mm central diameter running in minimum
140 mm diameter. anti-friction split type roller bearings / cooper roller bearings.
Bearings are to be mounted on slide rails and chain tensioning bolts. Level of tail
shaft should be at 1200 mm above FFL.
0202-6 Drive for auxiliary cane carrier (for feed table)
Helical type gearbox for auxiliary cane carrier (for feed table)
Quantity: 1 No.
The gearbox shall be helical type triple reduction fully enclosed pressure lubricated
and rated for continuous transmission of power as under at 1500 rpm.
Input power - 45 kW (AC-VFD Drive)

Input speed - 1500 rpm
Output speed - 15 rpm
Service factor for strength - 1.7 as per AGMA standard
Service factor for wear - One lakh working hours
Gearbox is to include input and output shaft geared coupling.
Open spur gearing for auxiliary cane carrier (for feed table)
Quantity: 1 set
The details of gearing shall be as under:
Type : Open spur gearing
Pinion teeth : 21
Gear teeth : 96
Module : 18 mm
Face width : 350 mm

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Material hardness
Pinion : 311 BHN
Gear : 248 BHN
Gear speed : 3.3 rpm
The gearing shall be designed for continuous rating at rated speed detailed as
above under shock load conditions and shall conform to IS 4460-1967.
The low speed reduction gearing unit should have pinion of EN 24 machine cut
teeth and gear of CS IS 2644 Gr III, with machine cut teeth by gear generating
process in both cases. The shaft of these gears shall be 45C8 forged steel quality
conforming to IS 1570 or equivalent having minimum tensile strength of 63 kg/cm2
and supported on anti-friction split type roller bearings. The gearing unit shall be
complete in all respects.
Suitable guard of mild steel construction, minimum 3 mm thick with sufficient

stiffeners is to be provided.
AC-VFD for auxiliary cane carrier (for feed table)
Quantity: 1 No.
45 kW TEFC squirrel cage induction motor 1500 rpm, directly coupled to totally
enclosed helical gearbox with anti-runback device and single stage open gear pair.
Carrier speed range required 3.6 m/min to 12 m/min. Power rating of spur gears at
ultimate capacity and shall conform to IS : 4460-1967.
Input parameters :

acceptable.
Altitude : 1580 m from MSL.

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for Sugar Mill.
Overload current rating : 150 % for 120 seconds

200 % for 10 seconds
Output torque rating : Full load torque between 40-100% speed

variation.
Rectifier system : 12 pulse, 4Quandrant Operation
Harmonic filter : *
Type of control : *

1500 rpm.

protection.
0202-7 Cane kicker for auxiliary cane carrier (for feed table)
Quantity: 1 No.
Located on inclined length of carrier to suit 2300 mm wide auxiliary cane carrier.
Reversed rotation to cane flow having approx. 18 fabricated curved arms having
250 mm pitch secured on hollow pipe having outside diameter 600 mm.
Pipe shall be made of min. 16 mm thick plate conforming to IS: 2062. Diameter
over the tip of arm shall be 1500 mm.
Shaft shall be supported on 140 mm bore, heavy duty Cooper roller bearings in cast
steel Plummer blocks.

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Clearance between the arm tip and slat shall be approx. 750 mm. Clearance should
be adjustable within ± 50 mm. Suitable supporting structure shall be provided for
mounting of kicker.
30 kW/1500 rpm, TEFC foot mounted slip ring induction motor directly coupled to
suitable helical reduction/planetary gear box with service factor 2. Kicker speed
shall be approx. 36 rpm. Suitable strong supporting structure, attendance platform
with hand railing and access stairs are to be provided.
0203 Truck tipper (Optional)
Quantity: 1 No.
Optional –To quote seperatly.
The unit shall have lifting capacity 50 t and complete with power pack consisting
hydraulic system including pump, oil tank reservoir and hydraulic cylinder.
Hydraulic truck tipper specification:
Frame size – Top : 3200 x 8400mm

Lifting capacity : 50 t
Maximum lift : 55 deg
Hydraulic system:
Pump capacity : 45 lpm

Tank capacity : 200 liters
Motor : 15 kW
Motor speed : 1450 rpm
Operating pressure : 140 bar
0203-1 Auxiliary cane carrier for truck tipper (Optional)
Quantity: 1 No.
Installed to receive the cane from the truck tippler. Apron type, 4600 mm (approx.)
wide carrier, shall be installed in line with truck tipper and feed cane carrier.
Horizontal sprocket center distance shall be 25 m and inclination of carrier shall not
more than 15º. Level of this loading portion (top of slat) shall be above ground level.
Carrier chains shall be lubricated type, 8 strand, 200 mm pitch, minimum breaking
strength 60,000 kg. Slats are to be 8 mm thick confirming to IS 8236-1976 fixed to
the chains by bolts and nyloc nuts (similer to feed cane carrier).

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The carrier structure shall be of steel construction with 8 mm thick side plates. Side
plate thickness at truck tipper unloading portion shall be minimum 10 mm. The side
plates shall be adequately stiffened with angle irons.channels. height of side plates
above top of slats shall be not less than 2500 mm.
Support columns are to be rolled steel channels minimum 250 mm x 80 mm size

(Box type) or equivalent. Columns at the unloading zone of truck tipper should be
strong enough to withstand impact loading of cane. These columns should be
minimum 250 x 80 mm double channels box section or equivalent.
All columns shall be adequately braced with angles/channels. Column spacing is to

be not more than 3000 mm. The column spacing in the cane unloading zone shall
not more than 1500 mm.
chain runners are to be minimum 200 mm ISMB with 8 mm thick Mild Steel strips
exit points of the chains.
The return apron of carrier is to be supported on suitable runner with 8 mm thick

wear pad.
Slat ends at both sides to be provided with renewable wear pads. Sprockets are to
be cast steel, minimum 18 machine cut teeth, and bores of sprockets should be
suitable for hollow pipe shaft.
Head shaft is to be of hollow pipe fabricated from 16 mm thick plate, confirming to

IS 2062, approx. 600 mm outside diameter. Bearings are to be 260 mm diameter
spherical roller bearings fitted in fabricated/cast steel plummer block.
Columns under the head shaft and carrier drive shall be extra heavy section to
withstand vibrations.
Tail shaft is to be of hollow pipe fabricated from plate, 16 mm thick confirming to IS

2062 outside diameter of pipe approx. 450 mm. Tail shaft bearings are to be 150
mm diameter spherical roller bearings fitted in fabricated/cast steel plummer block.
Bearings are to be mounted on side rails to have tensioning bolts. Inclined end plate
of minmum 10 mm thick shall be provided with 5 mm thick SS lining at carrier end.
The inclined plate shall be provided with angle iron backing from back side.
Suitable platform along the carrier shall be provided. Staircase and platform for feed
table drive and kicker drive shall be provided.
0203-2 Drive for auxiliary cane carrier (Optional)
Helical type gearbox for auxiliary cane carrier

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Quantity: 1 No.
The gearbox shall be helical type, quadruple reduction, fully enclosed, pressure
lubricated and rated for continuous transmission of power as under at 1500 rpm.

