Manual Wambeck.
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OIL PALM PROCESS SYNOPSIS By Noel Wambeck. - June, 1999
V
Volume I – OIL PALM MILL, SYSTEMS AND PROCESS
OIL PALM PROCESS SYNOPSIS By Noel Wambeck - June 1999 2nd Edition - Update 3rd March 2001
Volume 1 - OIL PALM MILL SYSTEMS AND PROCESS. 1.0 INTRODUCTION 2.0 A BRIEF OF THE WRITER's EXPERIENCE 3.0 BRIEF HISTORY OF OIL PALM * Palm Oil Processing Flow Chart * Picture of Palm Fruit & Fruit Bunches * Uses of Palm Oil * Oil Palm Tree Matrix * Apparent Density of oils at various temperatures * Malaysia Palm Oil Products Export Procedure. 4.0 HISTORY OF OIL PALM PLANTATIONS IN INDONESIA 5.0 OIL PALM MILL, SYSTEMS AND PROCESS * Palm oil mill schematic process flow chart * Matrix Oil Palm Mill Process * Pictures of sections the oil palm milling process * Process Mass Flow and Losses During Production * Typical Empty bunch Incinerator. * Typical Effluent ( Ponding ) Treatment system of Anaerobic & Aerobic process. * Matrix of Oil Palm Mill Process & Waste Water Effluent Ponding System. 6.0 AN ENVIRONMENTAL CONTROL PLAN (ECP) * Potential Hazards and Control Plan. * Oil Palm Mill Environment Control and Waste Disposal Flow Chart. * Placement Avenue for empty bunch, fonds and treated effluent for land application. * POME Sludge process with the Decanter & Dryer - Schematic flow diagram. * Schematic diagram for Boiler three element control and scrubber system. * General layout of Anaerobic & Aerobic ETS. * Typical Layout of an Oil Palm Mill with the ECP effluent treatment plant. * Typical Furrow Layout. 7.0 OIL PALM MILL PROCESS MONITORING & CONTROL (PMC) SYSTEM. 8.0 THE DEVELOPMENT OF OIL PALM IN MALAYSIA. 9.0 THE OIL PALM EXTRACTION PROCESS MATCHING WITH TYPE OF FFB. 10.0 OILPALM EMPTY BUNCH DISPOSAL BY INTEGRATED INCINERATION. 11.0 FAO- FEEDING PIGS IN THE TROPICS : CHAPTER 4 - AFRICAN OIL PALM. 12.0 PREPARATION OF AN OIL PALM MILL PROJECT * Matrix for oil palm mill project. * Project manager's checklist. * Typical project monthly report
13.0 OIL PALM MILL DESIGN BASIS * Specific Gravities and Densities of Oil Palm Components & Substance. 14.0 A PALM KERNEL OIL EXTRACTION MILL PROJECT * Matrix for Palm Kernel Oil ( Expeller Press ) Extraction * Proposed Palm Kernel Oil Mill - Typical General Layout * Photors of a Palm Kernel Oil Mill * General arrangement drawing. 15.0 REFINING PROCESS FOR PALM OIL AND OTHER DOWNSTREAM PROCESSES * Introduction to Refining process for palm oil and other downstream processes. * Rationale of an integrated oil palm mill and refinery complex project. 16.0 USEFUL INFORMATION * Palm Oil Registration & Licensing Authority Activities. * PORLA Fresh Fruit Bunch Grading Manual * PORLA Fresh Fruit Bunch Grading Form * PORLA Basic Extraction Rate for Oil & Kernel based on year planted. 17.0 ABBREVIATIONS & GLOSSARY USED IN THE OIL PALM INDUSTRY
The complete Oil Palm Process Synopsis set includes the following: Vol.2 - TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL Vol.3 - OIL PALM MILL MAINTENANCE MANUAL
Revised 3rd March 2001
OIL PALM PROCESS SYNOPSIS Volume 2. TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL 2 nd Edition - 3nd March 2001
1.0
INTRODUCTION
2.0
A BRIEF OF THE WRITER's EXPERIENCE
3.0 A B C D E F
TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL Introduction Preparation Test procedures. Finalization Taking over and certification test. Training and Manpower
4.0 A. B C D E
APPENDICES Master list of machinery Checklist of oil palm mill. Electric motor list Palm Oil Mill Schematic Process Flow Matrix oil palm mill process.
5.0
SPECIFICATION FOR MACHINERY
6.0
MECHANICAL & ELECTRICAL DRAWINGS The complete Oil Palm Process Synopsis set includes the following: Vol.1 - OIL PALM MILL, SYSTEMS & PROCESS Vol.3 - OIL PALM MILL MAINTENANCE MANUAL
Noel Wambeck June 1999. Revised 3nd March 2001
OIL PALM PROCESS SYNOPSIS Volume 3. - OIL PALM MILL MAINTENANCE MANUAL 2nd Edition - Update 3rd March 2001.
1.0
INTRODUCTION
2.0
A BRIEF OF THE WRITER's EXPERIENCE
3.0
WELCOME TO PRODUCTIVE MAINTENANCE
4.0
STORE AND PARTS MAINTENANCE
5.0
MAINTENANCE OF HYDRAULIC SYSTEMS
6.0
DIGESTER USE AND MAINTENANCE Effective use of the Digester. Digester operating instructions and spare parts.
7.0
TWIN SCREW PRESS USE AND MAINTENANCE Operating instructions & spare parts manual. Effective use of the screwpress.
8.0
MULTI-HYDROCYCLONE SYSTEM Use of the Multi-Hydrocyclone system Automatic Triplex Multi-Cyclone Desanding System - Westfalia type ADP-100-3
9.0
DECANTER FOR CLARIFICATION SYSTEM. Alfa Laval Westfalia
10
CENTRIFUGE OIL PURIFIER Alfa Laval Westfalia China
11
SLUDGE CENTRIFUGE SEPARATOR Alfa Laval Westfalia Star Bowl Type - Local
12
NUT CRACKING MACHINE UDW rotor ring type - use and maintenance Ripple mill type - use and maintenance
Contents ……….
13
HYDRO CLAYBATH USE AND MAINTENANCE
14
STEAM BOILER ( Generator )
15
GEARBOX & GEARMOTOR USE AND MAINTENANCE
16
MAINTENANCE GLOSSARY & TERMINOLOGY
17
GLOSSARY OF BEARINGS
18
COMPRESSED AIR TERMINOLOGY AND SYSTEMS
19
PIPE FITTING AND VALVE GLOSSARY & TERMINOLOGY
20
PUMP MAINTENANCE Pump maintenance programs pay. Pump maintenance. Why Seals Fail. Pump performance checklist. Pump seal maintenance. Troubleshooting Electro-Hydraulic Pumps.
21
ROLLER CHAIN DRIVES Roller chain drives installation. Roller chain maintenance. Roller chain drives maintenance. Roller chain drives lubrication. Roller chain drives - Troubleshooting Guide.
22
V-BELT INSTALLATION AND MAINTENANCE.
23
USEFUL TABLES.
The complete Oil Palm Process Synopsis set includes the following: Vol.1 - OIL PALM MILL, SYSTEMS & PROCESS. Vol.2 - TESTING AND COMMISSIONING MANUAL FOR OIL PALM MILL.
Noel Wambeck June 1999. Revised 2nd March 2001
OIL PA LM PRO CE SS SYNO PSIS - Oil Palm Process Handbook By Noel Wambeck. - June, 1999
This oil palm process synopsis or handbook intents to be a series of reference books to the recipient, Manager, Engineer and people who are involved in the oil palm industry, it contains information such as the function, activities, the milling process and systems, specification of products, by- products, processing mill and plant design basis, the operation, commissioning, maintenance, useful data, flow charts and graphs etc…. The handbook also hopes to encourage the expansion of product development and improved oil palm processing facilities, which can lead to greater commercialisation of oil palm, its products and to the betterment of the manager, engineer and all who seek knowledge. The Oil Palm Process Synopsis handbook is in three volumes, which are: Volume 1.
Oil Palm Mill, Systems and Process including the Preparation of an oil palm mill project and enclosures.
Volume 2.
Testing and Commissioning manual including specifications & drawings
Volume 3.
Oil palm mill maintenance manual including proprietary equipment installation and operation manuals.
The handbooks sized A4 with retractable binder hinged for flexibility in terms of being expandable whereby, occasional periodical in an update manner and series distribution can be filed into this handbook for continuous usage. The contents of this handbook are also available in CD-ROM The writer acknowledges with sincere appreciation the generous assistance given him by colleagues and friends who made many valuable suggestions. Any error or omissions are regrettable.
June 1999 Noel Wambeck.
A Brief on the writer’s experience. Noel Wambeck @ Nurehsan born in Penang during the Japanese occupation to James Godfry Wambeck and Dorothy Symons of Dutch descendents. Educated at St. Xavier’s Institution in Penang with an engineering diploma from Gurney Technical Institute, Kuala Lumpur in the year 1969. Married to Fadilah A. Hamid in 1990 a Singaporean and fathered four children, two boys and twin girls. 30 years experience in the Agro-based engineering field of project management, project study, appraisal, market development of equipment, plant, system design and its implementation in such areas as edible oils industry, food processing plants, Rubber processing, Co-generation systems, pollution, effluent treatment and control systems. Some of the projects commissioned, are Padang Piol Oil palm Mill (Felda), Sarawak Oil palm mill (CDC), Fuji Oil refinery project ( Singapore) Ghana Rubber processing plant (Ghana), World bank projects PNP X Bekri, Betung PNP III Aek Raso Oil Palm Mills ( Indonesia ) Nalfico Premier for Palm kernel oil solvent extraction plant ( Malaysia) Indopalma extraction & refining of edible oils project ( Czech & Slovak) Coconut milk production for S&P Coconut Sdn Bhd (Malaysia) Rotary Dryer for Tioxide project (ICI Malaysia) Study on Pricing and distribution policies for Veg.Oils in Indonesia (ADB) Study on EB treatment / co-generation & PK crushing mill for Higaturu POM. ( CDC / PNG ) Study of production capabilities and marketing potential for coconut oil by products in Chuuk ( Fed.States of Micronesia) OPIL Oil palm Mill (India) PORIM Oil palm Mill ( Guthrie / PORIM) Kunak & Lumadan Oil palm mills ( Project manager with Konsultan Proses for Borneo Samudera Sdn Bhd. Sabah). He has consulted for commercial clients such as United Brands U.S.A., Cargill, Experience Inc., GFA International Management Consulting GMBH as well as donor agencies such as World Bank, KFW Bank (Germany), ADB, IBRD, UNIDP, CDC in Central America, Africa and Asia, including Malaysia and Indonesia. Noel Wambeck is at present an associate partner of Perunding AME – Consulting Engineers with on going assignments for consultancy services. The assignments are for oil palm mills for Borneo Samudera Sdn Bhd, Sabah, project study for PT. Kebun Ganda Prima in Kalimantan, Indonesia, project study for Low Yat Group in Sabah and detail engineering for the M&E works for a dry mixed cement plant for Chuan Cement Industries of Singapore.
June, 1999.
Brief History of Oil Palm ( Its
development in Malaysia).
by Noel Wambeck. - 8th November 1993. (Revised)
The oil palm ELAEIS GUINEENSIS grows around the globe in a zone of 10 degrees latitude to the north and south of the equator. Its utilization as basic nourishment had always been of vital importance to the inhabitants of this equatorial regions and its existence is reported as long as 3000 BC, when palm oil was known to the Egyptians under Pharaoh’s reign. The Oil Palm originates from Africa where there is a wealth of oil palm genetic material. The natives of Guinea coast who had made a living by raiding for slaves, were induced to find a new occupation in processing and selling the oil for export; for through the trade in palm oil firmly established before 1850. It has been selected by the Africans over the ages to provide palms with a high proportion of kernels and palm with a high yield of palm oil. The first planting of oil palm of the Deli type, brought from Africa and planted in the Buiterzorg botanical garden, Java, Indonesia in 1848, four plants being received, two from Bourbon and two from Holland and during the ten years of experimental observation, showed very good growth, and fruited. Their progeny was distributed from 1853 forwards and the stock in the Dutch Indies, in general, came from them. The palm was brought to Singapore about 1870, probably from Java. These seeds was soon distributed to various places, chiefly to gardens of those who cared to grow it as an ornamental tree. In 1879 Buitenzorg gardens in Java had sent seeds to Sumatra and the palm grew well; so that Sumatra appears to have received its first two supplies of the palm from Buitenzorg stock, one direct and the other through Singapore. Some of the oldest palms on the St. Cyr tobacco estate in Sumatra, figured by Rutgers are recorded as from seed from the botanical gardens of Singapore; and these trees, in turn, supplied material to many other places in Sumatra. The idea of a common origin is supported by and large the characters which all the old trees have in-common.
Rutgers thinks that the actual trees of 1879 were subsequently removed to make room for the town of Medan as this tree race is the old Deli type. The material bred from these palms is referred to as DURA DELI. It is very stable and uniform in oil and kernel contents. The vernacular names for the palm in Java are “ salak minyak’’, ‘’klapa sawit’’ and ‘’klapa sewu.’’ The tree was then freely distributed in that island, and about 1906 interest in the oil palm was aroused among Malayan planters, who planted a few trees on their estates by way of experiment. The new era of advancing communications and transport, fueled the growth of liberalism in Europe as telegraph system was introduced in 1856, the postal system in 1862 and the opening of the Suez canal in 1869. The fast growth of plantations in the Golden era of plantation companies, before the first world war saw the expansion in acreage, productivity and diversification of crops. In 1903, the department of Agriculture made several importation of seeds to Batu Tiga experimental plantation and the public gardens in Kuala Lumpur. The foundation of the Industry is generally attributed to M. Adrien Hallet, a Belgian with some knowledge of the oil palm in Africa, who planted palms of Deli origin in 1911 in the first large commercial plantation in Sumatra. Hallet’s plantings on Sungei Liput, Atjeh and Pulu Radja, Asahan estates are recorded as being contemporary with the establishment of 2,000 palms by K. Schadt, on his Tanah Itam Ulu concession in Deli. He also recognised that the avenue palms growing in Deli were not only more productive than palms in Africa, but had a fruit composition superior to the ordinary Dura palms of the west coast. A potential oil content of 30% in the fruit was recongnised in the early 90’s. The climate of Malay Peninsula and Eastern Sumatra has proven ideal for growing Elaeis or Oil Palm trees. In the meantime, a Frenchman M. H. Fauconnier, who had been associated with Hallet, had established during 1911 and 1912 some palms of Deli origin at Rantau Panjang in Kuala Selangor. These palms were in full bearing by 1917 and in that year the first seedlings were planted on an area later to be known as Tannamaram estate.
It was during this period that the DURA palm and Pisifera palm were cross to produce a hybrid progeny, that all modern planting and milling systems are designed. Thus the birth of the Malayan Hybrid palm “ TENERA” was introduced to the Oil Palm Industry. The second commercial oil palm plantation, also in the Kuala Selangor district, was developed at “Elimina” Barlow’s estate ( Sungei Buluh ) Selangor in 1919 and the first 40 acres planted in 1920. In 1922, selected seeds from the experimental plantation were planted at the new experiment plantation in Serdang, Selangor. During this period the boost in prices of major commodities before the first world war, was the main factor in the expansion of plantations in Malaya. The number of plantations increased from 1925 to 1930 with an expansion in the development in the Palm Oil processing Mills which began only at the beginning of the nineteenth century when its possibilities were realized, alike in Europe and America. There are two oils in the fruit, one in the fruit wall ; the other is in the kernel. The methods of manufacture, then employed was badly, often abominably prepared, if the working be quoted from a letter from Accra, Gold coast, in 1877 and printed in the Kew bulletin ( 1889 p 263 ) whereby the writer describes the bunches of fruit as cut down from the tree and heaped in the open air for 7 to 10 days, during which the pedicels become weak and the fruit easy to detached. The dry fruit bunch is then shaken off and fruitlets gathered together. A hole about a meter deep is dug in the ground and lined with banana leaves; into this hole the fruitlets are put and left for a period between three weeks and three months for decomposition to set in, and the pericarp to become quite soft. Part of the accumulation of fruitlets, if not decomposed enough, will next be boiled in an iron or earthware pot and returned to the heap, and the entire quantity transferred to another hole, which is lined with rough stones, where it is pounded until the pericarp and kernel are separated. The pericarp are folded into a coarse cloth, and by twisting the ends, the oil is extracted and the nuts are collected manually.
Another method, which was used in Portuguese West Africa; describes that the fruit, after they have been detached from the pedicels are put into baskets and submerged in swamps to ferment, before they are beaten in order to detach the fruit from the kernel and are again left to ferment for a few days before the oil is extracted. Off course, oil so crudely process is full of fatty acids, even up to 80% FFA or sometimes called a “ Hard oil “. At first the Africans offered in trade the oil of the kernel mixed into the oil of the pericarp; and as they commonly cracked the shell by heat, the addition imparted a peculiar smell to the mixture; but, about 1870 the market began to offer a price for the kernel, which activated the interest of the locals to collect and sell the whole kernels to the trading stations, who than bagged them for export. Primitive methods of processing palm oil with crude machines during the course of the development of the extraction process, saw changes such as the hand press, centrifugal basket, hydraulic press and the present day screw press, which also changed the process system, flow and Mill layout design.
The method in winning the oil in the early 1900’s was that the bunches were transported from the field to a convenient place, where they remain for the fruit bunch to soften, so that the fruitlets may be removed. Next the detached fruitlets are sterilized by heat; and this kills the enzymes, which would otherwise spoil the oil by leading to the production of fatty acids. Keeping in mine that most of the equipment, machinery and plants were designed to handle Dura type material in the early 1900’s and not until 1960’s did the change in the Mill design take place, when Tenera type material made its prominent appearance in Malaya, when most of the further developments took place in the Mill layout and selection of processing equipment. Modern Palm Oil Mills with screw presses were first introduced into Mongana ( Zaire ) in the early 1950’s and soon after, about 1956 in Malaya at Jendarata Mill ( United Plantations ) and Limablas, Slim river Mill ( Socfin ) henceforth to process Malayan Tenera type material ( D X P ) fresh fruit bunches. The search for new process and the development of oil palm extraction plants, equipment and machinery continues ..................... End.
Kernel Shell Mesocarp
OIL PALM TREE MATRIX
OIL PALM COMPONENTS, BIOMASS AND ANALYSIS
by Noel Wambeck UNIT MEASURE
WEIGHT
BASIC DATA Type of Palm tree Planting density Growth of fronds per year Tree growth rate per year Inflorescence Number of fruit bunch produced per hectare / year
ELAEIS GUINEENSIS Tenera ( D x P ) Number of trees per hectare New leaves per year Vertical trunk height full production at every number of fruit bunch
Trees per hectare Nr. Of Fronds mm / year days per cycle Nr / year
143 21 - 25 1000 15 1250
7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9
COMPOSITION OF FFB Weight of Fresh fruit bunch (FFB) Empty Bunch (EB) Nos in EB Water in EB Oil in EB Fruitlets in each bunch Weight of each fruitlet Nuts in Bunch Pericarp
average weight average weight average weight average weight average weight Individual fruitlet Individual fruitlet average weight average weight
kg kg kg kg kg Nr grammes kg kg
20 5 1.4 3.2 0.4 1500 8 to 10 3 10
8 8.1 8.2 8.3
YIELDS FFB yield per year Crude oil yield per year Palm Kernel yield per year
average weight per hectare in a year average weight per hectare in a year average weight per hectare in a year
mt / year mt / year mt / year
25 6.25 1.5
9 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14
BIOMASS Biomass of fronds pruned annually Biomass of Fibre Biomass of Shell Biomass of Empty bunch Moisture in bunch Solid matter in bunch Biomass of spears Biomass of cabbage Biomass of inflorescences Biomass of Leaflets ( average 40 fronds ) Biomass of Rachies ( average 40 fronds) Biomass of frond bases ( average 40 fronds) Biomass of Trunk ( 6-9 m length ) Biomass of matured palm tree in total weight
average weight per year / hectare average weight per mt FFB average weight per mt FFB average weight per mt FFB average weight per mt FFB average weight per mt FFB average dry weight of spears / palm average dry weight of cabbage / palm average dry weight of inflorescences / palm average dry weight of leaflets / palm average dry weight of Rachies / palm average dry weight of frond bases / palm average dry weight of Trunk / palm average fresh weight of palm tree 6-9 m
mt / year / ha kg kg kg kg kg kg / palm / dry kg / palm / dry kg / palm / dry kg / palm / dry kg / palm / dry kg / palm / dry kg / palm / dry kg / palm tree
10 120 80 240 200 40 9.4 4.5 6.3 58 118 130 302 2200
1 2 3 4 5 6
10 10.1 10.2 10.3 10.4 10.5 10.6 10.7
ENERGY Energy value for Oil palm products Fibre Shell Empty Bunch Crude Palm Oil Input energy per ha /year Output energy per ha /year
10.8 10.8.1 10.8.2 10.8.3 10.8.4 10.9
Energy consumption in oil palm plantation
10.10
Gas liberated by anaerobic digester contain
11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20
BULK DENSITIES Air Ash Bunch Cracked mixture Crude Palm Oil Diluted crude oil Fibre Fresh Fruit Bunch Fruitlets Palm Kernel Oil Palm Nuts Palm Olein Palm Stearin Press expelled cake Pure water without air at 30degC Shell Sludge Sterilized Fruit Vegetable oils Water at 4 deg.C max
Methane yield of kg mill effluent dry matter
3/3/01 23:56 Percentage
100% 25% 7% 16% 2% 65% 15% 50%
25% oil 6% Palm kernel
12% 8% 24% 20% 4%
9% 19% 21% 48% kcal
Net Calorific Value of FIBRE Net Calorific Value of SHELL Net Calorific Value of EMPTY BUNCH Net Calorific Value of CRUDE PALM OIL Annual energy values - INPUT Annual energy values - OUTPUT Energy values
kcal / kg kcal / kg kcal / kg kcal / kg GJ / ha / year GJ / ha / year Ratio
2,700 4,000 2,000 10,300 19.2 182.1 9.5
INPUT Fertilizers GJ / ha / year Pesticides, herbicides, rat baits GJ / ha / year Machinery GJ / ha / year other GJ / ha / year average yield of methane is litres per kg dry matterl / kg
11.2 0.8 5.14 2.06 230
methane percentage 60% carbon dioxide percntage 35% other gas percentage 5%
230 135 19
average weight in kg per m3 average weight in mt per m3 same same same same same same same same same same same same same same same same same same
l / kg l / kg l / kg kg / m3 mt / m3 same same same same same same same same same same same same same same same same same same
1.177 0.437 0.550 0.653 0.890 0.900 0.350 0.480 0.680 0.890 0.653 0.900 0.880 0.650 0.990 0.750 0.900 0.660 0.950 1
Kernel 6%
2420 3640 1600
Moist. % oil % 30 - 45 7 10 0 33 - 45 2
12 12.1 12.2 12.3
AIR ABSORPTION / EMISSIONS OF PALM TREE Absorption of Carbon Dioxide Carbon Dioxide emission to produce kw Oxygen emmissions per hectare
tonnes of carbon dioxide per hectare tonnes displacement of fossal fuel / tons carbon dioxide per kwtonnes tonnes of oxygen per hectare tonnes
5
13 13.1
Soil enrichment contribution Carbon contribution of root biomass at
contributes carbon per hectare at replanting
mt / ha
8
13.2
Nutrient stocks of above ground biomass for replanting cycle
N P K Mg Ca
kg / ha kg / ha kg / ha kg / ha kg / ha
577 50 1255 141 258
POME application
3 rounds a year or equivalent to twice rate of Nitrogen
kg N/ ha/ year
pH BOD COD Total solids Suspended solids Volatile solids Ammoniacal Nitrogen Total Nitrogen Oil & Grease
mean mg / Liter mg / Liter mg / Liter mg / Liter mg / Liter mg / Liter mg / Liter mg / Liter
14 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 15 15.1 15.2 15.3 15.4 15.5 15.6 16
Process waste water from th oil palm mill Properties of raw effluent (POME)
Page 2.
650 4.1 25,000 53,630 43,635 19,020 36,515 35 770 8,370
ANALYSIS of dried sludge (POME) Moisture Ash Silica Ether extract Crude fibre Crude protein
5 - 15 % 15 - 22 % 7 - 10 % 11 - 13 % 11 - 14 % 11 - 13 %
N 1.8 - 2.3 % P 0.3 - 0.4 % K 2.5 - 3.2 % Mg 0.6 - 0.8 % Ca 0.6 - 0.8 %
B 20 ppm Cu 20-50 ppm Fe 3000-5000 ppm Mn 50-70 ppm Zn 20-100 ppm
kg / m3 Mpa Mpa Mpa (N)
220 - 550 800 -8,000 8 to 45 5 to 25 350 - 2,450
OIL PALM STEM ( Trunk )
16.1
Properties
Density ( Oven dry ) MOE MOR Compr // to grain Hardness
16.2
Chemical Composition
Alcohol benzene Hot water solubes Alkali ( 1% NaOH ) soluble Holocellulose Alpha - cellulose Acid- insoluble lignin Pentosans Ash
16.3
Sugar Contents ( after acid hydrolysis )
% of O.D. original fibre Glucose Xylose Galactose Arabinose Mannose Rhamnose
9.8 14.2 40.2 45.7 29.2 18.8 18.8 2.3 Persentage
Average % 35 14.,47 0.5 1 0.83 0.2
APPARENT DENSITY OF OILS AT VARIOUS TEMPERATURES (3) (Decimal point omitted)
RECOMMENDED VALUES FOR (CRUDE) PALM OIL PRODUCTS Palm Oil MS814:1983, Rel density 50/25 deg.C AOCS, Spec.grav. 37.8/25 deg.C Equivalent 50/25 deg.C Codex Aliment. Rel density 50/20 deg.C Equivalent 50/25 deg.C
Range 0.8919 0.888 0.880 0.891 0.892
to to to to to
0.8932 0.901 0.893 0.899 0.900
0.9001
to
0.9028
0.8816
to
0.8915
Palm Olein MS816:1983, Rel density 40/25 deg.C
Palm Stearin MS815: 1983, Rel density 60/25 deg.C
Source: Porim technology No.12 Aug 1985 “ The Density of oils in the liquid state.” 16th August 1997./ NW
MALAYSIA PALM OIL PRODUCTS EXPORT PROCEDURE 1. The buyer and the seller sign a sales contract in accordance to products and standard contract forms for PORAM, FOSFA, MEOMA, MOPGC, GAFTA 2. PORLA licensees are required to register the contracts with PORLA within 24 hours after the contracts are concluded, A copy of the contract must be submitted to PORLA within 30 days. 3. The seller fills in the Exchange Control Form (KPW 3) and submits it to the bank for approval of foreign exchange. 4. The buyer instructs his bank to Issue a credit in favour of the seller. 5. The buyer’s bank advises or confirms the credit to the seller’s bank. 6. The seller’s bank informs the seller that the credit has been issued. 7. The seller is in a position to load the goods and dispatch them to the buyer 8. The following documents are required for the exports. a. b. c. d. e. f. g. h. i. j. k. l.
Commercial Invoice. Bill Of Lading. Packing List. Marine Insurance Policy (CIF) Customs Declaration Form (CD 2) Exchange Control Form (KWP 3) Survey report. Analysis Certificate. Ship Masters Authorisation Letter for shipping agent to sign Bill Of Lading. IASC Heating Instructions. Masters Certificate For The Last Three Cargoes. Masters Certificate certifying vessel tank, heating oil, manifold pipe and pipelines, valves and fittings do not contain copper or copper alloy. m. Cargo Shipped Under The Appropriate FOSFA Contract n. Other document as and when required, may include: § § § §
Phyto Sanitary Certificate Radiation- free Certificate Lard-free Certificate Certificate Of Origin
9.
The seller then remits to the seller’s bank the documents evidencing the shipment as follows:
a. b. c. d. c. d. e.
Commercial Invoice Packing List Certificate of Origin Bill Of Lading Marine Insurance Policy Original Letter of Credit Survey/Analysis Certificate
10. After checking the documents against the credit, the bank will pay, accept or negotiate according to the terms of the credit to the seller. 14th September 2000./ NW
THE HISTORY OF PLANTATIONS IN INDONESIA.
THE HISTORY OF PLANTATIONS IN INDONESIA Noel Wambeck June 21st 1992 ( Revised )
To appreciate the present developments in the Indonesian Oil palm industry, one has to look back into the history of plantations in Indonesia. Large plantations were first established 170 years ago by the Dutch colonial administration, and term what was known as Cultuur Stelsel ( forced cultivation ) . Oil Palm Plantations today are not only divided into large and small holding plantation, but also Nucleus Estates Schemes or ( PIR ) which constitutes a form of cooperation between large plantation companies and small holders. Development of the plantations since 1830 to present day operations are as follows:
Period I. ( 1830 to 1870 ) During this period, plantation consist of camps established by the Government, then the Dutch Government on the cultuur stelsel system with forced labour. But prior to this period, trade went on in the normal way between the VOC a Dutch trading company and with Indonesian growers with chosen agents who were important to the Dutch. The agents were mostly ethnic Chinese, officials of the Indonesian Kingdoms or Dutch nationals. The VOC set up a number of warehouses in areas near a port to facilitate the trade. The commodities were the products grown by the Indonesian farmers which were controlled and managed by VOC who later on handed over the monopolized trade to the Dutch Government which brought about the start of the Dutch colonial power in Java. The process of domination of the country was hampered by the situation in Europe for a period, when the Netherlands was under the French Napoleon rule. The Napoleon war from 1800 - 1816 and then the Diponegoro war from 1825 to 1830, caused financial problems, which prom the Dutch Governor Daendles at that point of time to surrender Indonesia to Britain for a period, and after the defeat of Napoleon, the Dutch regained a foothold and power in Indonesia. The Dutch Government with the lack of funds, took on a program to cope with the budget deficit, whereby the cultuur stelsel was introduced which started the forced cultivation in 1830 the farmers were forced to set aside one fifth of their land to grow export crops and further to work 60 days per year, without pay for the Government. The cultuur stelsel system earned the Dutch Government 18 million guilders a year or 60% of the Dutch budget revenue.
1
THE HISTORY OF PLANTATIONS IN INDONESIA.
The first crops to be grown were, sugar and indigo, but later the crops range were diversified to include coffee, tea, tobacco, pepper, cinnamon and cotton of which coffee grew to become the main crop. Plantation were established in West Java for Sugar, coffee and pepper whereas indigo was stopped after it turned out to be not profitable as a synthetic substitute was discovered. The first plantation of palms of the Deli type was made in Java in 1859, and during the ten years of experimental observation, showed very good growth, and fruited. It was brought to Singapore about 1870, probably from Java, seed was soon distributed to various places, chiefly to gardens of those who cared to grow it as an ornamental tree. In 1879 Buitenzorg had sent seed to Sumatra and the palms grew well; so that Sumatra appears to have received its two first supplies of the palm from the Buitenzorg stock, one direct and the other through Singapore. Some of the oldest palms in Sumatra, those on the St Cyr tobacco estate, figured by Rutgers are recorded as from seed from the Botanic gardens of Singapore; and these trees, in turn, supplied offsprings to many other places in Sumatra. The idea of a common origin is supported by the characters which all the old trees have in common. Rutgers thinks that the actual trees of 1879 were subsequently removed to make room for the town of Medan as this tree race is the old Deli type. The vernacular names for the palm in Java are ' salak minyak ', ' klapa sawit and ' klapa sewu'. The tree was then freely distributed in that island, and about 1906 interest in the oil palm was aroused among Malayan planters, who planted a few trees on their estates by way of experiment.
Period II ( 1870 to 1900 ) Liberalism in Europe in 1850 opposed the cultuur stelsel system enforced by the colonial countries which marked the begaining of the privatisation of plantations in Indonesia. The new era of advancing communications and transport, fuel the growth of liberalism in Europe as telegraph system was introduced in 1856, the postal system in 1862 and the opening of the Suez canal in 1869.
The Agrarian law in 1870 made it possible for private companies to secure land title for 75 years, which were considered long enough for plantations. Dutch ownership of plantations companies, mushroomed with the support of Dutch Government, banks, trading houses, communications and transport facilities. The Dutch built railways to facilitate transport of the plantation commodities and irrigation systems for the crops.
2
THE HISTORY OF PLANTATIONS IN INDONESIA.
In Deli north Sumatra, investors were allowed to lease the land owned by the Sultan for 75 years and growing of the reknowned Deli tobacco was established and later on orther plantations were opened to include Rubber, Coffee and Oil Palm estates.
Period III. ( 1900 to 1930 ) The fast growth of plantations in the Golden era of plantation companies, before the first world war saw the expansion in acreage, productivity and diversification of crops. The first rubber plantation was established in 1905 and followed by Oil palm plantation in 1911. The importance of Chinese tea was changed for Assam tea and Arabica coffee for Robusta. The Indonesian Kings or Sultans had their powers reduced in 1915 and the Dutch authorities began collecting tax on land. During this period the boost in prices of major commodities before the first world war, was the main factor in the expansion of plantations in Indonesia. The number of plantations increased from 2130 in 1925 to 2467 in 1930 with an expansion in the acreage from 2.6 million hectares to 2.8 million.
Period IV ( 1930 to 1940 ) The depression period which began with the crisis in 1929 resulted with a steep fall in prices, whereby the supply exceeded the demand for most commodities including plantation crops in the world market which hit rock bottom in 1933. According to the Javasche Ban, exports in 1933 were worth only 40% of the export prices for the same commodities in 1929. The global recession forced the Government to impose restriction on production and exports through a quota system on tea, rubber, sugar and copra in 1933. Farmers were even prohibited to tap rubber, under what was called ' rubber restrictie' whereby the Dutch government offered cash compensation for rubber plantations. A team was set up to supervise the distribution of the compensation of which the government charged levies on certain plantation crops to finance research and marketing promotions. The number of plantations and acreage is shown in the table below: Details 1930 1933 1938 --------------------------------------------------------------------------------------------------------------------------Plantations. 2467 2395 2402 Acreage held under HGU ( Ha) 2,876,000 2,410,000 2,485,000 Acreage cultivated (Ha) 1,048,000 1,089,000 1,171,000 source ; Institute of Asian Studies.
Many sugar mills were forced to shut down operations as a result of the recession; leasing of small holder's lands declined by 51% where many concession holders with land title (HGU) returned the land to the government, resulting in a sharp shrinkage in the acreage of plantations.
3
THE HISTORY OF PLANTATIONS IN INDONESIA.
Period V. ( 1940 to 1950 ) The advent of world war II in 1941, communication with the Netherlands ceased and in March 1942, Japanese forces landed on Java and the occupation of Indonesia. All development hauled as many foreign planters and owners left the country or were arrested by the Japanese; leaving the larger plantations without proper management, however the small holders of local Indonesian farmers increased in numbers as they had to be self-sufficient; resulting in the expansion of small holding plantations. The Japanese authorities took over the management of plantations and reinstated forced cultivation of the land. The Dutch which returned to resume colonial administration in Indonesia, after Japan surrendered, relied mainly on plantations for finance. Rehabilitation of some of the plantations, where it was possible under the tense situation as the during this time, were the plans made by the locals for the war of independence of Indonesia. The original foreign owners of the plantations could only regain and operate their plantations in the areas where the Dutch military could effectively maintain authority.
Period VI. ( 1950 to 1970 ) This period marked by the consolidation and fostering of plantations which were still productive; pre and post independence of Indonesia. The process of transferring ownership was made between Indonesian private companies and the colonial or foreign owners which took place from 1959 to 1962 during the campaign to free Irian Jaya from the Dutch colonial rule. The number of plantations, continued to decline and the acreage reduced from 1,819,000 Ha in 1950 to 841,800 Ha in 1970. The plantations were managed and operated by state-owned companies in 1962 which were gradually changed into limited companies. The Indonesian Government took direct control over British, Malayan and Singapore plantations in Indonesia; following the campaign against the establishment of the new Malaysia which was later returned to its original owners, when the control was lifted towards the end of the 60's.when Indionesia and Malaysia resume a relationship. The implementation of the Agrarian law No. 5 in 1960, replaced a similar Dutch law the Agrarische Wet of 1870. The law maintained the controlling rights by the state over land. The law regulated the land title as follows: a. The land title for exploitation was for 25 years and could be extended to 35 years. b. Concession rights was lifted and replaced with HGU. c. HGU for land wider than 25 hectares was available only for a company based in Indonesia.
4
THE HISTORY OF PLANTATIONS IN INDONESIA.
d. A HGU land was at least 5 hectares and no wider than 25 hectares could be held by an individual A concession holder was required to convert its land title to HGU and in the process the holder is required to hand over part of the land to the state to be given to a new private company which resulted an increase in the number of private plantation companies.
Period VII. ( 1970 to date ) The new order period, called the ' Repelita' ( five year development plan.) marked the start of the phase development of the plantation sector, with the focused on improvement of productivity and efficiency. The main commodities were given greater attention for development are sugar, rubber and oil palm as a number of state owned plantation companies received credit aid from the world bank to improve productivity and efficiency. The Government's prime concern was for the farmer, and in the middle of the 1970's introduced a new system for development of plantations for the small holder which is known as the " small holder nucleus pattern ( PIR ); A state plantation company ( PTP ) planning to expand its acreage must use the PIR pattern whereby under the system, PTP act as an agent of development of the tree crop projects. Private companies could use the National Private Plantation (PBSN) scheme without having to use the PIR pattern. Working relations between small holders and the large plantations companies were maintained through the selling of crop by the small holder and purchase by the PTPs who is responsible for the processing and marketing of finished products. The Government have adopted two systems in the development of the plantation sector, such as in the intensification and diversification programs; One is based on the initiative of the farmer with government guidance and the other is program oriented, based on the government program with partial or integrated approaches. The partial approach is assistance to plantation companies by providing part of production, usually in the form of seedlings and guidance, while the integrated approach, the government provides all production factors which includes fund, management, operation and marketing. Great progress has been made in Indonesia in recent years to improve the lot of its citizens. The Indonesian oil palm industry have also advanced and are poised for a major leap forward; this has been made possible by an enlightened Government and by the efficient implementation of the government directives.
BIBLIOGRAPHY. Selected documents, data, studies and books available in the project file are :
• •
Economic Products of the Malay Peninsula by I.H. Burkill dated 1935. Indonesia tree crop processing project 6949-IND dated 11th Jan 1988.
5
THE HISTORY OF PLANTATIONS IN INDONESIA.
• • •
Study on Indonesian plantations and market of Palm Oil 1990 Book by PT. Capricorn Indonesia Consult Inc. Progress and development of Oil palm industry in Indonesia by Adlin U Lubis dated Sept.1991. Notes from the Institute of Asian Studies.
6
0
OIL PALM MILL SYSTEMS & PROCESS
OIL PALM MILL, SYSTEMS AND PROCESS. By Noe l Wambe ck ( Re vi sed June, 1999 )
&INTRODUCTION The aim of the writer of this paper is to provide an overall brief description of the Oil Palm Mill flow process and its systems employed based on concept and collective experience of the firm. Any errors in intention are regrettable
The synopsis of the Malaysian Oil Palm Industry success is basically due to the following factors: •
Commercially sound investment with state encouragement.
•
Practical Project Study Preparation.
•
Good management of the plantation who will provide for and ensure good genetical planting material, soil conditioning, harvesting, collection standards, handling and transportation of FFB to the mill and let nature do the rest.
•
Proper selection of the process system, machinery equipment and plant ( eg. Process matching with type of FFB ) for high extraction yield, quality palm oil and palm kernel.
•
Efficient transportation of the finished production to the bulking station or refinery.
•
Good shipping facilities for loading and discharge of the finished products for the export market.
•
And last but not the least, a dedicated and loyal workforce whose ambition is filled with grit.
Malaysian engineers can to-day provide Oil Palm Mill and process systems designs to achieve lower production cost, train and organize a stable work force, which will maintain the oil palm mill effectively and produce the best quality product at maximum yield extraction for the minimum cost.
OIL PALM MILL SYSTEMS & PROCESS
2
&THE REQUIREMENT OF A MODERN OIL PALM MILL. The requirements of a modern oil palm mill shall be with consideration for and incorporation of the latest technology available in the Industry and to include the following : a)
To be suitable in every respect for processing fruit from Tenera palms;
b)
To recovery with the minimum loss the palm oil and the kernels;
c)
To produce oil and kernels of the highest quality;
d)
To facilitate the disposal of the shell, fibre; and empty bunches;
e)
To incinerate the empty bunches for the recovery of the potash for fertilizer or to treat the empty bunch to recover 0.25% additional oil and used as fuel to produce steam for more valuable electrical power generation.
f)
The plant and process shall be Environmentally friendly and to dispose of waste water (sludge) in such as a way as not pollute local rivers and waters;
g)
To be reliable and suitable for local conditions of labour supervision and maintenance.
h)
Consideration and the incorporation of safety aspects that comply with Occupational Safety and Health act, such as to provide for good ventilation, working space, dust free and noise levels within permissible limits.
i)
The incorporation of operating procedures, equipment, plant and process systems to meet the ecological, hygienic and cleanliness of the plant on par with good food manufacturing industrial plant standards.
j)
Designed for cost effectiveness for operation and maintenance.
&THE PALM. Practically all the oil palm planted in the Far East are directly related to one, two or four oil palms which were brought from Africa and planted in the Buiterzorg botanical gardens in Java in 1848. The material bred from these palms is referred to as Dura Deli. It is very stable and uniform in Oil and kernel content. An average content of the fresh fruit bunch ( FFB ) is 25% oil, 5.5% kernel, 6% shell, 9% fibre, 25% empty bunch ( EB ) and the balance is moisture. In recent years another parent has been introduced to produce the material referred to as Tenera. The same Dura Dali palm is used to produce the Tenera palm seed but it is pollinated with pollen from a selected Pisifera palm ( the selected Pisifera when self pollinated produce fruit with a small kernel and little shell ). The resultant Tenera material produces fruit with more oil than Dura material, the same kernels as Dura but less shell than Dura.
3
OIL PALM MILL SYSTEMS & PROCESS
For this reason, it is now always planted in preference to the straight Dura Deli and it is for Tenera material that all modern oil palm mill systems should be designed. The quality of the palm oil and kernels is at its highest just before harvesting, collection and milling. The extent to which the oil is degraded depends on the system used and the care with which is executed.
&TENERA BUNCH COMPOSITION. The bunch composition will very from bunch to bunch and from tree to tree particularly in respect of shell thickness but the average bunch content for Tenara material (D x P) with an assumed average composition of Fresh Fruit Bunch ( FFB ) or now called Palm Fruit Bunch ( PFB ) from matured palms having a maximum 2.5 ffa for the extraction of Crude Palm Oil and Palm Kernel. TENERA MATERIAL COMPOSITION ( PORLA STD ) Empty bunch
25%
Evaporation
10%
Fruitlets
65%
Total PFB
= = =
Nos 7% water 16% Oil 2%
=
ash 0.5%
= =
nuts 15% pericarp 50%
= = = =
kernel 6% NOS 7.5% water 19.5% Oil 23%
100% ==== Total Oil Plus FFA =
25% to Palm Fruit Bunch
&HARVESTING. Harvesting is normally a 6 to 8 day cycle. It is important that the fruit must not be harvested before it is ripe, that is until the process of photosynthesis, which converts the carbohydrates into fat, is well in advance. The oil content of unripe mesocarp may be in the order of 35% whereas the oil content of ripe mesocarp is usually between 50% and 55%. The harvesting of under ripe fruit can cause losses in the order of 8% of the possible yield.
OIL PALM MILL SYSTEMS & PROCESS
4
&FREE FATTY ACID ( FFA) The FFA content of the oil in the bunch before harvesting may be in the order of 0.1% whilst the FFA of the oil in the same bunch when it is received at the mill will never be less than 1%, normally in the order of 3%, and is frequently above 3% under bad conditions. A low FFA content is the first characteristic to which edible oil refiners pay attention. A premium of 1% of the sale price is paid for every one percent, should the FFA content be below 5% and the Refining loss will be 1.25% to 1.80% per 1% of FFA. The rise in the FFA content from harvest to mill will make possible the harvesting of riper fruit with higher oil content and recovery of higher quality oil with a lower FFA. The riper the fruit the more vulnerable it is to damage during transport and handling. Of all different stages of processing, the harvesting of the palm tree and the transport of fruit to the edible oil refiner has the most effect on quality.
&FRUIT COLLECTION AND TRANSPORT. There are two basic systems used for fruit transport. One is the collection of fruit directly into the sterilizer cages and the other is the collection of the fruit in trucks or trailers and then transferred into sterilizer cages at the oil palm mill. The transfer system is less costly but results in some loss of oil and a higher FFA content due to the extra handling and damage to the fruit. The other system requires that the sterilizer cages be taken to the field for direct loading from the collection points. At such points the harvester’s place the fruit on nets which are lifted by crane to load gently into the sterilizer cages. At the time when the fruit is lifted in the nets it is convenient to weigh, using a weighing cell. This is particularly important for the collection of small holder crops.
5
OIL PALM MILL SYSTEMS & PROCESS
OIL PALM PROCESSING. The flow diagram and matrix relating to the processing of fruit from Tenera palms is shown in the appendix enclosed.
1.0
FFB Reception.
The FFB bunches loaded on trucks, cages or trailer are weighed on arrival at the mill and on departure when empty by weighbridge of 50 ton capacity and automatically recorded, that is computerised. After weighing-in process of the truck, cage or trailer, the PFB are dumped into the inclined hopper at the ramp that will hold 900 mt PFB ( 2 lines of 15 bays x 30 mt PFB ). Modern mills in Malaysia are equipped with the following in the reception area of the mill: A. Load cell ( pitless ) 50 tons weigh bridge of 3.3m W x 15m L and computerised. B. Larger loading ramp with double door hoppers of 30mt capacity per bay. C. FFB Cage and bogie with capacities of 5, 7 and 10 mt of wheel spanned of 800mm gauge. D. FFB loading into cages by conveyor system E.
Straight line railway system with Cage transfer carriage located at both ends of the railtrack system to facilitate easier operation of the 2-door sterilizer and shunting of the cages can be handled easily with the capstan and Bollard.
On opening the hopper door ( 2 doors to a bay ) the bunches drop into the 7mt cages with bogies placed beneath it. The loaded PFB cages are then conveyed by the transfer carriage on the rail track and pushed into the sterilizer, by a winch and ballard system for sterilization.
2.0
Sterilization.
The sterilizer process is done in 5, 7 and today 10 tons capacity FFB cages which are pushed into long cylindrical steel vassel with special doors and subjected to steam at approximately 3 BAR. One of the effects of sterilisation is to inactivate the fruit enzyme. inactivated the rise of the FFA is virtually stopped.
Once this enzyme has been
The objective after harvesting is to sterilize the fruit as quickly as possible with the minimum of handling and damage. In addition to arresting the development of the FFA content, the sterilizing of the fruit also facilitates: a.