Output speed - 7.5 rpm
Open spur gearing for auxiliary cane carrier
Quantity: 1 set

Pinion teeth : 21
Gear teeth : 96
Module : 18 mm
Face width : 350 mm
Material hardness
Pinion : 311 BHN
Gear : 248 BHN

AC-VFD drive for auxiliary cane carrier
Quantity: 1 No.

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enclosed helical gearbox with anti-runback device and single stage open gear pair.
Carrier speed range required 2 m/min to 6 m/min. Power rating of spur gears at
ultimate capacity and shall conform to IS : 4460-1967.
Input parameters :
a) Voltage : 400 V  10%, AC 3 Phase
b) Frequency : 50  5%

acceptable.
Altitude : 1580 m from MSL

for Sugar Mill.

Continuous output : 100 % of full load

variation.
Rectifier system : 12 pulse, 4 Quandrant Operation
Harmonic filter : *
Type of control : *

Page – 17 / 51

1500 rpm.

protection.
0203-3 Cane kicker for auxiliary cane carrier (Optional)
Quantity: 1 No.
Located on inclined length of carrier to suit 4600 mm wide auxiliary cane carrier.
Reversed rotation to cane flow having approx. 30 fabricated curved arms having
300 mm pitch secured on hollow pipe having outside diameter 600 mm.
Pipe shall be made of min. 16 mm thick plate conforming to IS: 2062. Diameter
over the tip of arm shall be 1500 mm.
Shaft shall be supported on 160 mm bore, heavy duty Cooper roller bearings in cast
steel plummer blocks.
Clearance between the arm tip and slat shall be approx. 750 mm. Clearance should
be adjustable within ± 50 mm. Suitable supporting structure shall be provided for
mounting of kicker.
45 kW x 1500 rpm, TEFC foot mounted slip ring induction motor directly coupled to
suitable helical reduction/planetary gear box with service factor 2. Kicker speed
shall be approx. 36 rpm. Suitable strong supporting structure, attendance platform
with hand railing and access stairs are to be provided.
0300 CANE HANDLING & PREPARATION
0301 Feed cane carrier
Quantity: 1 No.
Apron type, 2300 mm wide. Overall length of the carrier is to suit layout
requirements.The main requirements of layout are as follows:
- Horizontal length above ground level will be approx. 40 m.

Page – 18 / 51
-
Inclination of carrier shall not be more than 3.5° as per Drg. No. 4LO –2201
–R1.
- Depth of carrier should be suitable for the final factory capacity of 261 tch
plus 10 % based on density of cane 150 kg/m 3
The horizontal cross section of the carrier shall have the inclined sides suitable to
feeder table arrangement.
Carrier chains shall be lubricated roller type, 4 strands, 200 mm pitch and minimum
60,000 kg breaking strength.
Slats are to be 8 mm thick conforming to IS: 8236-1976 and fixed to the chains by
bolts and nyloc nuts.
The carrier structure shall be of steel construction with minimum 8 mm thick side
plates. Side plate thickness at the chopper/leveller and fibrizor locations is to be
minimum 10 mm for a length of 3500 mm in each case. The side plates shall be
adequately stiffened with angle irons.
Support columns are to be rolled steel channels 250 mm x 80 mm size or equivalent

section with base plate and gusset plates. Foundation bolts are to be supplied. The
bearing centres shall not be less than 3500 mm.
Columns at the cane chopper, leveller and fibrizor location shall be 250 mm x 80
mm double channels or equivalent section. All columns shall be adequately braced
with angles. Column spacing is to be not more than 3000 mm. The walkway of 800
mm width shall be provided along the cane carrier from drive end side and suitable
platform; railing and staircase at chopper, leveller and fibrizor drives.
Chain runners are to be minimum 150 mm ISMB with 8 mm thick mild steel
exit points of the chains. Flat iron wear pad 6 mm thick x 75 mm wide shall be tack
welded on the side plates of the cane carrier to protect the side plates from the cane
carrier slats. The return apron of the carrier is to be supported on the angle
runners, minimum 75 x 75 x 10 mm with 6 mm thick wear pad. Slats are to be
provided with renewable wear pads.
The carrier runner lifting arrangement shall be provided below chopper and leveller
to adjust clearance/setting between top of salt and tip of knives to + 100 mm.
Sprockets are to be of cast steel, with minimum 18 at headend & 12 at tailend
machine cut teeths.
Head shaft is to be of 45C8 forged steel or equivalent quality steel, minimum 280
mm at centre. Head shaft bearings are to be minimum 220 mm diameter anti-
friction split type roller bearings / cooper roller bearings. The shaft shall be
designed for drive from both ends. Columns under the head shaft and carrier drive
shall have extra heavy section to withstand vibrations.

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Tail shaft is to be 45C8 forged steel, 200 mm central diameter running in minimum
140 mm diameter. anti-friction split type roller bearings / cooper roller bearings.
Tensioning arrangement shall be provided at tailshaft. Level of tail shaft should be
at 1200 mm above FFL.

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Helical type gearbox for feed cane carrier
Quantity: 1 No.
The gearbox shall be helical type triple reduction fully enclosed pressure lubricated
and rated for continuous transmission of power as under at 1500 rpm.

Output speed - 15 rpm
Open spur gearing for cane carrier
Quantity: 1 set
Pinion teeth : 21
Gear teeth : 96
Module : 18 mm
Face width : 350 mm
Material hardness
Pinion : 311 BHN
Gear : 248 BHN


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AC-VFD for feed cane carrier
Quantity: 1 No.
enclosed helical gearbox with anti-runback device and single stage open spur gear
pair. Carrier speed range required 3.6 m/min to 12 m/min. Power rating of spur
gears at ultimate capacity and shall conform to IS : 4460-1967.
Input parameters :

acceptable.
Altitude : 1580 m from MSL

for Sugar Mill.


variation.

Page – 22 / 51
Harmonic filter : *
Type of control : *
Motor reversal : Reversing facility at lower speed to be

provided.

1500 rpm.

protection.
0302 Secondary cane conveyor (Belt type)
Quantity: 1 No.
Flat belt conveyor to receive prepared cane from fibrizor and deliver to feeding to 1 st
mill Donnelly chute, as per the following requirements :
Design capacity - 261 tch
Bulk density (Prepared cane) - 350 - 400 kg/m3
Total width of belt conveyor - 2100 mm
Horizontal C. D. - * To suit layout.
Belt speed (variable) - 8 m/min to 80 m./min
Belt material - Synthetic rubber (nylon plies) General Duty

belt, M24 grade confirming to IS 1981 with
top cover 5 mm and bottom cover 2 mm
thickness.
No. of plies - 4 (min)
Suitable head end, tail end, snub and tension pulleys shall be provided. Head and
tail end shaft bearings shall be spherical roller type. The head shaft shall be
designed for drive from both ends.
Side plates should be 450 mm height and should have rubber skirts. 8 m long
portion below fibrizor from tail pulley should be completely closed up to 2 m height
above top belt to damp windage created by fibrizor.
Guide rollers are to be provided to prevent belt drift.