The purification of the palm oil by coagulating nitrogenous and mucilaginous matter and thus preventing the formation of emulsions during verification of the crude oil.
OIL PALM MILL SYSTEMS & PROCESS
b.
6
The extraction of the crude palm oil by freeing the fruits from the bunch stalks and by breaking the oil cells in the mesocarp.
Majority of mills today has programmable automatic control systems to cater for proper sterilization of 90-minute cycle. Sterilisation is a simple process but it is essential, for the proper operation of the mill so that it is done correctly. This operation is the largest user of steam in the mill.
A STERILISER STATION WITH SINGLE DOOR STERILISERS
3.0
Stripping.
After the sterilisation the sterilised fruit in 3.5 mt PFB Cages are then winched out of the steriliser vassal by the arrangement of Bollard & winch and then placed in position for the remote control overhead hoist, for the activity of emptying the FFB into the threshing machine which will separate the empty bunches from fruit. Or for larger capacity mill with 5 mt FFB cages and above, into the cage Tippler machine a ring structure for emptying the contents of FFB onto a scraper type conveyor and transported to the thresher machine for stripping of the fruitlets from bunch. The fruit is then conveyed by screw conveyors and bucket elevators to the Pressing or Extraction station. New mills have included in their design bunch crusher and secondary thresher system for recovery of fruitlets of large or poorly sterilised bunches which are difficult to strip.
OIL PALM MILL SYSTEMS & PROCESS
4.0
7
Empty Bunches.
Empty bunches from 25% of the total weight of the ffb. They are then returned to the field as fertilizer after incineration for the recovery of resultant potash, in conventional mills. They have no food value and have a high silica content. When properly incinerated they yield 0.3 to 0.5% of potash. Utilisation of empty bunche for field application as fertiliser supplement is found to be cost effective by some plantation groups and to the others justification of logistics, other constrains or practical experience? seems to be the objection for use of EFB in the field. In recent years a system has been introduced in Malaysia for the Treatment of Empty Bunches which recovers a further 0.25% of the oil on ffb from the empty bunches and at the same time reduces the moisture content to approximately 35% so that they can be used as additional solid waste fuel for steam and power generation, required for other down stream process.
5.0
Oil Extraction.
The efficient extraction of the crude oil from Tenera fruit has presented problems but these have been overcome by the development of the continuous screw press, which is now used in all modern factories. The fruit from the stripper passes to digesters, which complete the breaking of the oil cells with slow moving arms. Digesters have a capacity of above 3 cubic metres.
TYPICAL SIDE VIEW OF THE EXTRACTION STATION
OIL PALM MILL SYSTEMS & PROCESS
8
The fruit mash then passes to the screw presses (capacities of 10–16Mt FFB per hour) which press the crude oil out through holes in the side of the press cage. The ‘press cake’, which is discharged from the end of the press, contains the ‘fibre’ and the ‘nuts’. The three products separated in this section are : a)
The crude oil which consists of water, dirt and palm oil. This is passed to the purification section;
b)
Nuts: 15% of the ffb. Is separated by the depericarper and kernel plant for the recovery of the kernels;
c)
Fibre: Approximately 15% of the ffb weight with moisture content of 37%. The residual oil content should be between 6% and 8% of oil to dry fibre. The fibre should also retain as far as possible the phophatides and other non-glycerides impurities. The fibre separated in the deparicarper winnowing system is conveyed to the boiler as fuel.
The proper design of the extraction section is important. Unsatisfactory practices such as excessive drainage of the crude oil before the extraction press leads not only to purification problems and losses but also to the higher absorption of iron by the palm oil. The importance of reducing the absorption of heavy metal, copper and iron is indicated by the totox value. For the production of superior quality palm oil, stainless steel moving the wearing parts should be used for extraction units (such as the digester and screwpress).
6.0
Kernel Recovery
The conditioning of the nuts starts in the sterilizer and the separation starts in the screw presses. After the screw press the nuts and the fibre traverse a heated breaker conveyor which further separates them and removes moisture from the fibre. The fibre and nuts then pass into a pneumatic separating column, called the “winnowing column” fitted with IC damper in operation, depending on the number of presses in operation. The fibre is blown into a cyclone close to the boiler and the nuts pass down a polishing drum, designed to handle a verity of nuts which removes any attached dirt or fibres and tramp iron.
9
OIL PALM MILL SYSTEMS & PROCESS
A. Press cake to winnowing B. Ejection of Nuts C. Fibre to cyclone D. Removal of dirt & tramp iron
A DEPARICARPER, WINNOWING COLUMN AND POLISHING DRUM STATION FOR FIBRE & NUTS SEPARATION
The nuts are conditioned in nut silos before being cracked in centrifugal nutcrackers or / and in present day Rippler mills. After cracking, the cracked mixture is separated in the double winnowing separating column for dry separating system or separated in hydrocyclones or clay baths. These processes are wet. A modern Hydroclay bath separator is more efficient than a hydrocyclone separator when processing more than 15% Dura material in the cracked mixture. A supply of suitable clay at the rate of approximately 450 kg to 100 tons of ffb is necessary for the clay separator system. Both systems depend upon the density of the shell being greater then the density of the kernels. The higher yield of PK compensates the addition cost of clay or kaolin required for the Hydro-clay bath separator process. The shell and kernels are washed and the kernels are passed to a kernel dryer to normalize the moisture content of 7% so as to minimize the development of FFA during storage and shipment. It is also advantages to sterilizer the kernels before shipment or storage with steam at atmospheric pressure. Kernel plants designed for Dura derived nuts are not suitable for the processing of Tenera derived nuts. There have been a number of experimental designs, which have proved failures. Caution and a wide experience are required in selecting the proper equipment and design for kernel recovery plant.
7.0
Palm Oil Purification
The modern purification or oil classification station is designed to recover and purify the crude oil as quickly as possible with the minimum heating and exposure to air. This is to minimize the damage by oxidation, which is caused by the exposure of crude oil to air at high temperature.
OIL PALM MILL SYSTEMS & PROCESS
10
The process begin at the crude oil tank of the extraction station and ends at oil cooler as finished CPO with dirt contents of 0.009% and moisture contents of 0.09%. The major effluent problem is eliminated by the decanter system, which removes the semi-solid sludge for treatment, by the sludge dryer, which reduces the moisture of the sludge from 45% to 10%. Adequate heat for drying of the sludge is obtained from the boiler exhaust flue gasses. The composition of the dryer decanter cake is shown in Appendix. The major contributor to poor quality oil is oxidation. Oxidation measured by the totox value, starts when the oil is above 60ºC and exposed to air During processing, storage and shipment.
8.0
Steam and Power Generation.
Utilization of existing energy resources is indispensable not only for large industrial processes but also for small production plant and in particular oil palm mills where the balance between heat and power are required for production process which are pre-condition for a “ combined heat and power ( CHP ) scheme.” Or commonly referred to as C0-GENERATION SYSTEM. Solid waste fuel in the form of shell, fibre and empty bunches which are by-products of the process are utilized as fuel for the boiler. Steam is required for processing at the approximate rate of 500kg per hour per ton ffb. This steam can be easily raised in a reasonably efficient water tube boiler with fuel available from the Fibre, shell and empty bunch. Power is required at the approximate rate of 15 to 25 Kw per ton ffb. This can be easily be provided by placing a back-pressure single stage steam turbine between the boiler and the header of the mill processing system. Steam is generated from the boiler at a pressure of say 20 Bar.g and into the steam turbo alternator at 18.5 Bar.g at 260ºC with back pressure of 3.16 Bar.g for the mill process which is convenient and effective for process Heating. The additional power generated in this system is made possible by burning of the empty bunches as shown in the enclosed Fuel /Steam /Power balance and Steam Production from 1 Ton Solid Waste Fuel for a Oil Palm Mill. Every ton of FFB can produce 733 kg steam and 30kw power shown, in the diagram below : A system has been introduced for the treatment and disposal of empty bunches and recovery of palm oil and at the same instance reduces the moisture contents of the empty bunches to approx. 45 % so that they can be used as solid waste fuel for the boiler and production of additional steam and electrical power.
OIL PALM MILL SYSTEMS & PROCESS
11
Every ton of FFB can produce 733 kg steam and 30kw power shown, in the diagram below :
Steam is produced by water tube boilers at pressures and temperatures higher ( 20 bar.g 207 deg. C ) than required for the process. First it is expanded in steam turbines, and then led into the process where the latent heat contained in the exhaust steam ( 3.16 bar.g ) is utilized for sterilisation of FFB and heating systems in the process. The diagram below show a typical CHP scheme of a modern oil palm mill.
The energy released during the expansion of steam is converted by the turbine into mechanical power to drive an alternator.
OIL PALM MILL SYSTEMS & PROCESS
12
There is a direct relationship between the number of palms cultivated and the corresponding harvest yield of a given plantation area processed by the mill, the primary energy available in the by product fuel, and power / heat requirement of the mill A properly design Oil Palm Mill will not only provide sufficient steam and electrical power for its operation requirement but will provide an additional 17 to 33 % more power for other planned integrated down stream processes, domestic use or sold to other consumers of power.
9.0
Effluent Control.
SOURCE OF SOLID WASTE, EFFLUENT & POLLUTION
Effluent discharge quantities in Oil palm mills is dependent on the extent of design of the milling process systems, in -plant process control, equipment maintenance and good house-keeping. The solid waste or by-products in the oil palm milling process, consist of :
• • • • • •
Empty bunches Shell and fibers Decanted solids Sludge centrifuge solids Boiler ash De-sludging of ponds.
Solid waste such as treated empty bunches ( de-water ) of approximately 25% to FFB and recovered dryed sludge of approximately 3% to FFB are by products that will be utilized in the plantation and sold as produces. The shell and fiber are sources of solid waste fuel for co-power generation in the oil palm mill. Waste water from the sterilizer condensate, clarificatio n effluent and hydro-cyclone or claybath discharges are sufficiently contaminated and require treatment. Some of the sources waste water discharged from the steam turbine condensate / cooling system and boiler blow down are relatively clean and can be put to good use in the process such as for the dilution system, screw press, oil gutter spraying and for the factory floor cleaning requirements. The liquid effluent total quantity of 0.6 to 1 mt per ton of FFB between the generating sources being as follows :
• • • •
Sterilizer condensate Calrification station Hydrocyclone / Claybath. Other waste water
13
OIL PALM MILL SYSTEMS & PROCESS
The table below presents the typical physical and chemical properties of raw effluent from Oil palm milling process. PARAMETER
MEAN
pH BOD COD Total Solids Suspended Solids Volatile Solids Ammoniacal Nitrogen Total Nitrogen Oil and Grease
4.1 25,000 53,630 43,635 19,020 36,515 35 770 8,370
* All values except pH are in milligrams per liter ( mg / L) Source : PORIM
The total liquid effluent could well increase if mill process wash water is included. The effluent is not toxic but it has a biochemical oxygen demand of above 25,000 (BOD) which makes it objectionable to fish life when introduced in relatively large quantities in waterways and rivers. The objective is to treat the oil palm mill effluent discharge so as to comply with conditions imposed by the Department of Environment (DOE) for disposal in accordance to standards as follows: Standard A. - For discharge to rivers shall be less than Standard B – For discharge to waterways shall be less than Standard C – For discharge to land & field shall be less than
– BOD 20 mg / l - BOD 50 mg / l - BOD 500 mg / l
A system to treat affluent by ponding or “ Oxidation ponds” is commonly adopted in Malaysia. The system of Anaerobic and Aerobic process in general conform to regulations which require a sizeable area of 65 to 75 days retention time for the ponds, proper monitoring, cost for power for circulation pumps and aerators, de-sludging of ponds, maintenance and supervision but at times are unstable as a result of a reduction of ponding volume due to silting with sludge, weather conditions and by contamination. Many systems are being tried but no generally accepted system has yet emerged. The systems tried including centrifuges, fitters, sun bed drying, air flotation / coagulation and mechanical extended aeration plants. Some pilot systems include Methane production units and “Effluent free system” or Zero discharge by means of a multi-Stage condensing unit and Thermal Oxidation plant to produce dry sludge in the finish product as POME which is sold as fertiliser and filler for animal feed. The search for new designs and systems continues…….. q q q
Oil Palm Mill Schematic Process Flow Oil Palm Process Matrix Process Mass flow and losses during Production
Noel Wambeck / October. 1997 / Revised June 23, 1999.
ALTERNATIVE CAGE TIPPLER SYSTEM
EMPTY BUNCH DISPOSAL BY INCINERATION FIELD APPLICATION OR OIL RECOVERY
DECANTER FOR SOLIDS REMOVAL
CRUDE PALM OIL 0.09% moist. 0.009% dirt.
DRY KERNEL 7% moisture 4.6% dirt.
Designed by Noel Wambeck - 25th. July 1992
05b. Matrix OPM Process.xls
MATRIX OIL PALM MILL PROCESS. POINT
BASED ON MALAYSIA TENERA MATERIAL WITH 25% OIL CONTENT
Mill Capacity: mt FFB / Hr >
SAMPLE AT POINT % / FFB
OIL
WATER
SOLID
OTHER
3
5
10
20
30
45
60
90
120
1,000
3,000
5,000
10,000
20,000
30,000
45,000
60,000
90,000
120,000
A
Fresh fruit bunches
100
25
48.5
26.5
B B1 B2
Empty bunches Liquid from EB Press Potash ( Bunch ash )
25 8.3 0.5
0.75 0.249
18 7.387
6.25 0.664
0 0 0.5
250 83 5
750 249 15
1,250 415 25
2,500 830 50
5,000 1,660 100
7,500 2,490 150
11,250 3,735 225
15,000 4,980 300
22,500 7,470 450
30,000 9,960 600
C C1
Fruitlets on bunch Fruitlets in Empty bunch loss
66 2
24.25 0.735
37 1.121
7 0.212
0 0
660 20
1,980 60
3,300 100
6,600 200
13,200 400
19,800 600
29,700 900
39,600 1,200
59,400 1,800
79,200 2,400
D D1 D2
Digested mash Press Cake Extraction CPO & water ex-press
64 26 38
23.52 1.56 21.96
35.88 10.9 15.2
6.79 14.0 0.84
0 0 0
640 260 380
1,920 780 1,140
3,200 1,300 1,900
6,400 2,600 3,800
12,800 5,200 7,600
19,200 7,800 11,400
28,800 11,700 17,100
38,400 15,600 22,800
57,600 23,400 34,200
76,800 31,200 45,600
E E1 E2
Wet Fibre & Nuts to depericarper Wet Fibre to boiler Wet Nut Ex- winnowing
25.75 12.0 13.75
1.55 1.08 0.47
10.82 3.60 0.76
13.39 6.48 12.53
0 0 0
257 120 137
771 360 411
1,285 600 685
2,570 1,200 1,370
5,140 2,400 2,740
7,710 3,600 4,110
11,565 5,400 6,165
15,420 7,200 8,220
23,130 10,800 12,330
30,840 14,400 16,440
F F1 F2 F3 F4
Cracked Mixture Kernel Shell Water for Hydrocyclone Clay for Claybath system
G G1 G2
Crude oil diluated with water Clarified crude oil to Purifier Sludge to Separator
53.2 25.00 42.31
21.96 21.96 21.74
30.4 2.20 19.81
H H1
Clean oil to Oil dryer Clean & dry CPO to stoarge tank
23.91 21.52
21.74 21.50
2.17 0.01
J J1 J2 J3
Raw water Boiler feed water Precess water Domestic water
1000 700 120 180
K K1 K2 K3 K4
Solid waste fuel to boiler ( 30% moist.) Fibre Shell Light particals De-oiled empty bunches
43 12 8 0.5 22.5
L L1 L2 L3
Boiler steam generation ( kg / ton FFB ) Turbine steam requirement Sterilisation steam requirement Process heating steam requirement
660 600 540 120
660kg 600kg 540 kg 120 kg
M M1 M2 M3 M4 M5
Wast water Effluent ( kg / ton FFB ) From Clarification From Steriliser condensate From PK recovery plant Boiler blow down From OTHERS & cleaning
1000 550 150 80 120 100
1000kg
N N1 N2 N3
Power generation ( kw / ton FFB / hr ) Process Mill lighting & grounds Domestic
Perunding AME / POMProMatrix / 16th November 1998 /nw.
12.5 5.5 7 80 5
25 20 2 3
kg
1 Weight in kg.
0 0 0 0
125 55 70 80 5
375 165 210 240 15
625 275 350 400 25
1,250 550 700 800 50
2,500 1,100 1,400 1,600 100
3,750 1,650 2,100 2,400 150
5,625 2,475 3,150 3,600 225
7,500 3,300 4,200 4,800 300
11,250 4,950 6,300 7,200 450
15,000 6,600 8,400 9,600 600
0.84 0.84 0.8
0 0 0
532 250 423
1,596 750 1,269
2,660 1,250 2,115
5,320 2,500 4,230
10,640 5,000 8,460
15,960 7,500 12,690
23,940 11,250 19,035
31,920 15,000 25,380
47,880 22,500 38,070
63,840 30,000 50,760
0.009
0 0
239 215
717 645
1,195 1,075
2,390 2,150
4,780 4,300
7,170 6,450
10,755 9,675
14,340 12,900
21,510 19,350
28,680 25,800
1,000 700 120 180
3,000 2,100 360 540
5,000 3,500 600 900
10,000 7,000 1,200 1,800
20,000 14,000 2,400 3,600
30,000 21,000 3,600 5,400
45,000 31,500 5,400 8,100
60,000 42,000 7,200 10,800
90,000 63,000 10,800 16,200
120,000 84,000 14,400 21,600
430 120 80 5 225
1,290 360 240 15 675
2,150 600 400 25 1,125
4,300 1,200 800 50 2,250
8,600 2,400 1,600 100 4,500
12,900 3,600 2,400 150 6,750
19,350 5,400 3,600 225 10,125
25,800 7,200 4,800 300 13,500
38,700 10,800 7,200 450 20,250
51,600 14,400 9,600 600 27,000
660 600 540 120
1,980 1,800 1,620 360
3,300 3,000 2,700 600
6,600 6,000 5,400 1,200
13,200 12,000 10,800 2,400
19,800 18,000 16,200 3,600
29,700 27,000 24,300 5,400
39,600 36,000 32,400 7,200
59,400 54,000 48,600 10,800
79,200 72,000 64,800 14,400
1,000 550 150 80 120 100
3,000 1,650 450 240 360 300
5,000 2,750 750 400 600 500
10,000 5,500 1,500 800 1,200 1,000
20,000 11,000 3,000 1,600 2,400 2,000
30,000 16,500 4,500 2,400 3,600 3,000
45,000 24,750 6,750 3,600 5,400 4,500
60,000 33,000 9,000 4,800 7,200 6,000
90,000 49,500 13,500 7,200 10,800 9,000
120,000 66,000 18,000 9,600 14,400 12,000
25 20 2 3
75 60 6 9
125 100 10 15
250 200 20 30
500 400 40 60
750 600 60 90
1,125 900 90 135
1,500 1,200 120 180
2,250 1,800 180 270
3,000 2,400 240 360
80kg 5kg
1000kg 700 kg 120kg 180kg 0.01 0.016 0.008 0.0005 0.008
12.9 3.6 1.2 0.025 6.75
kg kg kg kg 30.09 8.384 6.792 0.4745 15.742
kg kg kg kg kg KW KW KW KW
5/10/00
PROCESS MASS FLOW AND LOSSES DURING PRODUCTION Based on Tenera material Oil content FFA
FFB input in kg STERILISER 100 kg
Out Flow 12.3
STRIPPING 87.7 kg
25
EXTRACTION 62.7 kg
31.14 31.56
24% 2.5% max
LOSS
kg
kg
Evaporation Oil Loss
12 0.3
Empty bunches Oil Loss
24.5 0.5
Solids Liquids
6.56 2
Oil Loss Oil
16.19
KERNEL RECOVERY 14.95 kg NUTS 5.4
TOTAL in kg CPO Yield
WASTE
kg
Water Non-oily solids
OIL CLARIFICATION 31.56 kg
DEPERICARPER 31.14 kg
PRODUCT
0.75 22.25
Evaporation Oil Loss Fibre Kernel Loss
3.84
Evaporation Oil Loss Kernel Loss Shell Kernel
1.7
0.1 12 0.25
0.1 0.15 8 5
100 22.25
27.25
70.6
2.15
92.7%
Total OIL loss in kg
1.75
92.6%
Total kernel loss in kg
0.4
( Including FFA as Oil )
Palm Kernel Yield
QUALITY
Noel Wambeck Feb.1999
5
Moisture % Dirt % FFA %
0.09 0.009 3.5
Moisture % Dirt % FFA %
7 5 2.5
Empt y b unch Incinera tor for Oil Palm Mill ( c ap : 6,000 kg / hr )
TYPICAL FLOW DIAGRAM OF AN EFFLUENT TREATMENT PONDING SYSTEM FOR A 30 MT FFB PER HOUR OIL PALM MILL.
FAT PIT EFFLUENT OIL RECOVERY STATION WASTE WATER FROM : Steriliser Condensate, Clarification Station Kernel recovery station and wash water
Cooling Pond No 1 12 x 15 x 2.5
RAW EFFLUENT INPUT 432 m3 /day BOD 25,000 ppm.
302 m3 each Pond 1 day HRT
Cooling Pond No 2
Recycle Activated Sludge
Acidification Pond No.1 12 x 15 x 2.5
302 m3 each Pond 1 day HRT
Anaerobic Pond No.1 16 x 160 x 6
( 100%) 18m3 per hour
Acidification Pond No.2
Anaerobic Pond No.2 6629 m3 each Pond 61days HRT
Anaerobic Pond No.3
Anaerobic Pond No.4
RECYCLE PIPE LINE
RECYCLE PUMP
Facultative Pond 932m3 2 days HRT 16 x 30 x 2.5
Aerobic Pond No.1 16 x 80 x 2.5
2,611 m3 each 12 days HRT
Aerobic Pond No.2
Pipeline / Tanker
FINAL DISCHARGE TO PLANTATION FLOW RATE OF > 432 m3 / Day BOD REDUCTION = 99.6 % > LESS THAN 100 PPM BOD
Perunding AME/ ETP Flow Diagram
05g. MatrixPOMEffluent.xls
MATRIX OF AN OIL PALM MILL PROCESS & WASTE WATER EFFLUENT PONDING SYSTEM. Item
Details
1
Milling capacity
MT FFB / hr
2
Effluent Generation Rate a. FFB moisture b. Sterilizer condensiate c. Clarification station d. Kernel Plant e. Other & washwater Total per hour in kg.
kg kg kg kg kg kg
200 140 600 150 110 1,000
6,000 4,200 18,000 4,500 3,300 30,000
9,000 6,300 27,000 6,750 4,950 45,000
12,000 8,400 36,000 9,000 6,600 60,000
18,000 12,600 54,000 13,500 9,900 90,000
24,000 16,800 72,000 18,000 13,200 120,000
Flow rate of Effluent Per Hour Per Day ( 24 hours ) HRT of 75 days
m3 m3 m3
1 24 1,800
30 720 54,000
45 1,080 81,000
60 1,440 108,000
90 2,160 162,000
120 2,880 216,000
Suspended Solids at Fat / Sludge pit ( 22,000 mg/L ) at Final discharge ( 200 mg/L ) Rate of aerobic Biosolids produced
kg kg kg
39.6 0.36 39.24
1188 10.80 1177.2
1782 16.20 1765.8
2376 21.60 2354.4
3564 32.40 3531.6
4752 43.20 4708.8
5
Organic loading Rate ( 0.3 kg BOD/m3/Day )
kg
7.2
216
324
432
648
864
6
Rate of Re-circulation of Anaerobic effluent Anaerobic - HRT 5 days return to seeding pond ( 50 % ) Pump size number of pumpsets
m3 m3 / hr KW unit
120 0.5 0.33 1
3600 15 3 1
5400 22.5 4.5 1
7200 30 6 1
10800 45 9 1
14400 60 12 1
BOD of Effluent at Sludge pit - 25,000 mg / L at Anaerobic pond discharge - 5,000 mg /L at Aeration pond discharge - 50 mg /L at Stabilisation pond discharge - 20 mg / L
kg kg kg kg
4.5 0.90 0.009 0.0036
135 27.00 0.27 0.108
202.5 40.50 0.405 0.162
270 54.00 0.54 0.216
405 81.00 0.81 0.324
540 108.00 1.08 0.432
Aeration pumpsets Flow rate Drive motor Number required
m3 / hr at TDH 20 kw units
2
45 5.625
67.5 8.4375
90 11.25
135 16.875
180 22.5
3
4
7
8
1
30
1 x 7.5
45
2 x 5.5
60
2 x 7.5
90
2 x 10
120
4 x 5.5
PERUNDING AME – Consulting Engineers
1
AN ENVIRONMENTAL CONTROL PLAN (ECP) By Noel Wambeck April 1999.