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A rotating cleaning brush is to be provided on return side of belt for belt cleaning.
The brush is to be driven from the head shaft.
Idler spacing, maximum 1000 mm-on carrying side and 2000 mm on return side.
Idler within the fields of tramp iron separator are to be anti- magnetic type. Impact
idler for 4 m length under the fibrizor at 500 mm pitch shall be provided.
Joining of the belt shall be by vulcanizing. Provision is to be made for tensioning belt
after initial run-in period.
Following units shall be mounted on the belt conveyor :
- Cane equalizer.
- Tramp iron separator.

-
Gravity takes up arrangement for belt tension.
- Head pulley shall be rubber lined, crowned and will have herring bone ribs.
- Walkway on both sides along the length of this belt conveyor.
- Pull chord switch along the full length on the conveyor for emergency stop
of conveyor.
- Deck plate at the feeding point.
- Rubberized impact idlers, at 500 mm pitch at the feeding point.
- Zero speed switch, proximity type.

-
Conveyor should start on loaded condition after any stoppages.
- The conveyor shall be provided with load cell type electronic continuous
online weighing arrangement of prepared cane.
- Attendance platform with hand railing and access staircase along the
conveyor from both side shall be provided.
AC-VFD for secondary belt conveyor
Quantity: 1 No.
The belt conveyor shall be driven by 30 kW TEFC squirrel cage induction motor
1500 rpm, directly coupled to shaft mounted planetory gearbox having AGMA
service factor for gearbox 1.7 with antirunback device.

Page – 24 / 51
Input parameters :
a) Voltage : 400 V  10 %, AC 3 Phase

b) Frequency : 50  5 %

acceptable.
Ambient temperature : 40 0C

for Sugar Mill.

Continuous output : 100 % of full load

variation.
Harmonic filter : *
Type of control : *
Motor reversal : Reversing facility at lower speed to be provided

1500 rpm

protection.

Page – 25 / 51
Supporting structure, attendance platform with hand railing and access staircase is
to be provided.
0303 Cane chopper
Quantity: 1 No.
Located on horizontal length of carrier to suit 2300 mm wide primary carrier and with
reversed rotation to cane flow having 44 knives secured to cast steel hubs of IS
1030 Gr. 280/520 W mounted on a shaft of 260 mm diameter of 45C8 forged steel
quality. The diameter over tip of knives shall be 2000 mm. The journal centres shall
not be less than 3500 mm.
Shaft shall be supported on 220 mm diameter heavy duty split roller bearings
Cooper make in cast steel plummer blocks. The knives shall be of special shock
resisting steel having stellited / carbide self sharpening type, hardness 45 to 48
HRC and of bolt less design.
The shaft should be designed for drive from both ends, so that a second drive may
be coupled in future.
Clearance between the knives tips and primary carrier is to be about 1000 mm
adjustable. The knives shall have a reinforced hood of 12 mm thick mild steel plate
braced and attached to the cane carrier. The hood shall be provided with suitable
swing flaps and bolted doors at side plates of the hood. Design is to suit operation
of the chopper in reverse direction and shall be provided with flywheel of 900 mm
diameter x 200 mm face width.
For maintenance purpose 7.5 tons SWL capacity monorail with suitable structure
and protective shed shall be provided.
0303-1 Drive for cane chopper
Quantity: 1 No.
The chopper shall be driven by 300 kW / 600 rpm slip ring motor through enclosed
gearbox. Final speed of chopper shall be 300 rpm.
I) Design condition :
Installation : outdoor
Ambient temp. : 40 C
Altitude : 1580 m above MSL
II) Power supply:

Page – 26 / 51
a) Voltage : 400 V  10%

b) Frequency : 50 Hz  5%
c) Combined voltage :  10% & frequency
III) Electrical data:
a) Motor : Slip ring induction Type

b) Rating : 300 kW
c) Synchronous speed : 600 rpm
d) Speed variation : Constant speed
e) Direction of rotation : Unidirectional
f) Enclosure : Suitable to outdoor duty
g) Degree of protection : IP 54
h) Mounting : Horizontal Foot mounted
i) Insulation : Class ‘F’
j) Temperature rise : Limited to class B
k) Rated Amp. : *
l) Pullout torque : 2.25 x full load torque
m) Rotor volt : *
n) Rotor Amp : *
o) Efficiency at full load : 93% (Preferred minimum)
p) Power factor at : 0.85 full load (Preferred minimum)
q) Terminal box : 1. Suitable for 50* kA fault level at 400V
2. Segregation for winding and bearing
temp. detectors to be provided.
3. Enclosure IP-55.
4. Phase segregated.
r) Cable size : *
s) Earthing : 2 Earth studs to be provided
t) Slip : 15%
u) Method of cooling : CACA
v) Energy meter : Shall be provided for individual drive
IV) Duty conditions:
a) Method of starting : By Auto slip regulator and running.

b) Starting time : Should be less than thermal withstand
time.
c) No. of starts : - 2 consecutive cold starts & 1 hot restart
- 2 hot starts equally spread/hour
- 2 Additional hot starts/hour during
commissioning.
d) Load condition : 100% continuous;
200% for 10 seconds.
V) Other details

Page – 27 / 51
a) Tachogenerator : Not Applicable

b) Winding temperature detector : 6 nos.
c) Bearing temperature detector : 2 nos.
e) Space heater : To be provided
f) Speed variation range : Constant speed
g) Type of coupling : Direct through flexible / geared coupling
VI) Auto slip regulator
a) Application : To start 1 No. 300 kW, 600 rpm, 400 V,

slip ring induction motor for chopper in
sugar plant.
b) Quantity : 1 No.
c) Design condition:
Ambient temp. : 40C
d) Altitude : 1580 m above MSL
e) Nature of load : 1) High starting torque up to 1.5 x full load
torque
2) Occasional kick loads (up to 120%)
during running
3) Idle running for some time
4) Chopper has a large rotating mass with
flywheel action
f) Pulley : Not used. Rotor shaft is connected to
motor by flexible/geared coupling.
Torsional vibrations are not transmitted to
the motor
g) Time required to reach full speed: 30 sec
h) Duration of each peak load : 20 - 30 sec
i) Features required : 1) High starting torque
2) Starting current to be restricted to 3-
time full load current
3) Suitable for starting and running
j) Mounting : Free floor standing
k) Degree of protection : IP54
l) Rotor volt : *
m) Rotor Amp : *
n) Earthing : 2 earth studs
o) Slip : 15% (min)
VIII) Enclosed gear box
a) Input power : 300 kW

b) Type : Helical
c) Input speed : 600 rpm
d) Output speed : 300 rpm
e) Service factor on strength : 2 as per AGMA standard
f) Service life for wear rating : 1 lac working hours

Page – 28 / 51
g) Input / output coupling : Gear type
The drive shall be provided with rain protected shed.