FOR THE PROPOSED OIL PALM MILL WITH AN INTEGRATED EFFLUENT TREATMENT AND DISPOSAL SYSTEM, AIR POLLUTION AND SOLID WASTE DISPOSAL SYSTEM.
01. INTRODUCTION. The proposed Environmental Control Plan (ECP) will exploit every practical avenue to provide a complete effective system for Effluent treatment, solid waste disposal, air pollution control and minimising of the environmental impact, to the requirements and expectations of DOE, local authorities and inhabitant indemnity. The Department of Environment has set a target for Oil palm mills to achieve 100 percent compliance by the year 2000 in terms of meeting emission and effluent discharge standards, which are :
• Environmental Quality ( Licensing ) regulations 1977. • Environmental Quality ( Prescribed Premises) (Crude Palm Oil ) Regulations 1977 (Amendment) 1982.
• Environmental Quality ( Clean Air ) Regulations 1978. The overall objective of this project report is to determine and advise the client on the following : 1
Proposed project needs in terms of design, cost, capacity, manpower requirements and project schedule.
2
Selection of the Oil Palm Mill complex location.
3
Provide detail design and specification, supervision, commissioning, training of personnel and guarantee performance for the proposed project.
4
Care in the implementation of the project, and not to endanger the environment by providing the proper process, system and method for the treatment of effluent for 100 % land application, solid waste disposal and the control of noise and air pollution.
PERUNDING AME – Consulting Engineers
2
02. PROJECT SALIENT DATA. The following salient data is used in the design calculations:2.1
Milling capacity ( MT / FFB per hour. )
:
30 mt per hour 720 mt FFB per day
2.2
Amount of Empty Bunches for disposal (mt / hr.) Based on the ratio of 25% Empty bunches to FFB
:
7. 5 mt per hour 180 mt per day
Empty bunch decomposing period Area required for mulching ( 2333m3 / Ha )
: :
90 days 26 Ha
2.3
Ratio of raw effluent (POME) to FFB
:
60 %
2.4
B.O.D. level of raw effluent (POME)
:
25,000 mg/l
2.5
Processing hours – based on peak operation
:
24 hours.
2.6
Average flow rate of effluent (POME )
:
18 m3 / hr or 432 m3 / day
2.7
Effluent ( waste water ) treatment system : 1 No. Sterilizer condensate oil recovery tank 1 No. Sludge oil recovery tank 2 Nos Fat pits : 20m3 volume 2 Nos Cooling Ponds : 256m3 each 1 No. Mixing Pond 461m3 3 Nos Digesting Tanks : 3720m3 each 4 Nos Aeration reactor : 2000m3 each 1 No. Sludge drying bed : 6 x 30 m 1 No. Sludge Clarifier : 225.6.m3 1 No. Treated effluent holding tank
: : : : : : : : :
120 m3 120 m3 40 m3 461m3 / hr HRT 2.13 days 461m3/ hr HRT 1.07 days 11,160 m3 HRT 25.8 days 8000 m3 HRT 4 days 180 m2 225.6m3 HRT 12.5 hr
B.O.D. level of Final discharge Total BOD reduction 2.10 Proposed site area
:
< 20 mg/l 99.9 %
: :
122 ha
Area allocated for Oil palm mill complex
:
12 ha
Percolation Rate of liquid Effluent on proposed land
:
560m3 / day / ha
Area allocated for field / Land disposal of final effluent : in trenches / furrows ( based on 90 days cycle )
69 ha
2.11 Boiler Gas Volume
:
30 m3/ s
2.13 Dust load
:
4000mg/ NM3 max.
2.14 Boiler Air Emission
:
< 0.4g / NM3
PERUNDING AME – Consulting Engineers
3
03. SOURCE OF SOLID WASTE, EFFLUENT & POLLUTION Effluent discharge quantities in Oil palm mills is dependent on the extent of design of the milling process systems, in -plant process control, equipment maintenance and good house-keeping. The solid waste or by-products in the oil palm milling process, consist of :
• • • • • •
Empty bunches Shell and fibers Decanted solids Sludge centrifuge solids Boiler ash De-sludging of ponds.
Solid waste such as treated empty bunches ( de-water ) of approximately 25% to FFB and recovered dryed sludge of approximately 3% to FFB are by products that will be utilized in the plantation and sold as produces. The shell and fiber are sources of solid waste fuel for co-power generation in the oil palm mill. Waste water from the sterilizer condensate, clarification effluent and hydro-cyclone or claybath discharges are sufficiently contaminated and require treatment. Some of the sources waste water discharged from the steam turbine condensate / cooling system and boiler blow down are relatively clean and can be put to good use in the process suc h as for the dilution system, screw press, oil gutter spraying and for the factory floor cleaning requirements. The liquid effluent total quantity of 0.6 m≥ to 1m≥ per ton of FFB between the generating sources being as follows :
• • • •
Sterilizer condensate Calrification station Hydrocyclone / Claybath. Other waste water
The table below presents the typical physical and chemical properties of raw effluent from Oil palm milling process. PARAMETER
MEAN
pH BOD COD Total Solids Suspended Solids Volatile Solids Ammoniacal Nitrogen Total Nitrogen Oil and Grease
4.1 25,000 53,630 43,635 19,020 36,515 35 770 8,370
* All values except pH are in milligrams per liter ( mg / L) Source : PORIM
PERUNDING AME – Consulting Engineers
4
04. POLLUTION CONTROL SYSTEM. The proposed Pollution control and treatment systems are : 4.1 THE DISPOSAL OF EMPTY BUNCH. 4.2 THE PROCESS OF THE INTEGRATED DECANTER – DRIER SYSTEM 4.3 THE ANAEROBIC & AEROBIC EFFLUENT TREATMENT SYSTEM. 4.4 DISPOSAL OF TREATED EFFLUENT FOR LAND APPLICATION. 4.5 CONTROL OF AIR EMISSIONS.
The brief process description of the above systems are as follows:
4.1 THE DISPOSAL OF EMPTY BUNCH. Empty bunch a solid waste product of the Oil Palm Milling process has a high moisture content of approximately 55 – 65% and high in silica content , form 25% of the total weight of Palm Fruit Bunch. The treated Empty bunch are mechanically crushed ( de-watered and de-oiled ) in the process but are rich in major nutrients and contain reasonable amounts of trace elements. They have a value when returned to the field as mulch for the enrichment of soil. The use of empty bunch for field application as mulching material is preferred by the client, therefore we shall confine to this method of disposal of empty bunch for the proposed oil palm plantation. The land application .mulching system is said to have a cost savings of RM 250 per ha annually in place of fertiliser supplement. In Perak state, several estates have this system of land application of empty bunch mulching, including Seri Pelangi, Nova Scotia, Jendarata Estate, since 1973 on a commercial scale. Other mills that used the same method of disposal are; Ulu Basir, UIE, Southern Perak, Changkat Chermin, Topaz Emas, Foong Lee etc To do this, adequate hopper and conveyor system will be provided at the oil palm mill site for storage and an arrangement of tractor & trailer with a capacity of 5 -10 mt EFB shall be deployed for the transportation of the treated empty bunches ( de-watered ) to the field for disposal. On arrival at the estate, the train of two or more trailers are parked on the road adjacent to the inter row to be mulched and with the aid of the extended draw-bar, the trailers are unhitched one from the other. The trailers are towed one at a time into the inter rows and tipped while slowly moving forward. The empty trailers are then hitched back one to the other by lifting with the tractor draw-bar and pins put into position, they than return to the mill to repeat the process.
PERUNDING AME – Consulting Engineers
5
The drainage pattern in most fields is four palm rows to a drain, to ensure that all palms benefit from mulching, the empty bunches are applied in the avenue between row 2 and 3, and between palm points in the two outer drain side rows ( see the diagram of the Placement of empty bunches in the appendix.) In the latter, the side-tipping trailers are particularly useful. Manual labour is used to make minor improvements where leveling may be required. The rate of application ranges between 75 to 100 tons empty bunches per hectare.
In conclusion, bunch mulching of oil palms on a commercial scale is recommended as a viable proposition in plantation where the terrain and ground conditions allow mechanisation of the operation.
4.2 THE PROCESS OF THE INTEGRATED DECANTER – DRIER SYSTEM ( FOR THE PRODUCTION OF SOLID WASTE SLUDGE ( POME ) AS ANIMAL FEED OR FERTILISER. )
The Decanter – Drier integrated system reduces the volume and handling of oil palm mill effluent discharge of about 75% of the total BOD load discharge from the mill. The system also provide a means of a dust collecting system for the boiler flue gas with the advantage of being able to produce an added value by product of dried sludge ( POME ) for animal feed or fertiliser, resulting in better returns on investment of the project. The source of solid waste effluent are : 1. 2. 3. 4. 5. 6.
Decanter solids Steriliser condensate sludge Clarification station sludge Boiler ash De-sludging of the effluent treatment system De-sludging of all process tanks
The use of the Decanter in the oil clarification station for the removal of solid matter, reduces the load on the separator and static clarification settling tank by about 50 – 75% while there is not change in the load on the other machinery of the clarification station process. Process dried sludge has certain properties:
• • •
Releases nutrients slowly It supplies trace elements And it improves water retention.
The system proposed has been developed and in operation over 20 years at United Plantations Mills, Keck Seng and several other mills in Malaysia and Indonesia.
PERUNDING AME – Consulting Engineers
6
The proposed system details are as follows : A. Multi cyclone separator. The multi cyclone will remove coarse sand and other solid matters with a particle size of more than 50 microns or about 50% of the solid matter from the crude oil. B. The Decanter system. The decanter will remove approximately 90% of all suspended solids from the crude oil. C. Rotary Drum drier. Solid sludge is conveyed by the screw conveyor and fed to the Rotary Drum Drier located close to the boiler house for heating by the Boiler flue gas. The rotary drum drier in which the flue gas from the boiler, is in direct contact with the wet solids discharged from the decanter, multi cyclone and oil pit – effluent recovery system. Flow of the flue gas and solids is con-current. The flue gas is tapped from the chimney above the boiler fan. The ducting size would be the same size of the chimney and the portion of the chimney above the ducting is closed with a damper for flue gas control. The diamension of the rotary drum drier is 2 meter in diameter and about 15 meter in length. D. Dried sludge clarification screen. The dried sludge material with a moisture content of 10% is discharged at the end of the rotary drum drier and conveyed by a screw conveyor and fed to the vibrating screen. A circular vibrating screen will screen the dust and sludge grains before the mixing and packing in polybags for storage as the finished product and sold to buyer. The product POME ( Palm Oil Mill Effluent Dried sludge ) The best prospects for POME as an animal feed because of its ability to substitute some of the expensive imported components of feed meals and as a fertiliser, POME is a good source of major and minor nutrients. Commercial value of POME fertiliser is about RM 500 per ton and sold to plantations, flower gardens, golf club application to turf etc. A comprehensive analysis of dried sludge is given in the table below:
Moisture Ash Silica Ether extract Crude Fibre Crude Protein
% 5 – 15 15 – 22 7 – 10 11 – 13 11 – 14 11 – 13
N P K Mg Ca
% 1.8 – 2.3 0.3 – 0.4 2.5 – 3.2 0.6 – 0.8 0.6 – 0.8
B Cu Fe Mn Zn
p.p.m. 20 20 – 50 3000-5000 50 – 70 20 – 100
PERUNDING AME – Consulting Engineers
7
In conclusion, we can say that dried sludge or POME improves the water availability, carbon and nitrogen content, a provider for microbial activities in soil and a useful source of plant nutrients for crops grown on normal or degraded land. An added attraction of the system that is of growing importance, is the reduction in air pollution brought about by scrubbing of the boiler flue gas in the drier and finally its yields an income as waste by-product.
4.3 THE ANAEROBIC & AEROBIC EFFLUENT TREATMENT SYSTEM. The effluent is not toxic but it has a biochemical oxygen demand of above 25,000 (BOD) which makes it objectionable to fish life when introduced in relatively large quantities in waterways and rivers. The effluent treatment system developed for use in this project shall be of a modern biological system, characterised by the anaerobic and aerobic process phases. The total effluent from the proposed Oil palm mill process is approximately 0.6 tons per ton ffb. which is made up of : 1. 2. 3. 4. 5.
Sterilizer condensate Classification station dicharge of effluent Hydrocyclone / Claybath waste water Boiler blow down. Wash water, make up the balance.
The proposed Anaerobic & Aerobic effluent treatment system, shall be located within the oil palm mill complex, that will require an area of approximately 100 m x 100m ( 1 ha ) and will consist of :
• • • • • • • • • • • • •
Sterilizer and Sludge oil recovery tank Fat trap pits Compressed air flotation unit. Cooling & Mixing tanks Anaerobic digesting tanks Aeration reactors Solids removal clarifer Effluent metering. Drying bed. Final effluent holding tank Monitoring & control system Pumps and Air compressor Inter-connecting piping, valves and fittings.
A schematic flow diagram and system calculations are enclosed in the appendix.
PERUNDING AME – Consulting Engineers
8
The system will be monitored on site for pH, volatile fatty acids (VFA), total alkalinity (TA) and solids contents whereas the more complex tests for BOD, COD, ammoniacal nitrogen (AN) and total organic nitrogen (TKN) analysis will be sent out to reputable laboratory for samples test. The proposed effluent treatment system shall be procured from experience environmental control equipment and system vendor who will guarantee its performance. Full advantage is to be made of the “ decanter “ and the “ decanter solids “ dryer, design to dry all of the wet solid sludge removed from the system. To this end part of the sludge outlet water is to be used at the screwpress, in place of the existing dilution water, to assist the transport of the crude oil to the clarification plant.
THE PROCESS The effluent treatment system will include two main parts, the anaerobic section and aerobic stabilisation process before the final discharge of treated palm oil mill effluent onto the plantation for palm tree irrigation. The condensate discharge from the sterilizers is pumped to the post static clarifier an oil recovery system tank. The oil skimmers removes the highly contaminated oil from both the clarifier and sludge decanter tank which is isolated in a special drumming holding tank. The sludge will than pass through a CAF unit for the removal of disolved oils, grease by flotation process etc,… before being fed to the cooling pond. Every precaution is to be taken to ensure that this oil cannot and does not contaminate the crude oil system. The objective is to reduce the loading of the effluent treatment system by the removal of the oil and solid matter in sterilizer condensate at an early stage. The deoiled sterilizer condensate is then discharged in to its own isolated effluent collection pit And overflow to the effluent treatment sys tem. The sludge slurry which are drained from the static clarifier and sludge decanter tank are discharged to the drying bed or conveyed to the rotary sludge dryer for the drying process. The anaerobic phase is favoured by higher temperature and the absence of air. The influent from the sterilizer sludge pit and the clarification pit is to be pumped to the cooling pond and than to the mixing pond. The anaerobic process start to take place in the first pond and end at the digester tanks. There the complex organic materials are first solubilized by the extra cellular enzymes and then converted to volatile acids by acid producing bacteria.
PERUNDING AME – Consulting Engineers
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In the last methane fermentation phase the volatile acids are transformed to methane and carbon dioxide. The process is to be accelerated by the circulation of the bacteria laden sludge into the mixing pond of the material from the last digester tank. The acidification process will have an HRT of 1 day. Effluent from the mixing pond is pumped from the collecting sump and into the digesters with a total HRT of more than 20 days. The discharge from the overflow of the final anaerobic tank is to be discharge into an open pit and pumped into the aerobic reactor tanks for the extended aeration process equipped with over powered mechanical aerators. The overflow of the aerobic reactor tank, operating in tandem with a total HRT of 4 days will be pumped to the clarifier tank for the removal of solids. The sludge scum is to be held back and removed from the ample sized “sludge clarification tank”. Sludge accumulated at the bottom of the clarifier, and drying bed, are to be removed by the auto programmed system provided for the sludge removal process. The separated sludge cake can be dried in rotary dryer and used as plant nutrient in compound form as a by product. The treated effluent is now pumped to the final effluent holding tank. A finish effluent holding tank will hold the effluent waste water with a BOD of 20 ppm for displacement into furrows in the plantation disposal area. The system is to be stable and is to be capable of with standing reasonable shock loads. The efficiency of the system is facilitated by a monitoring and programmable control system design which requires only simple maintenance and operational skills.
4.4 DISPOSAL OF TREATED EFFLUENT FOR LAND APPLICATION. The recycling of POME in plantations is now widely accepted as an economically viable and environmentally acceptable waste management technique. Treated Effluent are pumped or discharged by gravity to the pre-selected area as a good source of plant nutrients and a value added ( RM 350 per ha / year ) cost effective organic fertilizer. The disposal of treated effluent for land application require an area of approximately 69 hectares in the plantation, have been marked in the vicinity of the proposed oil palm mill to receive the effluent in loaded furrows. A typical furrow layout is shown in the report drawing section. Field drains on the sides of each plot which act as trenches to prevent poaching.
PERUNDING AME – Consulting Engineers
10
a. Methods of Land Application. The percolation through furrows or trenches method will be used in the land application of treated effluent of approximately 560m3 / day / ha for the given volume at an application cycle of mor e than 90 days, based on experience. b.
Factors for consideration.
The following factors effect the rate of application. • Soil characteristics such as porosity, water table, acidity of soil; • Characteristics of effluent, such as concentration of large solids; • Age of oil palms; • Vegetation in between the oil palms; Over application of the effluent must be avoided which may result in anaerobic conditions in the soil by formation of an impervious coat of organic matter on the soil surface. c.
The percolation through furrows or trenches system.
Waste Water Effluent is pumped or discharged by gravity to the high points of the pre-selected area and allowed to drain down the slopes in furrows or trenches shown in the appendix “ Typical Furrow layout”. The velocity of flow is given as a steady infiltration rate of 7 – 11 cm per hour, slow enough to enable percolation into the soil and also it prevents erosion. An area of approximately 110 hectares have been marked and allocated in the vicinity of the proposed oil palm mill, shown in the “ Soil suitability for land application of Palm Oil Mill Effluent Survey Report” enclosed. The furrows or trenches are about 90 cm / 60 width x 75 cm depth shown in the appendix and survey report. Field drains of each plot, which act as pits to prevent poaching and used as silt traps to contain sediments transported by surface erosion.
d. Effects of land application. Yields of oil palm increases with the use of oil palm mill effluent. The optimum rate of application is approximately 40 cm rainfall per year. The nutrient value of the soil also shows improvements with land application, especially the nitrogen, phosphorus, potassium and magnesium values. The effect on underground water and surface drainage, are negligible.
PERUNDING AME – Consulting Engineers
11
4.5 CONTROL OF AIR EMISSIONS. The Environmental quality ( clean air ) regulation 1978 stipulate the permitted level of solids concentration in gases emitted from solid waste thermal plants to be not more than 0.4 g per cubit meter. Air emissions from oil palm mills are from the boilers and incinerators, being mainly gases with particulates such as tar and soot droplets of 20 – 100 microns and a dust load of about 3000 to 4000 mg. / NM3. Incomplete combustion of the boiler and incinerator produces dark smoke resulting from burning of a mixture of solid waste fuel such as shell, fibre and some times empty bunches. A good design and properly rated boiler capacity with a closed loop control over the fuel feed rate and air supply will ensure steady state combustion in tandem with steam demand. The introduction of the proposed system will alter the situation whereby the thermal plant such as the waste fuel boiler shall emit clean smoke in accordance to the DOE standard requirements.
The scrubber system. Flue gas from the boiler furnace with a temperature of approximately 288 deg. C flow through the ducting to the scrubber. Water is sprayed from the top of the scrubber, through a manifold and then mixed with the flue gas and dust particles where the proc ess of separation of the particles, gas and water droplets take placed. The spray water of 10 m3 per hour used in this system are from the steam turbine cooling system and heat exchange steam condensiate waste water. The cooled clean gas is conveyed by the ID fan that blows the exhausted gas to the chimney Slurry from the separator is collected in a seal tank via a trap sump and pump to the effluent treatment plant. The scrubber system consist of :
• • • • • •
Scrubber unit Fan Moisture separator Pump Inter-connecting piping, valves, fittings and duct works. Control , Instrumentation & wiring.
The above system vendor guarantee an emission at the chimney outlet of less than 400 mg./ NM3 and in accordance to the DOE allowed standard.
PERUNDING AME – Consulting Engineers
12
5.0 PROJECT COST. The project cost of establishing the proposed mill with a capacity of 30 mt FFB per hour is estimated at the total cost of approximately RM 30 million. This amount is made up of RM 25.6 million for the conventional oil palm mill and the additional investment of RM 4.4 million or 17.19% more for the systems required for the proposed Environmental Control Plan. The expenditure is spread over the mill constructional period of two years. The summary of the above costs are as follows : PACKAGE DETAILS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
INVESTMENT
PRELIMINARIES SITE FACILITIES EARTH WORKS QUARTERS BUILDING WORKS RAW WATER SUPPLY AND TREATMENT CIVIL & STRUCTURE WORKS MECHANICAL & PI STORAGE TANK FARM ELECTRICAL WORKS EFFLUENT TREATMENT PLANT
330,000 270,000 1,400,000 2,800,000 800,000 7,500,000 10,500,000 600,000 1,400,000
25,600,000 TOTAL PROJECT COST in RM
ADDITIONAL
400,000
1,700,000 300,000 2,000,000
4,400,000
30,000,000
Additional Investment for ECP in % is approximately : 17.19 %
Preliminary estimates can vary extensively depending on terrain, type of soil, accessibility, selection of quality of equipment and design factors applied. The above estimate have taken into consideration of the following : a). Best applied technology, innovation and development for a modern oil palm mill. b). Proven design of machinery, systems and plant layouts.
c) The site for locating the proposed oil palm mill has been selected on the basis of substantial cost savings in transportation, as being one of the factors for its selection. “ Our aim is to help shape our common future and to save us from being submerged in sludge.” April 1999 Noel Wambeck
POTENTIAL HAZARDS AND CONTROL PLAN.
The potential hazards which could affect the public water supply and the proposed control plan in place, are as follows :
POTENTIAL HAZARDS.
CONTROL PLAN.
1.
Process wastewater
1.
Runs into process drains, fat pit collecting sump, effluent oil recovery and solid removal system before discharge to effluent pond system.
2.
System failure of mill during operation
2.