Page – 29 / 51
0304 Cane leveller
Quantity: 1 No.
Leveller shall be mounted on inclined portion of feed cane carrier. Knives tip
diameter shall be 2000 mm and width suitable to 2300 mm wide feed cane carrier.
Leveller shall be having 60 knives secured to cast steel hubs of IS 1030 Gr.
280/520 W mounted on a 45C8 forged steel shaft of 260 mm diameter. The journal
centers shall not be less than 3500 mm. Leveller shall be rotate in forward direction
of cane flow.
The knife shaft shall be supported on 220 mm bore, heavy duty split type roller
bearings of Cooper make in cast steel plummer blocks.
The knives shall be of special wear resisting (Tiscral) having stellited/carbide self
sharpening type, hardness 45 to 48 HRC and tenoned into the hubs eliminating
shear on the bolts which shall be of EN-8 steel or equivalent with nyloc nuts. Knives
shall conform to IS:8461-1977.
Flywheel of 900 mm diameter, and of CI grade 20 duly machined and balanced

shall be provided at non drive end of the shaft. The non-drive end of shaft shall be
provided with extension to enable an additional drive to be coupled in future.
Knives set shall be totally enclosed by suitably reinforced hood of 12 mm thick mild
steel plate attached to the cane carrier framework and provided with suitable swing
flaps and bolted doors at side plates.
For maintainance purpose 7.5 tons SWL capacity monorail with suitable structure
and protective shed shall be provided. Suitable interconnecting platforms, railings,
staircases shall be provided for chopper, leveller and fibrizor upto 1 st mill for easy
operation and maintainance.
0304-1 Drive for cane leveller
Quantity: 1 No.
Installation : Outdoor
II) Power supply:
a) Voltage : 400 V  10%


Page – 30 / 51

b) Rating : 500 kW
f) Enclosure : TEFC
k) Rated Amp. : *
m) Rotor volt : *
n) Rotor Amp : *
q) Terminal box : 1. Suitable for 50* kA fault level at 400V
3. Enclosure IP-55.
r) Cable size : *
t) Slip : 15%
v) Energy meter : Shall be provided for individual drives.
IV) Duty conditions:
a) Method of starting : By manual external slip regulator and

running
time.
commissioning.
150% for 120 seconds;
V) Other details


Page – 31 / 51

a) Application : To start 1 No. 500 kW, 600 rpm, 400 V,

slip ring induction motor for Leveller in
sugar plant.
b) Quantity : 1 No.
d) Nature of load : 1) High starting torque up to 1.5 x full load
torque
during running
4) Leveller has a large rotating mass with
flywheel action
e) Pulley : Not used. Rotor shaft is connected to
the motor.
f) Time required to reach full speed: 30 sec
g) Duration of each peak load : 20 - 30 sec
h) Features required : 1) High starting torque
i) Mounting : Free floor standing
j) Degree of protection : IP54
k) Rotor volt : *
l) Rotor Amp : *
m) Earthing : 2 earth studs
n) Slip : 15% min.
The drive shall be provided with rain shed.

0305 Cane fibrizor
Quantity: 1 No.
Swing hammer type - Located at the head end of carrier to suit 2300 mm wide feed
cane carrier having 172 swing type hammers. Weight of each hammer shall not be
more than 18 kg. The hammer shank shall be minimum 50 mm thick, minimum
hardness 600 BHN at tip made by welding. Detachable tip will be acceptable for
hammers in case design is strong enough to work without damage when tramp iron
is passing through. The hammers shall be fitted with S.S. bush at pin portion and
pin shall be SS material having diameter 70 mm.

Page – 32 / 51
The rotor shaft shall be heavy-duty, minimum 400 mm diameter at the hubs and
260 mm diameter at the bearing journals and shall be of 45C8 forged steel. Shaft
shall have provision for both end drive in future. The shaft shall be ultrasonically
tested after proof machining. The hubs shall be minimum 50 mm thick cast
steel/shock resisting steel plate construction and hard faced to 300 BHN where
hammer strikes during start and stop. The pin holes of the hubs are provided with
GM bushes. Rear chute plate shall be of MS minimum 10 mm thick. Deflection plate
of 16 mm thick with 2 mm S.S. lining shall be provided.
Anvil plate to be pocketed design, having wrap angle of about 160 deg. The base
plate thickness of the anvil shall be minimum 32 mm. Hard facing on the anvil
working surface is to be provided having minimum hardness 500 BHN. Anvil plate
shall be in two pieces and provision shall be made for adjusting the anvil
clearances. Side plates of 12 mm thick with proper stiffening arrangement shall be
provided.
Rotor shall be supported on two heavy duty self aligning double row spherical roller
bearings with adapter sleeve ( One side heavy duty double row spherical roller
bearing and other side heavy duty carb bearing) . Tip diameter of hammers shall
be minimum 2200 mm designed for running at maximum speed of 750 rpm.
Rotor shaft shall have extension on non-drive end for coupling at a future date, a
second drive being provided.
Rotor bearing plummer blocks shall be cast steel and shall be provided with water
cooling arrangement. Closed circuit forced lubricating system for bearings shall be
provided. The lubrication system shall be complete with motor, pump, reservoir,
cooler, valves, flow indicators, pressure drop alarm, oil strainer, etc.
0305-1 Drive for cane fibrizor
Quantity : 1 No.
Installation : Outdoor
II) Power supply:
a) Voltage : 11 kV  10%

Page – 33 / 51

b) Rating : 2000 kW
f) Enclosure : TEFC
k) Rated Amp. : *
m) Rotor volt : *
n) Rotor Amp : *
q) Terminal box : 1. Suitable for 500 MVA fault level at 11
kV
3. Enclosure IP-55.
r) Cable size : *
t) Slip : 15%
v) Energy meter : Shall be provided for individual drive.
IV) Duty conditions
a) Method of starting : By Auto slip regulator

time.
commissioning.
V) Other details


Page – 34 / 51
a) Application : To start 1 No. 2000 kW, 750 rpm, 11 kV,

slip ring induction motor for Fibrizor in
sugar plant
b) Quantity : 1 No.
d) Nature of load : 1) High starting torque up to 1.5 x full load
torque
during running
4) Fibrizor has a large rotating mass with
flywheel action
e) Pulley : Not used. Rotor shaft is connected to
the motor
f) Time required to reach full speed: 60 sec
g) Duration of each peak load : 20 - 30 sec
h) Features required : 1) High starting torque
i) Mounting : Free floor standing
j) Degree of protection : IP54
k) Rotor volt : *
l) Rotor Amp : *
m) Earthing : 2 earth studs
n) Slip : 15% min.
0305-2 Pusher for cane fibrizor
Quantity: 1 No.
Pusher shall be installed to act as a pressure feeding device to fibrizor.
The pusher shall be drum type, having 1800 mm diameter on tips. Drum shall be
fabricated from 20 mm thick welded pipe with 65 x 65 x 12 mm thick fins welded to
the drum in chevron configuration.
Setting of pusher shall be adjustable according to crush rate and power

consumption.