Shut down of operation for major problems or effect repairs immediately of equipment and plant for minor repairs, all runoffs into process drains.
3.
Wash water contaminated with oil.
3.
Runs into process drains, the Fat pit collecting sumps and effluent treatment.
4.
Oil tanks leakage, spillage during loading into oil Tankers.
4.
Runs into process drains and into collecting sump for recycling back to process.
5.
Fuel tanks spillage during unloading and pipe line Leakage
5.
Contained in bund storage area.
6.
Lubrication oils & Chemicals spillage
6.
Contained in bund storage area
7.
Boiler blow down waste water
7.
Runs into dedicated process drains
8.
Rain water flooding.
8.
Runs into dedicated storm drains.
9.
Oils and sludge in the sump
9.
Oil is skimmed and pumped into drums for sale, whereas the treated sludge and sterilizer condensate waste water will be treated in the effluent treatment system and than discharged of the effluent to the plantation with BOD of 20 ppm.
Fat pit collecting sumps. Ex- Oil room waste water, Sterilizer condensate water, Hydrocyclone / Claybath and wash water.
Perunding AME / 22 nd. February 1999.
OIL PALM MILL ENVIRONMENT CONTROL PLAN ( EPC System ) WASTE MATERIAL
REDUCTION Present system CONDENSATE SLUDGE TANK
STERILISER CONDENSATE
STATIC SEPARATION OIL RECOVERY
Liquid phase to Effluent ponds
CLARIFICATION STATION WASTE WATER
DECANTERED SLUDGE
EMPTY BUNCH FROM THRESHING STATION
INCINERATOR
Liquid phase to CAA system
STORAGE HOPPERS DEWATERING PROCESS
MULTI CYCLONE DUST SEPARATOR
WATER TUBE BOILER Subject to shock loads / unstable combustion
Discharge of air polluting dust to atmosphere
FINAL TREATMENT & DISPOSAL
CONTROL Anaerobic & Aerobic (CAA)system
TREATED EFFLUENT
EFFLUENT to Field
SLUDGE Drying System to produce Fertilizer products
Bag POME
POTASH production FIELD DISPOSAL Dewatered bunch for oil recovery and COGEN power production. FIBRE products
Full combustion for Reduction of dust particles to less than 0.2 mg / m3 in flue gas
POTASH
OIL and POWER
FIBRE products
CLEAN FLUE GAS
INSTALL SOUND DAMPERS TO HIGH SPEED MACHINERY.
PROCESS LINE & POWER ROOM MACHINERY NOISE
SOUND CANOPY PARTITIONED ROOM
MAINTAINED EQUIPMENT
Reduce to 50 dB / m sound Limits
NOISE CONTROL
ECONOMICS OF WASTE BUT WASTE NOT OF USEFUL VALUE ADDED PRODUCTS
SOLID WASTE
LIQUID EFFLUENT
© Noel Wambeck / 8th December 98.
& AIR POLLUTION
TREATMENT & CONTROL
ZERO HAZARDS DISPOSAL & PRODUCTION HAVE VALUE ADDED PRODUCTS
PROPOSED PLACEMENT AVENUE FOR EMPTY BUNCHES, FRONDS AND TREATED EFFLUENT FOR LAND APPLICATION.
PRESS STATION
CLARIFICATION STATION
BOILER HOUSE
STERILIZED FRUITLETS
WET SLUDGE FOR DRYING PROCESS
BAGGING OF DRIED POME
POME SLUDGE PROCESS WITH THE DECANTER & DRYER – SCHEMATIC FLOW DIAGRAM
HOLDING / DISTRIBUTING FURROW
FURROW
CONTIGENCY FURROW
EFFLUENT PIPE LINE – PUMPED FROM MILL
ESTATE RING ROAD FOR INSPECTION PURPOSE
Perunding AME / 20th April 99 / NW.
TYPICAL FURROW LAYOUT
PVC OVERFLOW PIPE
Oil palm mill process monitoring & control system
OIL PALM MILL PROCESS MONITORING & CONTROL (PMC) SYSTEM
CONTENTS. • • • • • •
Introduction. System description. Data Acquisition Features. Process Alarm. Interlocking Features. Systems for Individual Stations
1. 0 Sterilizer control system 2. 0 Crude oil dilution control system 3. 0 Depericarper control system 4. 0 Cracked Mixture Winnowing control system for kernel recovery plant 5. 0 Back-pressure vessel control system 6. 0 Boiler combustion control and scrubber system 7. 0 Specifications of hardware and software.
1
Oil palm mill process monitoring & control system
INTRODUCTION.
Spotting trouble before it strikes for most manufacturing plants, maintaining production equipment means keeping a process within well-defined parameters. Slight variance from those parameters introduces product defects, added machine wear, such as slipping belts, chattering chains and poorly meshing gears, resulting in equipment or system failure. To complicate the process further, critical signs or warning provided in the monitoring and control system are ignored and at times human errors in operation are the cause of total breakdown of the mill. When product defects or equipment failure occur, mill engineers must diagnose the situation and do so quickly to minimize production stoppage.
& Which component is out of specification ? & What is necessary to return the process to normal ? & What needs an adjustment ? & Replacement of new parts or an overhaul is required immediately ? Process monitoring and control (PMC) systems are the best available tools for the purpose. They record the process systems or equipment digitally, they allow instantaneous review, data measurement, and analysis of the data measured. Until now, mills seeking process monitoring systems that work properly had limited choices. The present availability of PMC systems, durable components and companies of reputation with full after sale service, makes rational sense in the investment of a good working process monitoring and control system for oil palm mills that are conducive to spotting trouble before it strikes.
2
Oil palm mill process monitoring & control system
SYSTEM DESCRIPTION. The Process and Monitoring Control (PMC) system shall be a user friendly PC based platform that is specifically designed for the monitoring of analog or digital inputs, graphic display, data logging and acquisition, trending and change of parameters of the network operation in the individual stations in an Oil Palm Mill The systems for the individual stations are : 01.
Sterilizer control system
02.
Crude oil dilution control system
03.
Depericarper control system
04.
Winnowing control system for kernel recovery plant
05.
Back-pressure vessel control system
06.
Boiler combustion control and scrubber system
There will be remote control panels with PLC cards, whereby each system will be linked to the control by their respective station. The remote control panels will be link to the Central Control Station that will be located inside the Central Control Room (CCR) through computer networking system. The proposed system shall be robust in construction, proven design, user friendly and widely used in oil palm mills. The Central Control Room which fully air conditioned shall contain the computer unit with screen, key board, mouse, backup battery unit and printer in a console work station. The PMC system shall provide a means for centralizing the tasks of monitoring, data recording, configuring and manipulating the process while using distributing processors to perform application, control and actual process interface functions. Further the system shall interface to printer, recorder and graphic annunciators for logging, alarming, the inter locking, trip override and real time trending of selected points.
3
Oil palm mill process monitoring & control system
DATA ACQUISITION FEATURES. The data acquisition features will include the following :
• Weighbridge data for FFB received, dispatched produce of CPO, Palm Kernel, Empty bunch, ash etc.
• Vehicle movements and registration numbers. • Sterilizer system operating status • Crude oil dilution system operating status • Depericarper system operating status • Winnowing system operating status • Clarification station operating status • Back-pressure vessel system operating status • Boiler operation operating status • Pressure and temperature of all salient equipment, machinery and plant. • KW recording of all salient equipment, machinery and plant. • Hour meter recording of all salient stations and plant. PROCESS ALARM. Data captured shall be monitored and information generated will be computed to rise the alarm when any of the parameters exceed the normal condition.
INTERLOCKING FEATURE. The system shall be wired for safety interlocking of the operating process as an example when the fibre cyclone airlock trips, the interlocking system will trip the upstream process line equipment such as the screw presses, the cake breaker conveyor etc.
4
Oil palm mill process monitoring & control system
SYSTEMS FOR INDIVIDUAL STATIONS.
0.1 STERILISER CONTROL SYSTEM. The system shall be designed to achieve the optimum utilization of steam for the sterilisation process in a continuous and balance mode. The steriliser programmable control system will regulate the sequence for sterilisation of the FFB for process with the objective of conditioning the FFB before the stripping of the fruitlets from the bunches. The system is designed to operate in the following modes :
• Automated operation controlled by PLC • Semi automatic operation by manual activation of pushbuttons. • Manual operation.
The Sterilizer Control System Features are : The system will start with a batch sequencing control where the sterilizer will start in sequence automatically and shall incorporate safety features whereby the steam inlet valves will operate if the following conditions are fulfilled :
• When the sterilizer doors are in closed position and that the safety lock is in placed. • The steam feed to the sterilizer can start on Auto mode or on the ready push button mode and on manual override by manually operating the sterilizer valves. The modulating valves will control the steam inlet valves based on the balanced pressure of the sterilizer, the back pressure vessel and boiler which are linked to Central Control Station via the PLC and network computer. The sterilisation cycle can be set or modified via user- friendly keypad, text and graphic display without interrupting the program or the process. The system shall be flexible and can be expandable to cater for future sterilizer units.
5
Oil palm mill process monitoring & control system
0.2 CRUDE OIL DILUTION CONTROL SYSTEM Crude oil mixture does vary in composition and therefore hot water dilution is a means of stabilisation to provide an accurate consistency of the crude oil mixture before the clarification process. The auto dilution control is to cater for the monitoring and regulating the amount of water dilution required for the stabilisation of the crude oil . The aim is to provide a dilution of 50% oil and 50% water plus NOS maintained at 95°C as the set point that is based on a variance of 40-60 % oil and 60-40% water including NOS of between 12 – 16% discharged from the extraction process. The set point of the unit can be adjusted to the operation requirements but over dilution must be avoided for best results. The CODC system consist of :
• Density monitor ( Vibrating reed devise) • Convertor • Pneumatic control proportional valve • Mounting steel frame • Control panel with PLC card. The Crude Oil Dilution Control system shall be linked to Central Control Station via the PLC and network computer.
6
Oil palm mill process monitoring & control system
0.3 DEPERICARPER CONTROL SYSTEM. The Depericarper control system shall be designed to achieve an efficient separation of nuts, kernel and fibre in the depericarper winnowing column and further to optimised the recovery of nuts and kernels. The control system is to monitor and maintain a consistent air flow velocity in the separating column irrespective of the volume of the material in the column.
The system will incorporate variable features of :
• Predetermined air velocity required for efficient separation. • The change of volume of material in the column • The number of screw presses in operation The system shall consist of : 01. Programmable Logic Controller (PLC). 02. Pneumatic control actuators and dampers. 03. Sensors for level switches, air flow and recorders. The sensor will measure the air flow and compare it with the set value which will automatically adjust the damper to the operating requirement. The Depericarper Control system shall be linked to Central Control Station via the PLC and network computer.
7
Oil palm mill process monitoring & control system
0.4 CRACKED MIXTURE WINNOWING COLUMN CONTROL SYSTEM. The CMWCC system shall be design to effectively monitor, separate and recover the kernel for the mixture. The control system is to monitor and maintain a consistent air flow velocity in the separating column irrespective of the volume of the material in the column.
The system will incorporate variable features of :
• Predetermined air velocity required for efficient separation. • The change of volume of material in the column • The number of screw presses in operation The system shall consist of : A. Programmable Logic Controller (PLC). B. Pneumatic control actuators and dampers. C. Sensors for level switches, air flow and recorders. The sensor will measure the air flow and compare it with the set value which will automatically adjust the damper to the operating requirement. The Cracked mixture winnowing control system shall be linked to Central Control Station via the PLC and network computer.
8
Oil palm mill process monitoring & control system
0.5 BACK PRESSURE RECEIVER (BPR) CONTROL SYSTEM. The system shall be designed to achieve the optimum balance of steam from the Boiler, during the sterilisation process and turbine operation in a continuous and balance manner. The system is designed to operate in the following modes :
• Automated operation controlled by PLC • Semi automatic operation by manual activation of pushbuttons. • Manual operation. The features of the system are that when the steam pressure at the back pressure receiver falls below a set point, the makeup valve will open via the reducing valve and regulate the high pressure steam from the boiler and into the back-pressure receiver. The makeup valve will close when the steam pressure at the back-pressure receiver exceeds the set point amount. In the event that the boiler pressure drops below the allowable limit the pressure switch at the upstream will override the makeup valve that will permit the turbine to operate at the cycle of frequency. The Back Pressure Receiver (BPR) control system consist of : I.
Programmable Logic Controller (PLC).
II.
Pneumatic control Valves with turn wheel for manual operation of the valves
III.
Sensors for pressure, temperature and recorders.
The BPR control system shall be linked to Central Control Station via the PLC and network computer.
9
Oil palm mill process monitoring & control system
0.6 BOILER COMBUSTION CONTROL ( with the 3 element control ) AND SCRUBBER SYSTEM. The system shall be designed to achieve the optimum utilization of waste solid fuel and the correct amount of air for effective boilers combustion, the generation of steam for the turbine operation, the sterilization operation and processing steam in a continuous and balance co-ordination. The system is designed to operate in the following modes :
• Automated operation controlled by PLC • Semi automatic operation by manual activation of pushbuttons. • Manual operation. The system shall consist of : A. Programmable Logic Controller (PLC). B. Pneumatic control actuators and dampers. C. Sensors for pressure and temperature D. 3 element boiler drum level switches. E. Air flow meter and recorders. F. Control valves. G. Fuel feeder and spreader complete with Variable speed drives. H. Boiler scrubber unit complete with water spraying equipment. The BCCASS control system shall be linked to Central Control Station via the PLC and network computer.
10
Oil palm mill process monitoring & control system
11
0.7 SPECIFICATION OF HARDWARE AND SOFTWARE.
The Process Monitoring and Control (PMC) System shall be supplied of proven in operation, rigid components designed specifically for an oil palm mill environment and consist of one or more racks containing modules, interconnecting power and data cables. The Oil Palm Mill environment conditions are : Temperature
27° - 40°C
Humidity
99%
Power
230 / 415 volts 50 Hz
Power Interruption
Operate through a total loss of power for 17.6 msec.
ITEM
DESCRIPTION
TYPE
1
Central Processing Unit (CPU) Server type
Intel PIII
1 unit
2 3
Programmable Logic Controller (PLC) Personal Computer (PC) complete keyboard, 21 monitor and mouse
Intel PIII
5 units 2 units
4
Printer - Colour graphic type
600x1200 pdi
1 unit
5
Modem ( Data / Fax/ Voice )
56 K bps
1 unit
6
Uninterrupted Power Supply (UPS)
2000 VA
1 unit
7
Custom built PMC system software
8
Microsoft Windows
NT Pro
1 lot
9
Microsoft Office
2000 Pro.
1 lot
10
AutoCAD
Ver. 14
1 lot
11
Acrobat Suite
12
Cables to field instruments
Perunding AME / March 1999 Noel Wambeck.
QUANTITY
1 lot
1 lot Bradon
1 lot
THE DEVELOPM ENT OF OIL PALM IN MALAYSIA.
1
THE DEVELOPMENT OF OIL PALM IN MALAYSIA. ACTIVIT IES FOR PALM OIL AND FRACT IONS By Noel Wambeck 2nd September 1997.
General Overview. The Malaysian oil palm based industry has grown to become the second largest foreign exchange earner in the country, next to petroleum and gas. Malaysia today exports about 95 percent of its total production of 9 million mt palm oil in the form of refined and fractionated products whereas the bulk of its palm kernel oil is still being exported in the crude form. Manufacture of higher value added products such as oleochemical and fat products based on palm oil and palm kernel oil is still limited and besides being the largest producer of oil palm, Malaysia is already the largest single exported of total oils & fats, ahead of the United States of America which had been the leader up till now.
Competitive edible oil. The existing high prices of all edible oils indicate the general trend in demand. The Tenera material makes possible in Malaysia yields up to 6 tons of oil per hectare ( 2.5 tons of oil per acre ) on alluvial clay soil and indications are that higher yields may be possible on rich volcanic soils such as those of Papua New Guinea, East Malaysia and Indonesia. The oil palm is by far the highest producer of oil per hectare of any commercial planting or crop.
VEGETABLE OIL YIELD PER HECTARE PER YEAR
Kg.
5000
Kernel
4500
1000
4000 3500 3000 2500 2000
4000
1500 1000 500 0
220
330
Cotton Seeds
Soybean
500
620
Rape Seed Sunflower
740
940
Coconut
Peanut
Kernel / Palm oil
Commodity
In this respect oil palm has an advantage over such competitive annual oil crops as soyabean, rape seed, sunflower, cotton seed, coconut and groundnut.
THE DEVELOPM ENT OF OIL PALM IN MALAYSIA.
2
To extend the advantage every measure should be taken to ensure technical development for the production of high quality palm oil. The Malaysian palm oil industry has undergone three distinct phases of growth, each reflecting a progress towards the overall establishment of the palm oil industry. During the first phase there was massive planting of oil palm and construction of Oil Palm & Palm Kernel Mills. This was in response to the encouragement given by the Government in the 1970’s to diversify Malaysia’s agricultural sector. The second phase of growth was in the rapid establishment of a palm oil downstream fractions processing and the establishment of the Oleochemical sector in the 1980’s. In the third phase of development was the joint venture projects undertaken by both, the Government and private sector in palm oil marketing and investment in palm oil refinery processing activities in foreign countries such as China, Vietnam, Egypt, Indonesia, England, etc. Malaysia is in position today to expend its planting activities and have embark on the forth phase of its plan which was launched in the early 1990’s by the establishment of joint venture plantation companies in counties where oil palm can be seen to have been planted, ie. Indonesia, Philippine, South America …. In business and government circles, there is a sense of exhilaration about what has being achieved but the process of de-regulation which started in the early 1990’s has brought about a virtual re-birth of the New Order in the industry and the Government has realized that the private sector is truly the engine of growth in the economy. There is an in-debt desire by the Government and business circles to achieve the aims of the new order but whereas the Government's inclination is for creating a macro economic balance and on the other hand agree to the continued expansion of the private sector's preference to profit in development.
Demand for Palm Oil. As the world population increases the demand and consumption of Edible oil’s will increase and in particular palm oil products to a level above 15.5 kg per capita consumption by the year 2000. The table below shows the actual and projected consumption of oils and fats up to the year 2000. 100 Million 96.0
* 85.5 79.0 67.6 Million MT
*
*
* 50 Million
YEAR POPULATION CONSUMPTION
1985 4.83 ( Billion ) 14.0 kg per capita
1990 5.45 14.5
1995 5.70 15.0
BASED ON UNITED NATIONS ESTIMATED POPULATION GROWTH.
2000 6.20 15.5
THE DEVELOPM ENT OF OIL PALM IN MALAYSIA.
3
Review of the marketing palm oil and fractions. The countries with the most need for edible oil, are usually those which are the least able to afford large scale imports. They are also likely to be the same countries least likely to have adequate processing facilities for crude palm oil. In the context of Malaysia's future activities for palm oil and fractions, the marketing of palm stearin represents a special case, as Malaysia increases the amount of Palm Olein placed on the world and its domestic cooking oil market, an inevitable consequence will be the co-production of increasing amounts of palm stearin. Not all of this additional production will be absorbed locally; discovering or creating new overseas markets for the balance, is a priority for the Malaysian marketing organization. Palm Stearin, although ideally food grate material has been placed with some success in those markets, usually serviced by beef and / or mutton tallow. Palm Stearin is a useful source of a completely natural, hard fat component, for such products as compound shortenings, pastry margarine and other products which capitalize on the specific crystallization attributes of palmitic acid. Commercial fatty acids are derived almost entirely from natural fats. The fatty acids are an abundant raw material, produced from a renewable resource, and serve as building blocks for the entire Oleochemical Industry. Historically, the main fats used for the manufacture of fatty acids have been beef tallow, as the source of Palmitic C16 acids and Stearic / Oleic C18 acids, together with coconut oil, the only significant source of lauric C12 acids. Tallow production is a function of red meat consumption and is estimated to be growing at a rate of only 1.5% per year. World population is projected to grow at a rate of 1.6% per year while world palm oil production is expected to grow at a rate of 7.3 % per year. (Oil World.) Palm Stearin and Palm Kernel oil, whose production growths have been out-stripping those of tallow and coconut oil by a wide margin, are equally rich source of these acids. It is to be expected that Palm oil derived inputs will continue to be available at prices attractive relative to those of tallow and coconut oil, and that their use in oleochemical manufacture will also grow. With recent developments in Eastern Europe an expanded market for Palm Oil based material, both for food and technical uses will emerge. Coupled with these regional changes, developments in the oleochemical field, driven by demands for even increasing utilization of renewable resources, mean that fats, oils and their fatty derivatives will be subject to increasing demands in the future; in other words the raw material supply will be available on long term with no effect on the year to year basis.
THE DEVELOPM ENT OF OIL PALM IN MALAYSIA.
4
Research & Development. It is evident that a lot has been achieved in the last century for the development and technology in the oil palm industry. Advances in R & D undertaken by the industry in brief, are: < Pioneer strategic marketing technique. < Development of palm oil e-business and e-commerce. < Advanced training programs for managers, planters, technical and process engineers. < Mechanisation in planting, maintenance and harvesting in the plantations. < Higher density planting of palm trees and the cloning of high yield oil palm research. < Biological pest control. ( Owls and Bats ) < New potential use of palm oil in food products and nutrition. E.g. Vitamin research < Use of palm oil for body care products, Biodegradable detergents, engine oil, inks, molecular electronics etc….. < Technical use of oil palm waste in the automobile, plastic & composite material. E.g. Fibre in car sits and mattress, trunk in fibre board, glassy carbon. etc. < New processing equipment and systems including Larger capacity oil palm mills, refineries and processing plants. < Quality product handling, packing and transportation ( ie. Containerization) of palm oil produces. < Better oil palm processing techniques and the use of IT systems, computerization, robotic, automation etc… < The incorporation of operating procedures, equipment, plant and process systems to meet the ecological, hygienic and cleanliness of the plant on par with good food manufacturing industrial plants standards. Palm oil production will be a major factor in 5 years time, but it is today, secondary to the increased production of seed crop oils. The superior quality of CPO and its derivatives are the marketing organisation’s assurance for the future of its product. Cultural and religious practices tend to favour Palm Oil derivatives. complete acceptance for both food and cosmetic applications.
In the Islamic world, it has
The favour which palm oil attracts is likely to grow and every marketing organisation using edible oils and fats will wish to have palm oil and its derivatives available for its products.
The development of Oil Palm continues ……………….. By Noel Wambeck 2nd September 1997.
THE OIL PALM EXTRACTION PROCESS MATCHING WITH TYPE OF FFB. By Noel Wambeck - 25th September 1974.
The oil extraction of palm fruit can be carried out by 3 different methods : a. b. c.
Centrifuge equipment by Leaching or wet process ( water washing ) Piston or discontinuous pressing ( Automatic hydraulic press. ) Continuous pressing ( by single or twin screw press.)
Other methods have been considered and experimented, such as solvent extraction, extraction by saturated steam, by pressing of fruit pulp only, simultaneous extraction of palm and palm kernel oil after crushing the whole fruit and high-pressure critical extraction.
The chart above shows the different methods that have to be applied for the selected fruit with different pulp contents.
THE PROCESS MATCHING WITH TYPE OF FFB.
Page 2.
A DURA cake is for instance, an agglomeration of nuts with fibres in between, whereas a TENERA cake is a fibre mattress with dispersed nuts. The ratio of nuts to fibre or nuts to pulp decides the type of equipment to be used for oil palm milling or extraction process. However, there are not only these ratios which will affect the choice of equipment, process systems and the design of the oil palm mill, but also the fact that pulp and fibre show characteristics that do not appear as long as they mixed with nuts, but become apparent when the continuous phase is made up with fibre and cellular debris. This important feature is the imperviousness of pulp and cake. This phenomenon is generally known as ‘’ OIL WALL “. Cake imperviousness is explained by the clogging up of fibrous mesh by cellular debris and cell clusters.
The introduction of TENERA material, came one of the most important process phases in modern oil palm milling, the extraction of oil from pre-treated digested fruit, the continuous twin screw press.
25th Sept.1998 Noel Wambeck.
THE PROCESS MATCHING WITH TYPE OF FFB.
Fig.1 Centrifugal type extractor.
Fig.3 UDW - P15 type Twin Screw Press.
Page 3.
Fig.2 The Automatic Hydraulic Type press
OIL PALM EMPTY BUNCH DISPOSAL BY THE INTEGRATED INCINERATION. By Noel Wambeck 22 nd April 1999.
The processing oil palm is one of the most unique self-sufficient processes in Agro-based manufacturing industry, yet the most pollution contributor to the environment. In 1998 about 400 oil palm mills were known to be in operation producing approximately 9.3 million tons of crude palm oil, 15 million tons Empty bunches of unused solid waste and 300 thousand tons of revenue yielding Potash per year in Malaysia.
The salient air pollutants from the oil palm mill process, are :
• •
Smoke and dust from the boiler. Smoke and dust from the incinerator.
The Smoke and dust from the boiler is a subject of another paper. This brief paper will deal with the disposal of empty bunches a solid waste from the process of an oil palm mill. Empty bunch a solid waste product of the Oil Palm Milling process has a high moisture content of approximately 55 – 65% and high in silica content , form 25% of the total weight of Palm Fruit Bunch. The treated Empty bunch are mechanically crushed ( de-watered and de-oiled ) in the process but are rich in major nutrients and contain reasonable amounts of trace elements. When properly incinerated they yield 0.3 to 0.5 % of ash and such ash contents the following average contitutients : • • • •
Potassium 28% Phosphorous 1.2% Calcium 2.3% Magnesium 4%
They have a value when returned to the field after incineration as POTASH for the enrichment of soil. Many new systems for empty bunch disposal other than the incineration process and
EMPTY BUNCH INCINERATION
2
disposal for land application are being tried but no generally accepted system by the industry has yet emerged.
The existing simple design of the incinerator to burn empty bunch is to be phased out and disapproved for use in new mills by DOE due to high air pollution and discomfort to the local Authority, who have to attend to complains of smoke and haze made by inhabitants of the area. The Incinerator which are subjected to shock loads and unstable combustion resulting in high amounts of dust particles in the flue gas emitted to the atmosphere. All efforts to find a solution are being encouraged by DOE, PORIM and the Industry and to some extend, partial results have taken placed in the development of ne w technology in the treatment of effluent and air pollution control. We envisage that the thermal oxidation system, being the direct approach to the problem may be able to solve the hazards and control of the environment in providing a means to reduction of the flue gas discharge of the incinerator. The integrated system proposed is for the empty bunches to be de-watered and where the oil is recovered in the crushing process and than finally the solid waste residue disposed off by thermal oxidation in the incineration process has economical merit when considering the alternative cost for the mulching system.
EMPTY BUNCH INCINERATION
3
OIL PALM MILL EMPTY BUNCH INCINERATOR WITH DUST COLLECTOR AND ASH REMOVAL SYSTEM.
The Environmental quality ( clean air ) regulation 1978 stipulate the permitted level of solids concentration in gases emitted from solid waste thermal plants to be not more than 0.4 g per cubit meter. Air emissions from oil palm mill incinerators, being mainly gases with particulates such as tar and soot droplets of 20 – 100 microns and a dust load of about 3000 to 4000 mg. / NM3. Incomplete combustion of the incinerator produces dark smoke resulting from burning of empty bunches. The introduction of the proposed system will alter the situation whereby the incinerator shall emit clean smoke in accordance to the DOE standard requirements. Dewater / de-oiled empty bunches are fed into the incinerator chute fitted with smoke trap door. Flue gas from the incinerator furnace with a temperature of approximately 600 deg. C flow through the axial flow votex tube type dust collector that is mounted in line of the flue gas ducting system. The Dust collector is an axial flow centrifugal separation devise used to separate particulate matter from gas streams by centrifugal action. The cooled clean gas is conveyed by the ID fan that blows the exhausted gas to the chimney The system consist of : • Inlet chute
EMPTY BUNCH INCINERATION
4
• Incinerator furnace complete with steel structure, fire bricks and insulation. • Shaking grate & pneumatic assembly.
• Ash removal conveyor • Dust collecting unit. • Induce draught Fan. ( 30 kw 20,000 m3 / hr 100 mm wg ) • Chimney with ladder and platform ( 22 m ) • Inter-connecting fittings and duct works. • Control , Instrumentation & wiring.
1. Capacity ( dewatered / deoiled )
: 9000 kg Empty bunch per hour
2. Persons to operate
: Two ( 2) for bagging of Potash
3. Power requirement
: 30 kW
4. Estimated cost of system
: RM 900 thousand.
5. Delivery schedule
: 9 months
The above system vendor guarantee an emission at the chimney outlet of less than 400 mg./ NM3 and in accordance to the DOE allowed standard.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
1
FAO / Chapter 4: African oil palm. Feeding Pigs in the tropics –
1998 ORLAC / FAO p 255 - 267
The African oil palm, Elaeis guineensis (Jacq.), is characterized by its vertical trunk and the feathery nature of its leaves. Every year, 20 to 25 new leaves, called "fronds", develop in continuous whorls at the apex of the trunk. The fruit bunches develop between the trunk and the base of the new fronds. Although new plantations start to bear at three years, generally the first commercial crop requires between five and six years and continues to produce for 25-30 years, or until the palms grow too high to be harvested. Once a plantation reaches full production, a new inflorescence is produced every 15 days. It weighs between 15 and 20 kg and can contain up to 1500 individual palm fruits of between 8 to 10 grammes each. The individual fruits consist of the following four parts: a pericarp, a thin outer skin, which upon ripening changes from brown to orange; a mesocarp, a layer of fibrous material, which surrounds the nut; an endocarp or hard inner shell (nut) to protect the seed or kernel, and the seed (kernel).
PRODUCTION AND TECHNOLOGICAL PROCESS Production The African oil palm, which yields about 20t/ha/yr of fresh fruit bunches (Bolaños, 1986; Espinal, 1986: Garza, 1986), is capable of producing between three to five t/ha of crude oil from the fruit (mesocarp) and an additional 0.6 to 1.0 t/ha from the palm kernels (Ocampo et al., 1990a). Its productivity is influenced by climate, soil type, genetic factors, maturity, rainfall, fertilization and the harvest period. Mijares (1985) has stated that for optimum annual production the African oil palm requires a minimum of 1600 mm of well distributed precipitation, a relative humidity no less than 75%, a minimum and maximum temperature of between 17 and 28 C., a total of 2000 hours of light and a soil depth of 100 centimetres. There are two distinct types of oil palm: the "dura" and the "pisifera". The basic difference has to do with the inner nut. The nut of the dura type of oil palm has a thick and hard shell while the pisifera type has a small kernel, with no shell, but rather surrounded by a matrix of fibre. When a pisifera male is crossed with a dura female, a "tenera" type of fruit is produced; its shell is of intermediate thickness. Currently, it is this type of oil palm that is most widely grown in plantations. The African oil palm produces two main commercial products: raw or crude oil, approximately 22% of the weight of the fresh fruit bunch, and the palm nuts which represent 4-6%. When the nut is processed, it yields palm kernel oil and palm kernel meal. The two main industrial residues, the oil-rich fibrous residue and the palm nut shells, are used as sources of energy to run the factory. The empty fruit bunch is normally incinerated and the ash is returned to the plantation as fertilizer.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
2
The initial interest in the African oil palm as a feed resource for pigs was in the extracted and nonextracted palm kernel meal. This was because when nuts of the oil palm were first brought to Europe from Africa as ship's ballast, they were jettisoned into the sea before the ships were reloaded. However, soon the oil millers recognized their value and began processing them for oil in order to supplement copra oil in the manufacture of soap, paints and for other industrial applications (Collingwood, 1958). The meal was used as a major protein supplement for pigs and cattle until soya bean meal became commercially available. Oil palm cultivation started at the beginning of this century (Devendra, 1977). By 1980, production of oil had risen to slightly more than five million tons and, by 1992, annual world production reached thirteen million tons. As seen in Table 4.1, the primary areas of production are Southeast Asia, followed by the west coast of Africa and Latin America. Currently, Malaysia produces half the world's production of palm oil, followed by Indonesia and Nigeria. Presently, the fourth and fastest growing producer of palm oil is Colombia, where production has more than quadrupled in 12 years. In that country, (Ocampo et al., 1990b) has reported that the average annual production of fruit is 15 t/ha of which raw oil represents slightly more than three tons.
Table 4.1. Production of African palm oil: world, regional and top four countries, tonnes (FAO, 1992). Geographical area
1979-81
1992
World
5 046 308
12 725 346
Africa
1 337 913
1 835 888
Nigeria
666 667
900 000
Latin America
190 780
753 251
Colombia
70 500
304 496
Asia + Oceania
3 502 851
10 136 207
Indonesia
720 826
3 162 228
Malaysia
2 528 947
6 373 461
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
3
TECHNOLOGICAL PROCESS The technological process by which the oil is extracted from the palm fruit consists of the following steps; note that the fresh fruit bunch includes the stem and the adhering individual palm fruits. Reception: where sand, dirt and gravel are separated from the fresh fruit bunch. Sterilization: necessary to rapidly inactivate certain enzymes which tend to reduce the quality of the oil by increasing the amount of free fatty acids. In addition, this process contributes to the mechanical separation of the fruit from the stem and to the rupture of the oil cells within the mesocarp. Oil extraction: An oil press, into which hot water is injected, is used to separate the crude oil from the solid or fibrous-like material containing the nuts. The crude oil is then pumped to the purification section. Figure 4.1 shows the quantities of the principal components of the oil palm based on 100 tons of the fresh fruit bunch. The nuts are treated and cracked to extract the kernel which contains approximately 50% oil. The oil-rich fibrous residue, traditionally used as a source of energy to run the plant, has a caloric value superior to 18.8 MJ/kg. This is largely due to the residual oil, calculated as between 8 and 18 percent (Brezing, 1986; Solano, 1986; Wambeck, 1990). Similar to the proposal for livestock diversification within the sugar industry (FAO, 1988), the integration of pig production within the oil palm industry might introduce a certain degree of flexibility in the entire enterprise, resulting in: an increase in the productive capacity of the plant, particularly during the period of maximum industrial yield; a significant reduction in plant maintenance; increased employment opportunities related to the utilization of the different byproducts for livestock feeding; the production of animal wastes and thereby organic fertilizer for the plantations and, perhaps most importantly, an overall reduction in the amount and/or concentration of the industrial effluents which threaten the contamination of the surrounding ecosystem (Ocampo, personal communication). As a follow-up to these observations, the following information summarizes the average daily amount of products and sub-products produced in a oil palm processing plant of 125 t/day and 10t/hour (Table 4.2). One factor that might require attention if derivatives from the African oil palm present new opportunities to be used as energy feed resources for pigs is the cyclic nature of its production. Bolaños (1986) has reported that in Costa Rica the average monthly yield of fresh fruit bunch can vary from 6% during the dry winter months to 10 or 12% during the rainy, summer season. In that country, the annual yield of the fresh fruit bunch is 20 t/ha and with the oil-rich fibrous residue representing 12% of this amount, this could mean the production of 0.3 t/ha of oil-rich fibrous residue during the wet season as opposed to only 0.15 t/ha during the dry or winter season.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
4
Table 4.2. Potential feed resources in an African oil palm processing plant, air-dry basis. mt / day
mt / year
mt / ha /yr
Fresh Fruit Bunch
125
25000
20
Palm oil
25
5000
4
Palm kernel meal
2.5
1000
0.8
Empty Fruit Stem
40
8000
6.4
Ash (from stem)
0.6
125
0.1
Effluent
80
16000
13
Oil-rich fibrous residue
13.7
2750
2.2
Shell (from kernel)
12
2500
2
Ash (from shell)
0.6
16000
13
Source: Brezing (1986) However, if sugar cane, generally harvested only in the dry season, was integrated into this feeding system, the two energy feed resources might complement each other. The data in Tables 4.6 and 4.7 tend to support this interesting concept.
USE FOR PIGS As earlier mentioned, one of the first references to the use of derivatives of the oil palm for pigs referred to the use of the extracted and non-extracted palm kernel meal in complete, dry rations for growing/finishing pigs. Most pig farmers contended that the gritty texture of the meal affected consumption, and therefore performance. However, palm kernel meal continued to be used for many years as a replacement for scarce cereals, mainly because it was available, relatively inexpensive and highly nutritious (Crowther, 1916, cited by Collingwood, 1958). In the 1930s, when a commercial process for extracting oil from the soya bean was perfected and it was seen that a higher quality animal protein supplement (soya bean meal), would be commercially available, the byproduct from the extraction of the oil from the kernel, palm kernel meal, was destined for ruminants (PNI, 1990). Currently, palm kernel meal represents about one per cent of world trade in oil seed meals. Table 4.3 gives the chemical composition of several oil palm byproducts.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
5
Table 4.3. Chemical composition of African oil palm byproducts. Component
Oil-rich fibrous residue a (% DM)
Dry sludge a (% DM)
Fresh centrifuged sludge solids b (% AD)
Dry matter
86.2
90.3d
15.0-20.8
Crude protein
4.0
9.6
3.1-3.4
Crude fibre
36.4
11.5
3.0-5.2
Ether extract
21.0
21.3
2.4-3.5
Ash
9.0
11.1
2.8-3.4
Nitrogen free extract
29.6
46.5
-
Calcium
0.31
0.28
-
Phosphorous
0.13
0.26
-
Gross energy (MJ/kg)
18.1
18.7
-
Sources: a Devendra (1977); b Ong (1982) To date, derivatives of the African oil palm have shown potential feeding value for pigs in conventional, cereal-based rations: the de-hydrated palm oil mill effluent and the fresh centrifuged sludge solids have been studied both by Devendra et al. (1981) and by Ong (1982), and the whole palm nut by Flores (1989) and Chavez (1990). However, recent interest has focused on the use of primary products and by-products of the African oil palm as a partial or complete energy source replacement in swine rations, particularly where the protein is offered separately, in the form of a restricted amount of a high-quality supplement. It has been shown that the oil-rich fibrous residue (ORFR), normally used as a source of energy to run the factory, can also furnish the necessary energy for the pig (Ocampo et al., 1990a, 1990b). As exemplified in following sections, the successful experimental use of the crude oil (Ocampo, 1994b), combinations of the crude oil and sugar cane juice (Ngoan and Sarría, 1994) and even the whole fresh palm fruit (Ocampo, 1994a, b) further emphasize the fact that other oil palm byproducts can serve to completely replace cereals in rations for swine.
Crude (raw) palm oil Crude palm oil has traditionally been used up to about 5% in dry diets for pigs in a manner similar to molasses: to improve palatability, to reduce dustiness, to supply vitamins and to improve the texture of rations prior to pelleting (Devendra, 1977; Hutagalung and Mahyudin, 1981). The oil contains approximately 80% of unsaturated fatty acids (Table 4.4) and 10% of linoleic acid, an essential fatty acid required at a dietary level of 0.1% for pigs (NRC, 1988).
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
6
Table 4.4. Composition of the fatty acids in the oil from fruit and kernel of the African oil palm (% AD). Fatty acids
Palm oil
Palm kernel oil
Myristic
1.6
-
Palmitic
45.3
7.8
Stearic
5.1
2.5
Oleic
38.7
12.6
Linoleic
9.2
1.7
Lauric
-
15.7
Capric
-
47.3
Caprilic
-
4.1
Caprolic
-
4.3
Source:Pardo and Moreno (1971), cited by Ocampo et al. (1990b) The addition of from 2 to 10% of crude palm oil in the diets of growing pigs was studied by Fetuga et al. (1975) who found no significant effect on performance. When palm oil was compared to groundnut oil, lard or beef tallow, there were no significant growth differences, however, increasing the level of palm oil in the diet slightly increased the percentage of lean cuts (Babatunde et al., 1971, 1974, cited by Devendra, 1977). This same observation was reported by Balogun et al. (1983) cited by Ngoan and Sarría (1994) who noted that the addition of 30, 64 or 97 g/kg of palm oil to the ration increasingly improved muscle development. In Malaysia, it was reported that six groups of pigs from 16 to 81 kg were fed iso-nitrogenous diets containing different levels of palm oil, from 5 to 30 percent. Although the results were reported as not significant, the average daily gains obtained on the experimental diets were 10% superior compared to that of the cereal control; in addition, where palm oil was included, the conversions were improved by an average of 17 percent (Devendra and Hew, cited by Devendra, 1977). Recently, Ocampo (1994b) showed that palm oil and a source of protein, either fortified soya bean meal and rice polishings, or combinations of fortified soya bean meal/fresh Azolla and rice polishings, might provide an interesting feeding system for the production of pigs in the tropics, particularly if the pigs were integrated with the palm plantations. Pigs of an initial average liveweight of 30 kg were fed diets in which 10, 20 and 30% of the protein from fortified soya meal was replaced by fresh Azolla filiculoides, a water fern (Table 4.5).
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
7
Table 4.5. Composition of diets using crude palm oil, rice polishings and fresh Azolla filiculoides as a replacement for the protein in soya bean meal (kg AD/day). % replacement of protein in soya bean meal by Azolla growing phase: 30-60 kg
finishing phase: 60-90 kg
0
10
20
30
0
10
20
30
Protein supplement
0.50
0.45
0.40
0.35
0.50
0.45
0.40
0.35
Rice polishings
0.10
0.10
0.10
0.10
0.15
0.15
0.15
0.15
Crude palm oil
0.50
0.50
0.50
0.50
0.80
0.80
0.80
0.80
Fresh Azolla
0.0
1.74
3.48
5.21
0.0
1.74
3.48
5.21
Source: Ocampo (1994b); * contains: soya bean meal, 86%; dicalcium phosphate, 10%; salt, 2% and a vitamin/mineral premix, 2% In the morning, the pigs were fed the daily ration of protein supplement and rice polishings, and half the daily allowance of oil and Azolla. In the afternoon, they received the remaining portion of Azolla and oil. The average daily gain (g) and dry matter feed conversion for the control treatment, without Azolla, and the groups where 10, 20 and 30% of the protein in soya bean meal was replaced by that of Azolla were: 526, 2.10; 561, 1.98; 535, 2.00 and 452, 2.20, respectively. In the same publication reference was made to a commercial piggery that used the following "palm oil feeding system". For that, a total of 170 growing/finishing pigs, in 4 groups, were fed daily one kilogramme of protein supplement and 0.5 kg of crude palm oil. The protein supplement contained: 450 g soya bean meal, 374 g palm kernel meal, 150 g rice polishings, 20 g dicalcium phosphate and 3 g each of salt and a vitamin/mineral premix. The initial average liveweight (kg), average daily gain (g) and dry matter feed conversion for each of the 4 groups were 32.0, 722, 1.80; 24.2, 628, 2.00; 25.8, 524, 2.40 and 26.0, 464, 2.80, respectively. In spite of the fact that the diet was the same for all groups, no explanation was offered for the observed variation in performance, inferring, perhaps, that the "palm oil feeding system" requires further refinement. Palm oil has also been studied as either a partial or complete energy source replacement for pigs, also fed fresh sugar cane juice and a restricted protein supplement. The oil replaced 25, 50, 75 and 100% of the energy in cane juice in both the growing and finishing phases of this most interesting and unique feeding system to study the potential integration of sugar cane and the African oil palm as dry/wetseason energy feed resource alternatives for pig production in the tropics (Table 4.6). The average daily gain was not significantly affected by treatment in the growing phase, however, during the finishing phase, gains were significantly lowered when palm oil replaced 75 and 100% of the juice (Table 4.7). In both phases, the average daily feed intake was lower for those pigs fed palm oil which according to the authors, might have been related to its low palatability or high energy content. They reported a digestible energy value for palm oil and sugar cane juice in pigs as 37.5 and 14.5 MJ/kg of DM, respectively. Feed conversions were significantly improved by the addition of palm oil. Carcass measurements were not affected.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
8
Table 4.6. Replacement of the energy in sugar cane juice (SCJ) by that in palm oil (PO) for growing/finishing pigs (kg AD/day). * Liveweight, kg
90
100 SCJ
6.0
7.5
8.5
9.5
10.5
11.5
13.0
>14
75 PO/25 SCJ
4.5/.1
6.0/.15
7.0/.2
8.0/.2
9.0/.25
10/.25
11.0/.3
12.0/.3
50 PO/50 SCJ
3.0/.2
4.0/.3
4.5/.35
5.0/.4
5.5/.45
6.0/.5
6.5/.55
7.0/.6
25 PO/75 SCJ
1.5/.3
2.0/.45
2.5/.5
2.5/.6
3.0/.65
3.0/.75
3.5/.8
3.5/.9
100 PO
0.4
0.6
0.7
0.8
0.9
1.0
1.1
1.2
Source: Ngoan and Sarría (1994); * plus 500 g/d of a 40% crude protein supplement Table 4.7. Performance of finishing pigs (50-90 kg) fed a restricted protein supplement (RPS)* with energy from sugar cane juice (SCJ) increasingly replaced by palm oil (PO). 100 SCJ
75 SCJ 25 PO
50 SCJ 50 PO
25 SCJ 75 PO
100 PO
Initial liveweight, kg
51.1
50.1
48.9
50.2
45.2
Final liveweight, kg
99.5
93.7
91.2
89.8
84.2
ADG, g
768
693
672
628
615
DM feed intake, kg/d
3.05
2.32
2.14
1.77
0.92
DM feed conversion
3.97
3.35
3.18
2.82
1.47
Source: Ngoan and Sarría (1994); Ngoan (1994); *The RPS was 500g/day of 91% soya bean meal, 6% minerals, 1% salt and 2% of a vitamin premix Oil-rich fibrous residue (ORFR) The residue which remains after the crude oil is separated from the sterilized fruit by means of a screwpress, represents approximately 12 to 15% of the fresh fruit bunch. The chemical composition of this residue is presented in Table 4.3. This material, reported to contain from 63% (Wambeck, 1990) to 70 or 85% dry matter (Solano, 1986) still contains from 6 to 8% of residual oil. It is of a deep yellowtangerine color, with a fibrous consistency, sweetish smell and greasy-like texture (Ocampo et al., 1990a). It is used as the main source of energy to run the plant. ORFR has been studied as a complete replacement for the energy derived from cereals. Diets in which sorghum was the sole energy source, or where 25, 50, 75 or 100% of the energy from sorghum was replaced by this residue, were offered ad libitum to pigs from 20 to 90 kg, also fed a restricted amount of fortified soya bean meal to meet the current, daily, NRC (1988) requirement for crude protein (Ocampo et al., 1990a).