Page – 35 / 51
Drive for pusher
Quantity: 1 No.
40 kW TEFC flange mounted squirrel cage induction motor 1500 rpm directly
coupled to planetary gearbox having AGMA service factor 1.7 to furnish final speed
of 5.5 rpm maximum. Gear box shall be in-line, planetory/helical type multi-
reduction fully enclosed, hollow shaft for direct shaft mounting with keyed
arrangement, oil lubricated and rated for continuous transmission of power.
0306 Cane equalizer
Quantity: 1 No.
Located on belt conveyor before tramp iron separator. The equalizer is to be drum
type with minimum 800 mm diameter on tips. Drum is to be fabricated from 650 mm
diameter x min 12 mm thick welded pipe with 75 mm x 10 mm flats welded to the
drum in chevron configuration. Cane equalizer rotates reverse to cane flow. The
equalizer is to be supported in sperical roller bearings mounted on structure of the
secondary cane carrier.
Duty requirements are as follows :
Width of drum - 2050 mm (Suitable to secondary carrier width)

Speed - 50 rpm
Clearance above belt - 60 to 200 mm (adjustable)
0306-1 Drive for cane equalizer
Quantity: 1 No.
10 kW TEFC foot mounted squirrel cage induction motor 1500 rpm directly coupled
to helical gearbox having AGMA service factor 1.7 to get final speed of 50 rpm
maximum.
Drive unit is to have independent support and should have attendance platform with
access from secondary carrier walkway.
0307 Magnetic tramp iron separator
Quantity: 1 No.
Continuous duty air cooled type, suspended self cleaning Electro-magnet capable
of separating iron pieces up to 30 kg from the prepared cane mat of 250 mm height.
The width of the magnet shall not be less than the full width of secondary carrier
(2100 mm), and approx. 1 m. in length. The magnet shall be positioned directly
above conveyor at a height of 300 mm above the secondary carrier to prevent any
tramp iron from passing the magnet.

Page – 36 / 51
Independent supporting structure shall be provided. Chute to discharge tramp iron

lifted from the conveyor on to the ground is to be provided.
The magnet shall be fabricated from high permeability mild steel and shall be totally
enclosed, dust proof, welded construction. The magnet shall be mounted on robust
construction frame work, which will accommodate drive and idler pulleys over which
a rubber cross belt with clits will be provided for discharge of collected tramp iron
pieces.
The cross belt shall be driven by a motor and a reduction gearbox. Clearance
between magnet and belt shall be 250 mm and the belt speed at 2 m/sec.
Drive for tramp iron separator belt conveyor
Quantity: 1 No.
5.6 kW TEFC foot mounted squirrel cage induction motor 1500 rpm directly coupled
to planetary gearbox having AGMA service factor 1.7 to get final speed of belt shall
be 2 m/sec maximum.
Drive unit is to have independent support and should have attendance platform with
access from secondary carrier walkway.
0308 Automation for cane feeding devices, mills and intercarriers
Quantity: 1 Set
System suitable for sensing, controlling and indicating functions of cane feeding
devices, mills and intercarriers shall be provided. System shall be suitable to hook
up to DCS control system which shall be supplied and installed in control room in
mill house. PC supervisory station with printer for report generation shall be
provided. UPS system with hot standby should be provided.
System involves following areas/equipments:
1) Drag type conveyor, auxiliary carrier Feed carriers, belt conveyor : cane blanket
height variation, load and speed variations.
2) Loads and speed of preparatory devices.
3) Donnelly chute levels.
4) Mill drive motor load and speed variations.
5) Intercarrier tripping and sequencing with load and speed variations.
6) Bearing temperature indicator with audio visual signals for motors.
7) Imbibition water control by mill roller lift/ 4th mill motor load/ last mill juice brix.
8) Mill roller temperature indicator.
9) The auto control system shall be provided nearby mill drive control room, etc.

Page – 37 / 51
0400 JUICE EXTRACTION PLANT
0401 Donnelly chutes
Quantity: 5 Nos.
Design parameters for the Donnelly chute are as follows :
Crushing rate - maximum - 261 tch

Fibre % cane - average - 16.5 %
- maximum - 18.0 %
Back plate height from under feed

roller to rake carrier discharge - 3 m approx.
Back plate angle with horizontal - 85 to 90
Working width - 2140 mm
Chute is to be fabricated from minimum 6 mm thick Mild Steel plates. Inside of the
chutes is to be perfectly smooth and lined with 3 mm thick stainless steel AISI 304
plates. Front and back plates are to be adjustable design. Bypass chute shall be
provided.
0402 Three roller mill with UFR
Quantity: 5 Nos.
Each mill roller shall have maximum outside diameter 1140 mm x 2134 mm length
with journals of minimum 540 mm diameter x 700 mm length. Rollers shall be
coarse grain cast iron having hardness 180 to 210 BHN.
The chemical composition of the shell material shall conform to IS: 11201 - 1985
and shall be -
Total carbon - 3.20 to 3.6 %

Manganese - 2.2 to 3.2 %
Silicon - 1.2 to 2.2 %
Phosphorus - 0.5 % max.
Sulphur - 0.15 % max.
Shell shall be hot shrunk on forged steel shaft of 45C8 steel conforming to IS: 1570
- 1979 or equivalent having a minimum tensile strength of 58 kg /sq. mm. All shafts
shall be interchangeable. Except last mill all top rollers shall be of lotus type. After
proof machining, all shaft shall be ultrasonically tested.

Page – 38 / 51
Bottom rollers shall be provided with juice rings and removable guards to prevent
entry of juice in the bearings. Stationary flange to be provided for top roller. Proper
sealing to avoid entry of juice into mill roller bearings to be provided.
Hydraulic system should be so designed to take maximum hydraulic load of 700

tons, on top roller. Hydraulic ram diameter shall be minimum 425 mm of forged EN 9
material.
Headstock shall be designed to facilitate installation of fourth roller of 17 % higher

than mill roller nominal diameter. Head stock shall be of cast steel as per IS: 1030 -
1974 Gr. 280/520 W. Head stock castings shall be rough machined and then
normalized by heat treatment before finish machining.
These will be king bolt less type, removable G.M. wearing plates to be provided on
top jaw on both feed and discharge sides with lubricating arrangement between top
roller bearing housing and wearing plates. The top & side caps shall be of cast steel
as per IS 1030-1974 Gr. 280/520 W. and shall be securely locked in position for
quick assembly. Eccentricity between top roller bearing centre and hydraulic cap
centre shall be minimum 40 mm towards feed side of the head stock.
The head stock and crown pinion shall be designed to accommodate roller of
outside diameter varying from 1060 to 1190 mm.
The centre distance between mill roller journals should be about 3200 mm.
All roller shells shall be arced with Azucar-80 surface roughening electrode
material. Arcing should be 1/3 rd depth from tip of 'V' -groove on feed and discharge
rollers and 1/2 depth from tip of 'V' - groove on top and discharge roller. Roller
grooving pitch shall be 50 mm for 1 st and 2nd mill and 35 mm for 3 rd , 4th and 5th
mills.
For first two mills, scrapers and trash plate groove angles should be 6º less than
that of roller shells and for remaining mills, it should be 8º less than that respective
mill roller shell to avoid interference with Azucar-80 weld deposits on roller teeth.
Cheveron grooves should be provided on all feed rollers and on top rollers of first
four mills. The grooving shall be differencial type.
Bearings shall be cast steel housing with phosphor bronze lined with water cooling
arrangement. All the top roller bearings shall be cast phosphor bronze and inter
changeable. Similarly all feed and discharge roller bearings shall be inter
changeable. The height of bearing shall not be less than 600 mm. The mills to be
provided with cast steel trash beam as per IS: 1030 Gr. 280/520 W., supported on
heavy steel brackets with pivoted journals fitted in the headstock and adjustable by
means of lever and tie rods.
Trash plates are to be of cast steel IS: 1030 Gr. 280/520 W. and fitted to the trash
beam by high tensile through bolts. Working surface of the trash plate shall be fully
welded with Azucar-100 or equivalent electrodes to 3 mm thickness. Top roller