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
9
Preliminary results showed that pigs can grow extremely well on this type of feeding system. Where ORFR replaced 100% of the energy supplied by sorghum, the average liveweight growth was 639 g/day. The pigs consumed a daily average of 0.75 kg of protein supplement together with 2.32 kg of oilrich fibrous residue (Table 4.8). Table 4.8. Oil-rich fibrous residue as a partial or complete replacement for the energy in sorghum for pigs (20-90 kg). 0% ORFR
25% ORFR
50% ORFR
75% ORFR
100%ORFR *
Initial liveweight, kg
19.8
20.6
21.7
22.2
22.6
Final liveweight, kg
89.7
91.1
92.5
92.6
94.2
Days to finish
133
119
112
112
112
ADG, g
525
592
632
629
639
DM feed intake, kg/d
2.1
2.1
2.2
2.3
2.8
DM feed conversion
4.00
3.59
3.49
3.75
4.47
Source:Ocampo et al. (1990a); * fed 0.55, 0.64 and 0.9 kg/day of fortified soya bean meal (see Table 4.5) during the 3 phases of: weaners, growers and finishers, respectively Following this initial trial, Ocampo et al. (1990b), attempted to prove an observation of Sarría et al. (1990), that when pigs are fed a restricted amount of a high quality protein supplement, particularly when the required levels of essential amino acids are supplied by soya bean meal, lower amounts of total crude protein are feasible. This amounts to approximately 200 g/day and can be provided in 500 g/day of a 40% protein, soya bean meal-based supplement. The concept had been first developed through feeding systems based on sugar cane juice (see Chapter 3). For this study, the basic diet was ORFR, fed ad libitum. Three groups of growing/finishing pigs were fed constant amounts (high, medium or low) of fortified soya bean meal throughout the entire experimental period. A fourth group, the control, received different amounts of fortified soya bean meal (high, medium and low) to correspond with the needs of each of the three developmental phases: weaners, growers and finishers (Table 4.9). The authors concluded that the two groups that received the least amount of protein exhibited an inferior performance but gave the highest economic returns. A more recent trial studied the effect of supplementing this unusual feeding system (ad libitum ORFR and a restricted amount of protein supplement) with methionine and/or B-complex vitamins (Ocampo, 1992). None of the experimental treatments produced significant results.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
10
Table 4.9. Different amounts of restricted protein supplement (RPS) * and free-choice oil-rich fibrous residue for pigs from 22 to 90 kg. Control **
High kg/d)
Initial liveweight, kg
22.7
22.8
22.8
22.1
Final liveweight, kg
90.2
90.0
90.4
90.3
Days to finish
121
126
124
135
ADG, g
558
532
545
505
AD feed intake, kg/d: RPS
0.70
0.64
0.57
0.50
ORFR 2.33
2.44
2.22
2.56
4.80
5.20
4.60
5.40
DM feed conversion
(0.64 Medium (0.57 kg/d Low ) kg/d)
(0.50
Source: Ocampo et al. (1990b); * see Table 4.5; ** 0.50, 0.64 and 0.90 kg/day of RPS fed during three consecutive 40-day periods: weaners, growers and finishers.
Palm oil mill effluent and palm oil sludge The palm oil mill effluent, the final liquid discharge after extracting the oil from the fresh fruit bunch, contains soil particles, residual oils and suspended solids but only 5% of dry matter. While Wambeck (1990) stated that it represents 0.5 t/t of fresh fruit and can cause serious problems to the entire surrounding ecosystem, Brezing (1986) went one step further and estimated that a processing plant with a capacity of 10 tons fresh fruit per hour would require a water treatment plant comparable to that required by a population of half a million inhabitants! Palm oil sludge is the material that remains after decanting the palm oil mill effluent (Devendra et al., 1981). It can be either filter-pressed, before dried and ground to produce dehydrated palm oil mill effluent, or centrifuged in the wet state, after having undergone anaerobic, thermophilic and acidophilic fermentation. In the latter case, the product is known as fresh centrifuged sludge solids of 15 to 20% dry matter and may be dehydrated to form dry centrifuged sludge solids of between 94 and 97% dry matter (Table 4.3). The composition of the essential amino acids in palm oil sludge and palm kernel meal is given in Table 4.10. Although, there is insufficient information concerning the amino acid composition of different African oil palm products, data from Table 4.10 suggest that lysine is not present in an appropriate proportion in the protein.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
11
Table 4.10. Composition of essential amino acids in palm oil sludge and palm kernel meal (% CP). Amino acid
Palm sludge
Arginine
0.19
Histidine
oil Palm meal
kernel
Amino acid
Palm sludge
oil Palm meal
2.20
Methionine+cystine
0.28
1.98
0.14
0.27
Phenylalanine+ tyrosine
0.77
1.28
Isoleucine
0.35
0.63
Threonine
0.34
0.54
Leucine
0.60
1.05
Tryptophan
0.12
0.17
Lysine
0.21
0.56
Valine
0.36
0.9
kernel
Source: Devendra (1977) Fresh centrifuged sludge solids have been incorporated in a concentrate ration daily at a level of 14% total dry matter for pigs from 30 to 90 kilogrammes. The average daily gain and dry matter feed conversion for the maize control group and one of the experimental treatments containing fresh centrifuged sludge solids was: 700g, 3.36 and 650g and 3.83, respectively (Ong, 1982). Dehydrated palm oil mill effluent has been incorporated up to 20% in dry rations for growing/finishing pigs; however, with increasing inclusion of dehydrated palm oil mill effluent, performance was poorer and carcass fat deposition increased (Table 4.11). Table 4.11. The use of dehydrated palm oil mill effluent for growing/finishing pigs (19-92 kg). 0%
5%
10%
15%
20%
Maize, ground
78.9
74.9
70.4
65.9
61.4
Soya bean meal
13.5
12.5
12.0
11.5
11.0
Dehydrated palm oil mill effluent
-
5.0
10.0
15.0
20.0
ADG, g
730
700
690
720
650
AD feed intake, kg/d
2.24
2.30
2.34
2.38
2.34
AD feed conversion
3.04
3.31
3.38
3.34
3.60
Fat, % of carcass
16.7
17.9
20.4
19.9
19.5
Source:Ong (1982); all diets contained. 5.5% fishmeal, 1.95% minerals and vitamins and 0.15% methionine
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
12
There have been numerous attempts to convert palm oil mill effluent into a viable animal feed resource; however, most methods have been discontinued due to the large initial capital investment required, and particularly to the cost of fuel for dehydration. In Malaysia, one method used to convert fresh palm oil mill effluent into a potential feedstuff involved concentration by centrifugation or decantation, followed by absorption on other dry feeds like tapioca chips, grass meal or palm kernel meal. The absorption process can be repeated several times before final dehydration (Webb, Hutagalung and Cheam, 1976, cited by Devendra et al., 1981). Perhaps, one idea would be to promote the use of the fresh centrifuged sludge solids (15-20% dry matter) for finishing pigs which, compared to younger animals, have a greater capacity to effectively use larger amounts of more liquid feeds. To date, apparently, this material has only been used in dry, concentrate rations (Ong, 1982). This approach might require supplementation to increase the crude protein content to that of a cereal, as well as some molasses to improve palatability. It would have to be fed immediately, preferably near the factory in order to avoid transportation of a product that contains 80% of water. Interestingly, this approach was indicated by Devendra et al. (1981) for feeding sheep and cattle (Devendra, 1992); he referred to the use of this residual product alone, or combined with oil-rich fibrous residue. Perhaps, this same recommendation might be applied to feeding pigs. In Ghana, oil palm slurry (sludge) has been used to replace 15, 20, 25 and 30% of maize in ad libitum diets for growing pigs to 70 kg. The control group was fed a maize-based diet; performance was not affected by the use of sludge. It was emphasized that with the exception of the loin-eye area, carcass measurements were improved when pigs were offered the slurry-containing feed (Abu et al., 1984). The use of unconventional feeds for pigs in Ghana was also studied by Hertrampf (1988), who reported using oil palm sludge in place of maize at a level of from 15 to 30 percent. An increase in the daily feed intake and the average daily gain, in addition to a significant reduction in feed costs, was reported.
Palm kernel meal The palm kernel represents 5% of the weight of the fresh fruit bunch; it contains approximately 50% oil (Beltrán, 1986). The meal is produced by extracting the oil from the kernel within the palm nut. The resultant meal, sometimes also referred to as "palm kernel cake", can contain from 12 to 23% of crude protein depending upon the efficiency of the process used to extract the oil (Table 4.12) . As expressed earlier, the first oil palm by-product reportedly used for feeding pigs was the extracted and non-extracted palm kernel meal. It was first used in Europe as a substitute for wheat bran in rations for growing/finishing pigs. Currently, because of its poor palatability and high fibre content, it is more commonly fed to ruminants where it produces a hard, white carcass fat in meat animals and a saturated fatty acid profile in the milk of lactating animals (PNI, 1990). In Nigeria, palm kernel meal was used for pigs but it ranked lowest in protein quality compared to other local protein sources and produced a loss in weight (Fetuga et al., 1974, cited by Devendra, 1977).
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
13
However, in Colombia, good results have been reported (Ocampo, 1994b) when almost 40% of palm kernel meal was used in the form of a restricted protein supplement that also contained soya bean meal. Correct storage, to reduce the risk of mould and the production of alfa-toxins, was emphasized. The chemical composition and digestibility of palm kernel meal is shown in Table 4.12. Table 4.12. Chemical composition/digestibility of palm kernel meal for pigs (%). average composition
digestibility
Dry matter
90
-
Crude protein
16
60
Crude fibre
16
36
Nitrogen free extract
48
77
Ether extract
10
25
Source: PNI (1990)
Whole fresh palm fruit The chemical composition of the flesh (mesocarp) which surrounds the palm nut, and interior kernel, is presented in Table 4.13. The whole fresh palm fruit constitutes a potential energy feed resource for the small-scale pig producer without access to factory produced palm oil derivatives, such as, crude oil or oil-rich fibrous residue. In an experiment to determine the performance of pigs from 27 to 90 kg, fed twice daily with a restricted amount of protein, and whole fresh palm fruit as a partial or complete replacement for sorghum, Ocampo (1994a) surprisingly found that, apart from consuming easily the fibrous material adjuring to the nut, the pigs often ate the entire fruit including the palm nut and the interior kernel. It was observed that first they ate the fibrous material surrounding various nuts, accumulated the nuts, then proceeded to crack and extract the kernel within the nuts. One interesting observation was that when the fresh fruit was stored for more than seven days, palatability, and therefore voluntary consumption, was noticeably affected.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
14
Table 4.13. The chemical composition of the pulp (mesocarp) and kernel of the fruit of the African oil palm (% DM). pulp
kernel
Crude protein
9.26
11.9
Crude fibre
25.5
31.6
Nitrogen free extract
31.3
25.9
Ether extract
28.6
26.9
Ash
5.4
2.5
Source: Ocampo (1994b) Although the data in Table 4.14 show that best growth was obtained when only 25% of the fresh fruit was used in place of sorghum, it was emphasized that best economic gains were when 75 or 100% of the fruit was used. In a second trial, Ocampo (1994c) used 4 groups to study the optimum amount of rice polishings as a source of carbohydrate for growing/finishing pigs, also fed a restricted protein supplement (500 g/day) and whole, unprocessed African oil palm fruit, fed ad libitum. The amount of rice polishings offered during the growing phase (20-60 kg) was 100, 200, 300 and 400 g/day, and during the finishing phase (60-90 kg), 150, 250, 350 and 450 g/day. During the entire experimental period, the average consumption of the fresh fruit was 1.1, 1.1, 1.0 and 0.9 kg AD/day; the average liveweights were: 485, 515, 492 and 497 g/day and dry matter conversions were: 3.20, 3.20, 3.30 and 3.30, respectively. Reportedly, the most economic levels of rice polishings were 200 g/day during the growing phase and 250 g/day during the finishing phase. Table 4.14. Whole fresh palm fruit (WFPF) as a partial or complete replacement for sorghum in diets for pigs from 27-90 kg. % WFPF
25%
50%
75%
100%
Initial liveweight, kg
28.1
27.0
26.7
27.0
Final liveweight, kg
89.3
85.7
90.2
85.7
Days to finish
98
98
126
126
1.30
0.86
0.20
0.00
0.54
0.97
1.43
1.53
ADG, g
625
598
503
466
DM feed intake, kg/d
2.02
1.94
1.68
1.59
DM feed conversion
3.20
3.20
3.30
3.40
AD feed * intake, kg/d: sorghum oil palm fruit
Source: Ocampo (1994a); *also fed 500 g/d of protein supplement : soya bean meal, 97.6%; dicalcium phosphate, 2%; salt, 0.3% and vitamin/mineral premix, 0.3 percent
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
15
For the low income farmer in the tropics, the possibility to fatten a pig with one's own fresh palm fruit, and perhaps purchase only 60 kg of a high-quality protein supplement, or even use some rice polishings, is definitely an example of an alternative feeding system for pigs. This same author also emphasized that if a feeding system based on the whole fruit was used, there would be approximately 100 g/day of protein availabe to the pig via the kernel, and that this fact merited even further study. Obviously, the African oil palm has definite potential as a feed resource for pigs in the tropics. Perhaps, its utilization might be improved if more basic information related to its nutritional value was available.
References Abu, A.A., Okai, D.B. and Tuah, A.K. 1984. Oil palm slurry (OPS) as a partial replacement for maize in the diets of growing-finishing pigs. Nutrition Reports International 30 (1): 121-127. Bolaños, M.A. 1986. La palma aceitera en Costa Rica. En: IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 23-25. Beltrán, C. 1986. Requisitos, Calidades y Usos del Palmiste. En: IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 145-146. Brezing, D. 1986. Subproductos de la Palma Africana en Plantas de Beneficio Primario: El Tratamiento de Efluentes. En: IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC FAO p 151-160. Chavez, J.M. 1990. Full fat african palm kernel nuts as energy source for weaned pigs from 5 to 10 weeks of age. Ing. Agr. Thesis, Panamerican School of Agriculture, Honduras pp 68. Collingwood, J.G. 1958. Palm kernel meal. In: Processed Plant Protein Foodstuffs Ed: A. M. Altschul, Academic Press, New York pp 995. Devendra, C. 1977. Utilization of Feedingstffs from the Oil Palm. In: Proc. Symp. Feedingstuffs for Livestock in South East Asia p 116-131. Devendra, C. 1992. Non-conventional Feed Resources in Asia and the Pacific: Strategies for Expanding Utilisation at the Small Farm Level. 4th edition International Development Research Centre, Sinapore, FAO Regional Animal Production and Health Commission for Asia and the Pacific, Bangkok.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
16
Devendra, C., Yeong, S.W. and Ong, H.K. 1981. The Potential Value of Palm Oil Mill Effluent (POME) as a Feed Resource for Farm Animals in Malaysia. Proc. of National Workshop on Oil Palm By-Product Utilization December 14-15 Kuala Lumpur. Espinal, M. 1986. Informe de la Coordinación Nacional Técnica en Palma Africana. En: IV Mesa Redonda Latinoameric ana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 31-34. FAO 1988. Sugarcane as Feed. FAO Animal Production and Health Paper No. 72 FAO Rome pp 319. FAO 1992. Production Yearbook. FAO, Roma . Fetuga, B.L., Babatunde, G.M. and Oyenuga, U.L. 1975. The effect of varying the level of palm oil in a constant high protein diet on performance and carcass characteristics of the growing pig. Ef. Afr. Agric. Ror. J. 40: 264-270. Flores, R. 1989. Full fat african palm kernel nuts as energy source for growing pigs. Ing. Agr. Thesis, Panamerican School of Agriculture, Honduras, pp 60. Garza, E.F. 1986. Situación actual de la palma aceitera en México. En: IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 35-36. Hutagalung, R.I. and Mahyudin, M. 1981. Feeds for animals from the oil palm. Proc. Inter. Conf. on Oil Palm in Agriculture in the Eighties. p 609-622. Hertrampf, J. 1988. Unconventional feedstuffs for livestock. Muhle + Mischfuttertechnik 125(9):108109. Mijares, N.R. 1985. Aspectos ecológicos de la palma africana de aceite. En:Potential Productivo de la Palma Africana en Venezuela, Facultad Agropecuaria, Maracay, Venezuela p 17-40. Ngoan, L.D. 1994. The use of African palm (Elaeis guineensis) oil as energy source for pigs. Swedish University of Agricultural Sciences. M. Sc. Thesis. Uppsala. Ngoan, L. D. and Sarria, P. 1994. Effect on growth performance of replacing sugar cane juice energy with African palm oil in diets for growing and finishing pigs. Conferencia presentada en el II Seminario Internacional "Sistemas Agrarios Sostenibles para el Desarrollo Rural en el Tr¾pico" y IV Seminario Nacional "Alternativas de Producci¾n Animal con Recursos Tropicales" Univ. Tecnologica de los Llanos Orientales, Villavecencio, Colombia. NRC 1988. Nutrient Requirement of Domestic Animals. Nutrient Requirement of Swine. 8th ed. National Academy Press, Washington, D.C.. Ocampo, A., Lozano, E. and Reyes, E. 1990a. Utilización de la cachaza de palma africana como fuente de energía en el levante, desarrollo y ceba de cerdos. Livest. Res. Rur. Dev. 2(1): 43-50.
FAO / Chapter 4: African oil palm - Feeding Pigs in the tropics
17
Ocampo, A., Castro, C. and Alfonso, L. 1990b Determination del nivel óptimo de proteína al utilizar cachaza de palma africana como fuente de energía en raciones para cerdos de engorde. Livest. Res. Rur. Dev. 2(2):67-76. Ocampo, A. 1992. Oil-rich Fibrous Residue from African Oil Palm as Basal Diet of Pigs; Effects of Supplementation with Methionine. Livest. Res. Rur. Dev. 4(2):55-59. Ocampo, A. 1994a Utilizacion del fruto de palma Africana como fuente de energia con niveles restringidos de proteina en la alimentacion de cerdos de engorde. Livest. Res. Rur. Dev. 6(1):1-7. Ocampo, A. 1994b. Raw palm oil as the energy source in pig fattening die ts and Azolla filiculoides as a substitute for soya bean meal. Livest. Res. Rur. Dev. 6 (1): 8-17. Ocampo, A. 1994c. Efecto del nivel de pulidura de arroz en una dieta basada en el fruto entero de palma africana para el engorde de cerdos. Livest. Res. Rur. Dev. 6(2): (18Kb). Ong, H.K. 1982. The Use of Palm Oil Sludge Solids in Pig Feeding. (Paper presented at First Asian Australasian Animal Science Congress, Sept. 2-5th, 1980) Animal Production and Health in the Tropics pp307-311. PNI (Pig News and Information) 1990. Palm Kernel Meal. 11(4) pp 11. Sarría, P., Solano, A. and Preston, T.R. 1990. Utilización de jugo de caña y cachaza panelera en la alimentación de cerdos. Livest. Res. Rur. Dev. 2(2): 92-99. Solano, R. 1986. Principales subproductos de las plantas extractoras de aceite. En IV Mesa Redonda Latinoamericana sobre Palma Aceitera, Valledupar, Colombia 8-12 de junio de 1986, ORLAC/FAO p 161-167 . Wambeck, N. 1990. La experiencia Malasiana en el desarrollo de la industria de la palma aceitera con la tecnologia avanzada de Estechnik. In: VI Mesa Redonda Latinoamerica sobre Palma Aceitera San José, Costa Rica 12-16 marzo 1990 ORLAC/FAO p 255-267
File:// 1990 ORLAC/FAO p 255 – 267 : 11. FAO Feeding pigs.doc Sep.1999/ NW.
PREPARATION OF AN OIL PALM MILL PROJECT. By Noel Wambeck ( Revised 30th October 1997 )
INTRODUCTION. Once a project have been initiated, and the decision has been taken to go ahead with a project, the management team will need the totally committed backing of the investors and that the degree of confidence and faith in the project can only come from a thoroughly prepared project study and appraisal. To the investor, it is important that they should generate a good cash flow as early as possible through well planned but speedy development, income arising from early plantings or from revenues, exploitation of natural resources, eg. Sales of timber from land preparation or from tree crops during replanting cycles. Timely provision of infrastructure including roads of access for development inputs and for produce evacuation, water supply, housing and offices, power, communications with adequate processing facilities and logistics for points of export, shall all be part of the preparation of project. Although a lot have been said and written on the subject of “ PROJECT STUDY “ the basic phases involved from project inception to project implementation are as follows: OVERALL APPROACH The project work will be divided into 4 main stages and later, further sub-divided in accordance with the yet-to-be-determined Phases of development. Stage 1 is described in detail and the subsequent stages are described in general since these stages depend on the Stage 1 findings.
We recommend that these work stages be as follows:-
Stage 1
:
Initial assessment of the proposed project site and preparation of a Feasibility Study Report.
Stage 2
:
Compilation of additional information and basic design for submission to Local Authority and approvals.
Stage 3
:
Detailed Project Design and Drawings, Tender Documents to Tender Evaluation and Contract Document.
Stage 4
:
Implementation and Supervision of the project.
PREPARATION OF AN OIL PALM MILL PROJECT.
2
STAGE 1. PROPOSED SITE SELECTION AND FEASIBILITY STUDY REPORT
The essential elements in Stage 1 are as follows :1.1
Discussions with the Client’s project members regarding their objectives for the proposed oil palm plantation project in the short, medium and long-term requirements. The discussions would include marketing strategy and determine whether Market Research or an Economic Study would be required at Stage 2.
1.2
The project team to inspect the proposed project site identified by the client. The site visit will include locating possible sites for the operation command base, plantation, nursery area, processing facilities and infrastructure such as, roads water source, waste water effluent discharge point, housing area, utility requirements for estate, such as treated water and electrical power etc…..
1.3.1
Liaise with local Authority in order to take into account any restrictions the Authority may have on the establishment and operation of the proposed project.
1.4
Assess location of plantation site with regards to the communication and transportation logistics.
1.5
Consider the following items to determine the advantages and disadvantages of each site.
1.6
Access to site during land preparation, construction of infrastructure, planting and during operation.
1.7
Location of each site relative to the shoreline and access roads.
1.8
Assess the size of each site for the proposed project.
1.9
Determine the capacity and zoning for expansion at each site.
1.10
Estimate the ground level at each site relative to the tide levels and assess the need for flood prevention including reclamation and shoreline protection.
1.11
Investigate the Environmental effects, including effluent disposal. Determine the requirements for the Environmental Impact Assessment which will be carried out at Stage 2.
1.12
Assess location of sites with regards to source for construction materials.
1.13
Investigate the requirements of Local Government and of other Approval Authorities for the construction of a project
1.14
Preliminary investigation into source of processing equipment and in particular, we would explore the possibility of using locally manufactured equipment.
1.15
Study the existing site investigation details. Determine the extent of further investigation and topographic and surveys required at each site. The Investigation and Surveys would be carried out at Stage 2.
PREPARATION OF AN OIL PALM MILL PROJECT.
3
1.16
Determine in principle the foundations required for the buildings and structures based on Existing soil information.
1.17
Identify whether Market Research and Economic Studies are required.
1.18
Prepare order-of-cost budget estimates for the preferred site, including approximate comparisons with the other site if appropriate. The budget estimate would include the cost of soil investigation, Earthworks, Reclamation, Infrastructure, Services, and the Processing Plant. In addition the estimate shall nclude i the approximate costs for upgrading existing roads if required.
1.19
The results of the study will be presented in a report highlighting the advantages and disadvantages of each site recommending which site should be selected for Stage 2 investigations.
This stage is intended to provide an overview of the main issues, and does not become involved in detail. The project site selection, assessment and feasibility study will make use of as much data that is available at the time, including charts or surveys indicating general topography and preliminary knowledge of soil conditions from the existing site investigation.
This data will be augmented by data obtained in the field during the site visit. The study will take into account the Client’s requirements in preliminary terms and will aim to confirm that the desired facilities within the development plan can be efficiently located on the proposed site. During Stage 1 it is expected that several discussions will take place in order to establish the medium and long-term requirements of the project. It will be identified whether there is a clash between the short-term needs of the Client and their long-term objectives. This will be assessed in Stage 2. The deliverables in Stage 1 would be presented as a document recording the data used and the risks involved pending later detailed surveys and soils investigations. It will include layouts at small scale with descriptive text and preliminary order-of-cost budget estimates. The cost estimates for the site will be based on the existing soil investigation at the site.