Page – 39 / 51
scrapers shall be of floating type. Scrapers for top and discharge rollers shall have
renewable cast iron as per IS:210 Gr. 20.
Messchaert groove scrapers for feed roller shall be of spring steel secured on
square shaft and supported on cast steel / fabricated steel blocks and provided with
adjusting arrangement.
Crown pinions are to be of cast steel IS: 2708 - Gr. 3, B, BHN 210 - 250 machined
teeth of 16 numbers and shall be of minimum face width 650 mm. Mild steel guards
and troughs shall be provided.
All mechanical parts of mills shall be designed for an ultimate capacity of 285 tch at
16.5 % average fibre. At this capacity rate, all the mills will be installed with heavy
duty fourth roller.
Automatic oil pump of 300 C/min capacity shall be provided for each mill. Each
lubricator shall be provided with 24 points for mill and UFR bearing lubrication.
Stand by arrangement with automatic oil pump shall be provided.
Supply includes scraper plates, water piping for mill roller bearings, bagasse chute,
and special spanners, all foundation bolts, etc.
Mill shall be high set so that no part of the juice tank and pumps are situated below
floor level. Foundation level below mill headstock should not be less than + 2500
mm from FFL.
Hydraulic system for mill
Each mill shall be provided with hydraulic loading system. Eleven hydro pneumatic
accumulators to be provided in the system, one accumulator for each top roller
bearing. The capacity of accumulator shall be 45 litres.
Accessories such as pressure pump, tank, gauges, remote control panel, electronic
roller lift indicator, piping, pipe fitting, connections, etc., to be provided. Roller lift
indicator shall be mechanical/electronic type reliable and sturdy.
The piping / pipe connections, total hydraulic system shall be suitable for oil
pressure of 340 kg/cm2(g). The hydraulic ram for top cap shall be minimum 425 mm
diameter., the oil sealing system in top cap shall be suitable to withstand oil
pressure up to 285 kg/cm²(g). while top roller is floating during working. One spare
accumulator shall be provided with the hydraulic system.
All accumulators with gauge panel shall be centralized system and pressure gauges
shall not be less than 150 mm dial. All piping from hydraulic top cap to centralized
system shall be provided.
Mill platform

Page – 40 / 51
Mills shall have common gangway on both side having width not less than 1200 mm
with chequered plates, and minimum three access staircases - one from last mill
side, and another from mill drive platform. Third is from carrier side. Cross gangways
between each mill are to be provided. Access from mill platform to rake elevator
drive platform shall be provided.
Drive platforms of intermediate rake carrier shall be interconnected and will have
chequered plate floor. Centre distance between mills shall be 14 meters.
Steel foundation bolts with washer anchor plates and nuts shall be provided.
Each mill shall be painted with one coat of red oxide zinc chromate primer and two
coat of enamel.
0402-1 Under feed roller
Quantity: 5 Nos.
Grooved cast iron shell shall be hot shrunk on shaft shall have the same material as
the mill roller shell. Pitch circle diameter 1250 mm and 2134 mm length. Shaft shall
be 40 C8 forge quality conforming to IS:1570 of 320 mm central diameter supported
on phosphor bronze bush split bearing of minimum 260 mm bore x 310 mm length.
Under feed roller to be driven from top roller through long teeth gears to give
surface speed 105 % of the mill roller surface speed. It shall have arrangement to
adjust the setting in axial direction by  50 mm (axis joining cetre line of under
feeder and top roller). The crown pinion width shall be minimum 200 mm.
The grooving should be suitable to get roller packed by bagasse during working.
Grooving angle : 35°

Pitch : 35 mm pitch
0403 AC Variable Speed Drives (AC VFD) for mills
Quantity: 5 Nos.
All the mills shall be driven by 650 kW, 1000 rpm, TEFC foot mounted squirrel cage
induction motor. Drive motor shall be provided with external motor cooling
arrangement, to operate the motor at 40 % of rated speed.
The speed control to be provided by variable frequency controller as specified

below.
Input Parameters:
a) Voltage : 11kV, 3 phase, AC

b) Voltage tolerance :  10 %

Page – 41 / 51
c) Frequency : 50 Hz
d) Frequency tolerance : 5%
Application : Speed control of 650 kW squirrel cage
induction motor 11 kV, 3 phase, 50 Hz, 1000
rpm
Over load capacity : As per Class V
Continuous output : 100 % of rated output
Efficiency : 97 % (Preferred minimum)
Output voltage : 3 phase, AC, 0 – 11000 V
Output frequency : 0 - 100 Hz with voltage/frequency constant

up to 200 Hz, field weakening range,
constant voltage.
Type of control : AC – PWM
Construction : Dust, water and vermin proof, vertical free

standing, IP44 protection with forced
ventilation.
Energy meter : Shall be provided for individual drives.
0404 Gearing system
0404-1 Enclosed gear box
Quantity: 5 Nos.
Input shaft shall be coupled to output shaft of AC motor through gear coupling.
Output shaft shall be provide with square end having 450 x 450 mm size. The
square end shaft supporting bearing of planetary gearbox shall be heavy duty to
accept the heavy thrust load from the top roller during workimg of mill.
The gear box shall be planetary type multi reduction fully enclosed pressure
lubricated and rated for continuous transmission of power as under at 1000 rpm.
Service factor 2 minimum on strength rating and working life should be 1.0 lac
hours.
Rating : 650 kW
Input speed : 1000 rpm

Page – 42 / 51
Output speed : 4.5 rpm
Each gear box is to include input and output shaft geared coupling. The input shaft
shall be provided with extension to other side for mill reversing arrangement.
In the planetary gear box first stage helical gears shall be replaceable to increase
the mill speed in future.
0405 Rope coupling for mills
Quantity: 5 Nos.
The mill top roller shall be connected to transmission shaft by means of square
coupling and tail bar/ rope coupling.
Square size - 450 mm
Length of tailbar - 2500 mm
Material - Cast steel/ Fabricated
Rope coupling torgue rating - 1600 kN-m ( provided tailbar
coupling)
0406 Rake type intermediate carrier
Quantity: 4 Nos.
Mill centres shall be 14 meters. Width of the carrier trough shall be suitable to
accommodate 2134 mm rake width and its cross section suitable for handling
crushing rate of 261 tch with 16.5 % fiber in cane. Trough depth should be suitable
to handle prepared cane when mill # 1 is by passed.
Chain runners shall be channels with 6 mm thick wear plate. Bottom trough plate
shall be 8 mm thick and 3 mm SS Plate with stiffeners and supported on steel
channel column provided with rigid base plate. The columns shall be adequately
braced.
The rake carrier chain shall be 229 mm pitch block type forgedd, having breaking
strength of minimum 60,000 kgs, driven over two cast steel sprockets having at
least 14 machine cut teeth mounted on 220 mm central diameter head shaft of
45C8 forged steel quality conforming to IS : 1570 or equivalent and running in 180
mm size sperical roller bearing in cast steel / fabricated plummer blocks. The shaft
shall be designed for drive from both ends.
Tail shaft of 180 mm central diameter and of 45C8 quality or equivalent shall have
two cast steel sprockets having 20 machine cut teeth and shall run in 150 mm size
spherical bearing with mild steel fabricated plummer blocks. Bearings shall be
outside the elevator trough. Tightening arrangement shall be provided with the tail
shaft bearings separately by idler sprockets. The rake carrier shall be suitable to
discharge bagasse, at head end to Donnelly type chutes.

Page – 43 / 51
The rake pipe shall be 125 NB and 40 schedule seamless pipe. The end rollers
shall be of Teflon construction.
Drive for rake carrier
Drive shall consist of the TEFC sq. cage induction motor of 30 kW, 1000 rpm
directaly coupled to shaft mounted type planetory gearbox of ratio 110:1. * AGMA
service factor for gearbox should be minimum *2.0.Final speed of rake carrier shall
be 25 m/min.
0407 Juice gutters
Quantity: 5 Nos.
Juice gutter under each mill shall be made of 5 mm thick stainless steel AISI 304
grade plate. Proper inclination of the gutter side plates is to be provided so that
bagasse will not remain stagnant on plates.
The gutter is to be bolted to the headstocks with stainless steel bolts and copper
washers. The joints shall be suitably sealed to prevent any juice leakage.
0408 Imbibition tanks and piping
0408-1 Juice tank for mill # I & II
Quantity: 2 Nos.
Juice whirling tank, with conical bottom, shall be provided for mill # I & II
Diameter - 1500 mm
Height - 1500 mm
Thickness of cylinder - 5 mm
Material - SS 304
The juice from mill # I & II shall be collected from mill juice trough through stainless
steel gutter and connected tangentially to whirler tank. Height of this tank shall be
adjusted such that juice gutter under mill should not over flow.
All whirler tanks shall be interconnected tangentially with gutters. Gutter should
have continuos slope from last mill towards 1st mill and flap at suitable level.
0408-2 Juice tanks for mill # III, IV & V
Quantity: 3 Nos.
Juice whirling tank, with conical bottom, shall be provided for mill # III, IV & V
Diameter - 1300 mm
Height - 1500 mm

Page – 44 / 51
Thickness of cylinder - 5 mm
Material - SS 304
The tank shall be connected to mill juice trough through 3 mm thick stainless steel
AISI-304 sheet gutter.
0408-3 Imbibition piping
Quantity: 1 LOT
All juice piping of S.S. quality with fittings and supports to be provided to suit 261
tch crushing rate. Imbibition juice distribution troughs of stainless steel AISI 304
and suitable surplus juice feed back device of mild steel to be provided. The
unstrained juice piping bends must be long to avoid choking.
0409 Imbibition juice pumps
Quantity: 3 Nos.
To pump juice individually from respective whirler tanks of mill III,IV and V.
Type : Chokeless
Capacity : 140 m3/h
Head : 12 m
Speed : 960 rpm
Juice to be pumped:
Specific gravity : 1.06
Temperature : 30 – 45 ºC
pH : 5.5 - 6.5
Viscosity : 5 cP
Solids : 50 % (minimum)
Material of construction
Casing : Stainless steel
Impeller : Stainless steel
Shaft : Stainless steel
Seal : Gland packing
Drive:
Type : TEFC, squirrel cage induction motor
Rating : 18.5 kW
Speed : 960 rpm
The pump shall be provided with coupling, motor, common base frame, guard and
foundation bolts.
0410 Unscreened juice pumps

Page – 45 / 51
0410-1 Unscreened juice pumps for mill # I
Quantity: 2 Nos. (1 working and 1 standby)
To pump juice from the whirler tank of mill I to rotary screen.
Type : Chokeless
Capacity : 180 m³/h
Head : 12 m
Speed : 960 rpm
Juice to be pumped:
Temperature : 30 - 45 ºC
PH : 5.5 - 6.5
Viscosity : 5 cP
Material of construction:
Drive:
Rating : 22 kW
Speed : 960 rpm
foundation bolts.
0410-2 Unscreened juice pumps for mill # II
Quantity: 2 Nos. (1 working and 1 standby)
To pump juice from the whirler tank of mill # II to rotary screen.
Type : Chokeless
Capacity : 180 m3/h
Head : 12 m
Speed : 960 rpm
Juice to be pumped:
pH : 5.5 - 6.5
Viscosity : 5 cP

Page – 46 / 51
Drive :
Rating : 22 kW
Speed : 960 rpm
foundation bolts.
0411 Rotary juice screen
Quantity: 1 No.
Wedge bar type rotary screen for sceering unstrained juice containing 50 %
suspended solid/fine cush cush particles. Rotary drum juice collection trough and
other parts in contact with juice shall be SS 304. Rotary screen shall have auto
cleaning system with water and steam periodically.
Technical data:
Capacity : 300 m3/h
Drum/screen diameter : 1800 mm
Screen length : 4500 mm
Wedge bar opening : 0.45 mm
Screening area : Suitable to handle above capacity.
Construction
A cylindrical rotary drum of adequate diameter and length to give sufficient

screening area, fabricated out of stainless steel material of AISI 304 grade and fitted
with rim fabricated in mild steel located on either ends for mounting the entire drum
on trunnions.
The screening area comprises of cylindrical shape welded wedge bar screen in
pieces by bolting arrangement to form a rigid cylindrical shape rotary screen. The
drive arrangement is to be provided with suitable cover to prevent the ingress of
splashing juice.

Page – 47 / 51
High pressure washing pump for wash water application with automatic timer
controlled output relay is to be provided to automatically start the wash water pump
periodically. The cycle of sprays can be adjustable to the requirement.
Drive for juice screen
Drive : Geared motor
Motor
- type : AC-VFD
- rating : 7.5 kW
- speed : 1440 rpm
Power transmission : Through chain/sprocket.
Drum speed : 2 -10 rpm
0412 Screened juice tank
Quantity: 1 No.
Cylindrical tank with flat bottom.
Capacity - 20 m³
Diameter - 2700 mm
Height - 3500 mm
Material - AISI, 5 mm thick
0413 Screened juice pumps
Quantity: 2 Nos. (1 working and 1 stand by)
To pump screened juice to raw juice buffer tank through mass flow meter.
Type : Centrifugal
Capacity : 300 m3/h
Head : 20 m
Speed : 1440 rpm
Juice to be pumped:
pH : 5.5 - 6.5
Viscosity : 5 cP

Page – 48 / 51

Drive:
Type : TEFC, squirrel cage induction motor with AC
VFD drive
Rating : 30 kW
Speed : 1440 rpm
foundation bolts.
0414 Imbibition water tank
Quantity: 1 No.
Vertical cylindrical tank with flat bottom.
Capacity - 12 m³
Diameter - 2500 mm
Height - - mm
Material - Mild Steel , 8 mm thick shell. 5 mm
thickness
is provided.
0415 Imbibition water pumps
Quantity: 2 Nos. (1 working and 1 stand by)
To pump imbibition water to the mills throeugh water flow meter and spray nozzles.
Type : Centrifugal
Capacity : 130 m3/h
Head : 60 m
Speed : 1440 rpm
Water to be pumped:
Temperature : Upto 90 ºC
pH : 7.0
Casing : Cast Iron
Shaft : EN8
Drive:

Page – 49 / 51
Rating : 37.5 kW
Speed : 1440 rpm
foundation bolts.
0416 Water flow meter
Quantity: 1 No.
Indicating, integrating and recording type. Capacity range 20 – 200 m 3/h. Water
temperature 90 0C maximum. Accuracy should be not less than ± 0.25 % of D.P.
transmitter and shall be installed on mill platform.
The flow meter is to be in-line installation in the delivery pipe line of pump. Flow
indicator shall be located at mill platform.
0417 Mill house crane
Quantity: 1 No.
Three motion electrically operated overhead travelling crane of double girder box
type construction for indoor installation, conforming to class II as per IS:3177 (1977)
and IS:807 specifications shall be provided.
Capacity : 20 t SWL, 2 # electrically operated crab, with independent trolley and

provision for synchronised operation of both crabs together in addition to individual
operation.
The crane span shall be to suit the mill house building span of 30 m. The gantry
length shall be approximately 138 m, suitable for covering complete mill house and
extended up to fibrizor.
The crane shall be provided with down shop lead, angle iron.
The specification for each crane shall be as under :
Height of lift - 13 m
Height to top of rail - 14 m
Main hoist speed - 2 m/min
Long travel speed - 10 m/min
Cross travel speed - 10 m/min

Page – 50 / 51
Main hoist motor should be squirrel cage TEFC and long travel and cross travel
motors should be slip ring TEFC. All motors should be of crane duty.
Drive Type of motor kW Rating
Hoisting drum TEFC sq. cage * 1 hour

Long travel TEFC slip ring * 1/2 hour
Cross travel TEFC slip ring * 1/2 hour
All gear boxes shall be totally enclosed, dust proof, helical type with designed
service factor of 2.0. All couplings shall be of flexible gear type / centrifugal type.
All brakes shall be of Electro-hydraulic thruster operated type.
Crane should be provided with a creep speed facility while hoisting at maximum
capacity to allow the heavier loads to be slowly and carefully handled. The crane
operation shall be from ground floor through pendent push button station moving
along with the crab/remote control operation.
The Supplier will provide the loading data and span details to enable the purchaser
to arrange suitable design columns for the crane.
Crane bridge box type mild steel welded construction having walkways on both side
with hand railing, rails for trolley, LT assembly, cross conductors, power rails and
collectors system for supply of electric power to the trolley bridge movement.
The crane shall be provided with down shop lead, angle iron with flat copper strips
and trailing cable type for cross travel.
0418 Mill roller lathe
Quantity: 1 No.
Manually operated, gap bed, back gear, heavy duty mill roller centre lathe for
installing in sugar factory for machining mill rollers. Major specifications of the lathe
are listed below :
Type - Gap bed, back gear, hollow spindle, extra heavy duty cetre
lathe, driven by suitable electric motor.
Size - Height of centre above saddle - 750 mm

Admit between centres - 7000 mm
Weight of the job to be machined - 30 tons
Speeds - Number of speeds (approximate) 6
Drive - Totally enclosed fan cooled 3 phase induction motor of

suitable capacity along with starter.

Page – 51 / 51
Accessories - Following standard accessories are to be included in the

supply :
i) Tool holder tool post

ii) 4 jaw manually adjustable chuck from both ends
iii) Dead cetres
iv) Chip tray

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WSSF-USI TECHNICAL SPECIFICATIONS Section – VI-D

0100 CANE WEIGHMENT.................................................................................................3

WSSF-USI TECHNICAL SPECIFICATIONS Section – VI-D

0408-3 Imbibition piping.........................................................................................42

WSSF-USI TECHNICAL SPECIFICATIONS Section VI – D

1st Stream machinery specifications for 6250 TCD Plant.

0100 CANE WEIGHMENT

0101 Electronic weighbridge for truck

The detailed specification of weighbridge is as under:

WSSF-USI TECHNICAL SPECIFICATIONS Section VI – D

0102 Electronic weighbridges for general purpose

0200 CANE UNLOADING

0201 Hilo type unloaders

0202 Drag type feed table

WSSF-USI TECHNICAL SPECIFICATIONS Section VI – D

0202-1 AC-VFD for feed table

Speed variation shall be through AC-VFD drive with DOL bypass.

Power Output required : 45 kW

Type of Enclosure : Dust, water and vermin proof, vertical free

Altitude : 1580 m above MSL.

Application : Speed control in the range of 40-100% of rated

Overload current rating : 150 % for 120 seconds.

WSSF-USI TECHNICAL SPECIFICATIONS Section VI – D

Continuous output : 100 % of full load.

Output torque rating : Full load torque between 40 - 100% speed

Control Method : Frequency control (V/F), Vector Control, *

Rectifier system : 12 pulse, 4 Quandrant Operation.

Motor reversal : Reversing facility at lower speed to be provided.

Motor Data : Three Phase sq. cage, TEFC, 400 V, 50 Hz,

Protective Functions : Under Voltage, Over Voltage, Earth Fault,

0202-2 Cane kicker for feed table

Drive for cane kicker

WSSF-USI TECHNICAL SPECIFICATIONS Section VI – D

approx. 36 rpm. Suitable strong supporting structure, attendance platform with

0202-3 Rotary drum type stone catcher for feed table

Drive for rotary drum stone catcher

Speed variation shall be through AC-VFD drive with DOL bypass.

Power Output required : 15 kW

Type of Enclosure : Dust, water and vermin proof, vertical free

Altitude : 1580 m above MSL.

Overload current rating : 150 % for 120 seconds.

WSSF-USI TECHNICAL SPECIFICATIONS Section VI – D

Continuous output : 100 % of full load.

Output torque rating : Full load torque between 40 - 100% speed

Control Method : Frequency control (V/F), Vector Control, *

Rectifier system : 12 pulse, 4 Quandrant Operation.

Motor reversal : Reversing facility at lower speed to be provided.

Motor Data : Three Phase sq. cage, TEFC, 400 V, 50 Hz,

Protective Functions : Under Voltage, Over Voltage, Earth Fault,

0202-4 Belt conveyor for rotary drum stone catcher

Other details of belt conveyor are:

- Idler spacing maximum 1000 mm on carrying side and 2000 mm on

- Joining of belt shall be by vulcanising. Provision is to made for tensioning

WSSF-USI TECHNICAL SPECIFICATIONS Section VI – D

- Belt conveyor shall be provided with suitable supporting structure and

Drive for belt conveyor

0202-5 Auxiliary cane carrier (for feed table)

- Horizontal sprocket center distance will be approx. 40 m.

Support columns are to be rolled steel channels 250 mm x 80 mm size or equivalent

Columns at the cane kicker location shall be 250 mm x 80 mm double channels or

WSSF-USI TECHNICAL SPECIFICATIONS Section VI – D