PREPARATION OF AN OIL PALM MILL PROJECT.
4
STAGE 2. COMPILATION OF ADDITIONAL INFORMATION AND BASIC PROJECT DESIGNS FOR SUBMISSION TO LOCAL AUTHORITIES AND APPROVALS.
The commencement of Stage 2 services would be dependent on written instructions from the Client to proceed. The activity and work components of Stage 2 would generally be as follows :-
2.1
Establish Short, Medium and Long-Term Requirements of the Plant
Based on the outline concept layout selected from the Stage 1 work, establish in precise terms by discussion, the detailed objectives and strategies required to achieve the Client’s business plan for the short, medium and long-term.
2.2
Review and Acquisition of Project Design Data.
At a detailed level, and in close cooperation with Operational Staff, considerable amounts of data will need to be reviewed, or if not available, acquired. Such data would include size of the proposed oil palm plantation, utility requirements including capacities and distribution round the processing plants. In addition, if it is found during Stage 1 that further studies such as Market Research and Economic Studies, these studies would also be carried out, during Stage 2. On completion of the required on-site surveys, investigations and the desktop studies, all such data would be entered into a Project Design Specification Document, which is updated and reissued to the Client as and when required. This document forms the basis for the recording of agreed data, and provides the Client with a permanent means of easy reference in the future. Stage 2 would also include an Environmental Assessment Report. The assessment would include a study into the present and future needs of the project against the present and expected future legislation. Included in the study will be required data and forms for the applications and approvals by Local Authorities.
2.3
Definition of the Agreed Project Scheme.
Based on the reviews of data, the acquisition of essential new data, and detailed discussions on proposed project scheme to meet business plan objectives. These Study report taken together with the Basic Design Specification document define the Agreed Scheme, from which on the instructions of the Client, detailed engineering would commence.
PREPARATION OF AN OIL PALM MILL PROJECT.
STAGE 3.
5
DETAILED DESIGN, TENDERS AND CONTRACT DOCUMENT.
The activity and work components of Stage 3 would generally be as follows: -
3.1
Detailed Engineering Design
Based on the Agreed Scheme layouts and associated drawings and on the contents of the Design Specification, taken in conjunction with the results of surveys and any necessary studies, detailed engineering calculations would be prepared together with sufficient general arrangement and detail drawings required to allow selected Contractors to submit concise tenders for each package of work. The project team would make use of our comprehensive in-house computer facilities for specialist design tasks and by means of our AutoCAD system for the production of almost all of the drawings. In addition to their own broad experience, the members of our Project Team would be able to call upon the specialized knowledge of experts within industry whenever required. The Consultant would also provide the Quality Management function ensuring both that the correct management and control functions are in place, and carry out key design checking procedures, which include the all important design reviews.
3.2
Technical Specifications
In conjunction with the preparation of detailed engineering design, full specification for materials and construction of the works and procurement of the plant will be provided, taking into account the latest thinking for the most efficient operation of a processing plant and for low maintenance. Emphasis will be placed on the use of practical materials and construction requirements including where possible the elimination of overly complex details to ensure easy maintenance and satisfactory durable structures suitable for the harsh environment.
3.3
Contract Documents for Tender Issue
On a contract by contract basis, these documents would generally comprise: • • • • • •
Tender Notice Instructions to tenderers Form or Forms of Contract, to be discussed and agreed with the Client taking into account Client specific requirements, project constraints, and international practice to include a reasonable allocation of responsibility between the contracting parties. Technical specifications, discussed above Any necessary schedules (e.g. of suppliers) Bills of Quantities
Client and site specific conditions would generally be dealt with under Part 2 of the General Conditions of Contract.
PREPARATION OF AN OIL PALM MILL PROJECT.
3.4
6
Tender Evaluation
The tender period would vary depending on the scale and complexity of the work. While there is always a desire to shorten tender periods in order to expedite the project, we would recommend the allowance of an adequate time to ensure that tenderer’s preparations are not rushed so that sufficient attention can be paid by them to the details of the work and the competitiveness of their bids. During the tender period members of our team would be available to answer tenderers queries and where appropriate, would undertake the issue of clarification notices to all tenderers. Upon receipt of tenders we would carry out a full evaluation and prepare a report for review by the Client. It is likely that this would take the form of a preliminary report on the tender submissions to be followed by meetings with those submitting preferred bids. The report would then be updated and include recommendations for the award of contract. In its final form the report would include: • • • •
A tender summary and breakdown of principal items for all tenderers More detailed price breakdown for the leading tender Notes of Meetings and Negotiations Comments on tenderers’ submissions and approach to the project
If alternative designs are submitted by tenderers these would be examined and assessed and, if necessary, discussed with the tenderer concerned. The final report would contain an assessment of such alternatives and recommendations as to whether or not this would be acceptable. The deliverables for Stage 3 would comprise initially a full set of tender documents for Client confirmation and, after receipt of final approval, a master set of tender documents for issue to all selected tenderers by the Client. The Consultant will provide assistance with the pre-selection of tenderers early on in Stage 3. In addition, the Client would receive detailed reports on the assessment of each of the tenders.
PREPARATION OF AN OIL PALM MILL PROJECT.
STAGE 4.
7
CONSTRUCTION STAGE, SITE SUPERVISION
The commencement of Stage 4 services would be dependant on written instructions form the Client to proceed. The activity and work components of the Stage 4 services would generally be as follows:-
4.1
Preparation of Contract Documents etc.
Upon confirmation of selection of Contractor by the Client we will prepare two sets of original contract documents including: • • • • • • • • • •
Form of tender Form of Contract Form of Bond Conditions of Contract Specifications Bills of Quantities/Summary of Prices as priced by the successful tenderer Schedule of Drawings Contract Drawings Technical Schedules Agreed notes of meetings, relevant correspondence and notices of clarification pertaining to the acceptance of the tender
These will be issued to the selected Contractor and then to the representative of the Client for signature and following this 3 certified copies would be prepared. The two originals will then be returned to the contract parties for retention. At the same time as the original contract documents are being prepared and processed, full sets of construction drawings, specifications and other documents will be prepared and issued to the Contractor.
4.2
Project Management Services
We would confirm that the nominated Project Manager, or equivalent alternative, is fully used to managing multi-disciplinary projects.
4.3
Pre-construction Meeting
We would hold a pre-construction meeting prior to the commencement of all the contracts. The purpose of this meeting would be to review with the successful Contractor the requirements of the Tender Documents to develop a list of information that he is required to provide as stipulated in the Tender Documents and to solicit from him, his programme of activities as required by the Tender Documents.
PREPARATION OF AN OIL PALM MILL PROJECT.
4.4
8
Review and Approve Contractor’s Programme
For each separate contract, the control programme submitted by the Contractor indicating his proposed timing and phasing of various operations will be reviewed. Following that review, advice will be given on any changes deemed necessary in the programme proposed by the Contractor. It is also necessary to monitor carefully the Contractor’s control programme to check his progress and compare actual progress with the programmed progress. From time to time as required by circumstances, the Contractor will be required to update his programme. The Client will be advised of any developments threatening the delay of completion and recommendations will be made on any actions necessary to facilitate timely completion. The construction programme must be prepared by the Contractors using CPM techniques and contain the key elements and timetables for the completion of his work. We will review the programmes and any subsequent changes deemed appropriate.
4.5
Establish Project Files, Prepare Monthly Reports and Attend Job Meetings.
Essential to any project is the establishment of a project filing system such that shop drawings, contract correspondence, daily reports, monthly reports, time schedules, etc., can be readily retrieved from files and utilized for the purpose of administering the Project. A computerised record file consistent with our needs as the Consultants and the Client is established. Monthly progress reports will be prepared for submission to the Client. These monthly progress reports will report on all phases of the work in all disciplines, on delivery schedules, on the development of programme updates, identify particular construction problems or quality control problems during the course of the month and will further include the degree of physical completion and expenditures under each contract. As the project construction proceeds actual costs may vary from the previously estimated costs due to changes in quantities of work and materials, or due to unforeseen circumstances. A close control over these costs and their affects on the overall project costs will be undertaken so that strict budgetary control is exercised. On a regular basis, formal progress meetings will be held with the Contractor. An agenda will be prepared with input from the Contractor and the Client.
We will prepare the final minutes of the meeting. It is important to the orderly progress of the job that progress-meeting minutes are maintained accurately.
PREPARATION OF AN OIL PALM MILL PROJECT.
4.6
9
Recommend Tests on Materials and Equipment
We propose that laboratory, shop, and mill tests on materials and equipment are incorporated in the Project. As appropriate, our sit e staff or representatives will observe the actual performance of such tests.
4.7
Review Test Reports and Witness Tests
At various points in the progress of the project it will be required by the Contract Documents that specific materials or equipment be tested and certificates be issued for their performance. The objective of such tests is to ensure that the Contractor complies with the requirements of the Contract Documents and that the materials and equipment meet the appropriate contract specifications. Where witness tests are required for specific pieces of equipment, we would be able to provide the necessary manpower to witness the tests as required by the Contract Documents. Under the provision of the Contract Documents, the Contractor will also be required to submit certification of materials testing and certified test results ensuing from such tests. This system will be monitored and such certificates and tests reports reviewed and approved and provided as historical records.
4.8
Review and Approval of Fabrication Drawings
The Contractor will be required to submit fabrication drawings for approval prior to construction and installation of specific materials and equipment items. These fabrication drawings will be reviewed in accordance with the procedures laid down in the Quantity Plan. It is also critical to the conduct of the Project that fabrication drawing review be expedited and that the Contractors’ submittals are as accurate as possible. Poor quality fabrication drawings frequently result in increases in engineering costs as well as frustrations to the Client. Detailed construction drawings, fabrication and erection drawings, charts, and any other related proposals required to be submitted by the Contractor, will also be checked for adequacy and compliance with the terms and conditions of the Contract Documents. Comments concerning required revision of the Contractor’s submittals will be prepared in writing for approval of the Client prior to presentation to the Contractor. Copies of Contractor’s submittals, comments and the finally accepted documents will be maintained in permanent files until completion and final acceptance of all construction undertaken by each Contractor.
PREPARATION OF AN OIL PALM MILL PROJECT.
10
Archiving will then be carried out in accordance with the Quality Plan with the transfer of appropriate document records to the Client as agreed.
4.9
Prepare Diaries and Records
During the execution of the work, we will prepare detailed daily diaries and records concerning the work, site, ground and weather conditions, material quantities delivered to the job sites, and related information. Copies of such records will be provided to the client upon request. These diaries and records are invaluable in cases of later disputes with Contractors and possible arbitration or legal action.
4.10
Evaluation of Extra Payment Claims
Contractors or suppliers may make claims from time to time for extra payment. Any such simple claims will be reviewed and evaluated impartially and professionally by the site staff and recommendations made to the client with respect to the admissibility of a claim. Where a claim is considered allowable and approved by the client, a variation order will be initiated for the client approval.
4.11
Variation Orde rs
Throughout the progress of the Project, certain changes by virtue of site conditions may be required. Changes may be required to plans and / or specifications due to site conditions being at variance with those assumed during design. We are obliged to advise the Client of any such changes and variation orders deemed necessary. When such conditions arise we will prepare the appropriate variation orders with the backup information and explanation as to the need and reason and submit it to the client for approval. Each variation order will accompanied by an analysis concerning the appropriate amount by which payments to the Contractor are to be increased or decreased as a result of the changes to the work included in the variation order.
4.12
Contractor’s Progress Payment
Progress payments by the Client will be made to the Contractor on a schedule basis throughout the job, based on payment certificates, which we will issue as Engineer. We will maintain records sufficient to review and check the progress payment request in detail. Monthly project photographic records will also be required, as these are often a substantial aid in identifying project conditions and degree of project completion.
PREPARATION OF AN OIL PALM MILL PROJECT.
4.13
11
Final Inspection
After the contracts are virtually completed, we will undertake final inspection during the period of each contract and advise the Contractor of any additional work required. On completion of the remedial work, we will issue a final certificate for each contract.
4.14
Supervise Commissioning and Handing Over
We will provide qualified personnel to supervise and monitor all required final tests and commissioning to be performed by the Contractor and to make appropriate recommendations. The relevant Government agencies and Authorities shall be notified in advance by the Contractor for final inspection and approval by such authorities. Supervision of the no load trial run of the plant and ancillary shall be carried out by the Consultant after which the Client will be notified to arrange for raw material for process to be delivered to the plant. A pre-commissioning meeting shall be conducted between the Contractor, Plant Manager, Supervisors, key personnel and Consultant on the procedure, safety requirements and expectations. It is suggested that the operators and / or other selected personnel of the Client, who will later be responsible for the operations of the new plant, should be in attendance during the final acceptance testing. This approach will familiarize those operators with the new systems. Following completion of the final tests and commissioning, a final report will be submitted to the Client.
4.15
As-Built Drawings and Documents
During the course of construction a record set of the contract drawings for each contract will be maintained and marked up by the Contractor and agreed by the Resident Engineer to show ‘as built’ work. This is particularly important where approved changes may have been made to the contract drawings so that their true location in the field is properly recorded. On completion of the construction contracts, the ‘as-built’ modifications will be recorded on a master set of reproducible AutoCAD drawings (reduced and full size) and 3 ½ inch diskettes which will be supplied by the Contrac tor and submitted to the Client as a permanent record of the asconstructed works. The appropriate specification, vendor’s data, spare parts lists and similar aspects will accompany the ‘as built’ drawings.
PREPARATION OF AN OIL PALM MILL PROJECT.
4.16
12
Operation and Maintenance Manuals and Training
All suppliers of machinery and equipment will be contractually bound to provide Manuals of Instructions to facilitate satisfactory operation and maintenance of mechanical and electrical and other equipment. The manuals will be compiled by the Contractor into bound documents, each of which explains the operational and maintenance programmes for each piece of equipment installed. The Client will then have easy reference to the methodology and requirements for operating and maintaining the equipment under their supervision. The Consultant shall advise and assist the Client in the recruitment of personnel. The on-site commissioning engineer will provide operation of machinery and plant, quality control and maintenance schedules, and prior and during the commissioning period short courses and training of personnel on the process systems.
4.17
End of Maintenance Period
A final inspection of the works will be carried out at the end of the maintenance period; corrective action list(s) will be prepared and submitted to the Contractor. The final completion certificate will be issued a completion of defect rectification.
4.18
WORK PROGRAMME
Stage 1 : Site Selection and Feasibility Study work is the starting point from which clear project definition emerges, it is appropriate at this very early stage of the Project to concentrate only on the work required to achieve completion of Stage 1. The Site Selection and Feasibility Study should be completed in final draft form within 6 weeks from the commencement of the initial site selection visit.
Salient notes of the size of plantation with the corresponding basic data and project cost of Oil Palm Mills are enclosed.
Noel Wambeck / Reprint June1999.
MATRIX FOR OIL PALM MILL PROJECT - DESIGN CAPACITY, COST ESTIMATES, BASIC DATA AND OPERATING REQUIREMENTS. APPLICABLE TO COUNTIES WITH AMOUNTS SHOWN IN ITS CURRENCY BELOW :
ITEM
Details
Design Capacity MT Fruit Bunches / HOUR
Basic Data for Project Planning
DATE :
5
10
20
30
20/40
45
30/60
45/90
60 / 120
BASED ON MALAYSIAN TENERA MATERIAL WITH 25 MT FFB / HA. 25% OIL CONTENT & OER AT 22% CPO 5% PK.
1 1.1
PLANTATION FRESH FRUIT BUNCH ( 25 mt / Ha )
ha mt / year
2 2.1 2.2 2.3
MILL CAPACITY Operating on 24 hours per day Operating on 20 hours per day Operating on 16 hours per day
mt / hr mt / hr mt / hr
3 3.1 3.2
PRODUCTION Production of CPO per Year Production of PK per Year
mt / 22% mt / 5%
4 4.1 4.2 4.3
HUMAN RESOURCES Management & Staff Manpower requirements Total manpower
persons persons / per shift persons / 3 shifts
5 5.1 5.2 5.3 5.4 5.5 5.6
OTHER REQUIREMENTS Water requirements Electrical power requirements Land required Mill & Appurtenance Effluent Ponds Project time schedule
m3 / hour KW hectares ha ha months
6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11
CAPITAL COST Land Preliminary/ Soil Invest./ Survey/ Prof. Fee Infrastructure / Earth Works & Piling Civil & Structure with Buildings Proprietary Equipment Mechanical & PI Electrical works Effluent treatment system Lab & Workshop equipment Vehicles Staff Quarters TOTAL for Malaysia
RM RM RM RM RM RM RM RM RM RM RM RM
7 7.1 7.2 7.3 7.4
COUNTRIES West Africa / South America India / Sri Lanka Indonesia Papau New Guinea
USD 3.8 India Rs.11.5 Indonesian Rp.2300 PNG Kina 2.8
Capacity mt/hr
1,000 25,000
2,000 50,000
4,000 100,000
5,000 125,000
7,000 175,000
8,000 200,000
10,000 250,000
15,000 375,000
20,000 500,000
3.99 4.79 5.99
7.99 9.58 11.98
15.97 19.17 23.96
19.97 23.96 29.95
27.95 33.54 41.93
31.94 38.33 47.92
39.93 47.92 59.90
59.90 71.88 89.84
79.86 95.83 119.79
5,500 1,250
11,000 2,500
22,000 5,000
27,500 6,250
38,500 8,750
44,000 10,000
55,000 12,500
82,500 18,750
110,000 25,000
3 12 39
3 24 75
3 28 87
6 30 96
9 34 111
9 36 117
9 42 135
9 50 159
9 56 177
10 150
20 300
40 600
60 900
80 1000
90 1125
120 1500
180 2,250
240 3,000
2 2 16
2 2 18
6 6 20
6 6 20
8 8 22
8 8 22
8 8 24
Client
Client
300,000 450,000 1,000,000 2,200,000 1,000,000 500,000 200,000 200,000 150,000 Not required 6,000,000
Client
550,000 900,000 2,000,000 3,150,000 2,500,000 900,000 500,000 300,000 200,000 Not required 11,000,000
Client
650,000 1,600,000 3,000,000 6,000,000 5,000,000 1,200,000 900,000 300,000 350,000 2,000,000 21,000,000
Client
800,000 1,800,000 3,600,000 7,200,000 6,900,000 1,400,000 1,200,000 300,000 400,000 2,400,000 26,000,000
5
10
20
30
2,052,632 69,000,000 15,870,000,000 2,785,714.29
3,763,158 126,500,000 29,095,000,000 5,107,142.86
7,184,211 241,500,000 55,545,000,000 9,750,000.00
8,894,737 299,000,000 68,770,000,000 12,071,428.57
Client 900,000 2,000,000 4,400,000 7,900,000 7,200,000 1,500,000 1,600,000 300,000 400,000 2,800,000 29,000,000
20/40 9,921,053 333,500,000 76,705,000,000 13,464,285.71
Client
1,100,000 2,250,000 4,950,000 8,600,000 7,700,000 1,800,000 1,800,000 400,000 400,000 3,000,000 32,000,000
45 10,947,368 368,000,000 84,640,000,000 14,857,142.86
1,300,000 2,400,000 6,600,000 9,500,000 8,800,000 2,100,000 2,000,000 400,000 500,000 3,400,000 37,000,000
30/60 12,657,895 425,500,000 97,865,000,000 17,178,571.43
10 10 24
Client
12 10 24
Client 1,600,000 2,700,000 7,700,000 11,100,000 9,300,000 2,900,000 2,400,000 400,000 500,000 3,900,000 42,500,000
45/90 14,539,474 488,750,000 112,412,500,000 19,732,142.86
1,800,000 3,600,000 8,800,000 12,900,000 10,800,000 3,300,000 3,400,000 400,000 500,000 4,500,000 50,000,000
60/120 17,105,263 575,000,000 132,250,000,000 23,214,285.71
Noel Wambeck 26th March 1999 revised.
5/13/00
Perunding AME / MaY 99 / NW.
PROJECT MANAGER'S CHECK LIST
DATE ; PROJECT NO.
PROJECT :
PROJECT MANAGER:
Project Deivery : ……………………………………………. Months Completion Date : ………………………………………………. 199……. ITEM
TASK IN BRIEF
A
Design stage - Preliminaries
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Master list of Machinery & Appurtenance Preliminary layout Engineer's Cost Estimates Project Report Drawing List Layout review & approval by client Proposal for Effluent control & system DOE site approval State Authority approval MIDA application ( Industrial manufacturing Licence ) PORLA application ( for Palm Oil projects ) DOE writen approval Fire Department Chieft Electrical Inspector Indah water approval Local town board approval for buildings Other
B
Preparation of Drawings & Documents
18 19 20 21 22 23 24 25 26
Clearance of all applications Pre-qualification of Contractors Soil investigation tender Proprietary equipment tender Earth works tender Civil & Structural works tender Mechanical & PI works tender Electrical works tender Other
C
Tender & Award Stage
27 28 29 30 31 32 33 34 35 36
Tender notice ads in local news / by invitation Tender acknowledgement Evaluation report Letter of acceptance Preparation of Contract Proformance bonds / guarantees Insurance certificate Prepare monthy reports to client / PORLA OR MIDA Certify claims by Contractors Other
STATUS
ACTION BY
TARGET
COMPLETION
DATE
DATE
COMMENTS
D
Construction Stage
37 38 39 40 41 42 43 44 45 46 47 48 49 50 51
Confirm taking over of site by contractor Check Contractors quarters and facilities at site Check bench marks and setting out of project sites Check all safety requirements & sign display at site Inspection of fabrication works at contractor's site Conduct pre-delivery meeting with proprietary supplies Check delivery schedules JKJ approval to commence installation of machinery & Plant Inspection of site works Conduct site meetings Certify works at site Issue variation instruction Prepare monthy reports to client / PORLA OR MIDA Certify claims by Contractors Other
E
Commissioning Stage
52 53 54 55 56 57 58
64 65 66 67 68
Check all machinery, equipment and plant installation, fittings etc. Call for CEI inspection & JKJ hydrostatic test of pressure vessels Conduct hydrostatic test & setting of safety valves Check drying out of Boilers & start up proceedures Loading of tanks with water to check for leakage & stabilisation Setting of switch gear, earthfault etc. & test power supply Check all piping & valves position, connections, supports & blowing out of steam pipes Check all lubrication requirements Fire & safety requirements & sign board displays Conduct pre-commissioning meeting with client, supplies & contractors Check all raw material, manpower and utility requirements Notice by letter to client, contractors, insurance company and authorities for confimation of commissioning date Conduct & supervice commissioning Chech and adjust speeds of machinery, fans & conveyors Conduct capacity test with control of performance Conduct training of machinery operators Follow up defective works by contractor
F
Closing of Project
69 70 71 72 73
Submit commissioning report & certify hand over cetificate Submit machinery parts & service manuals Collect & submit "as built" drawings Wind up all contracts Release all retention funds
59 60 61 62 63
STATUS
ACTION BY
TARGET
COMPLETION
DATE
DATE
COMMENTS
PROJECT MONTHLY REPORT
1
PROJECT MONTHLY REPORT PROPOSED CONSTRUCTION OF ………………………….
FOR ( Client ) ………………………………………………………………………………………………… …………………………………………………………………………………………………
(For the month of November 1998)
Prepared by :
PROJECT MONTHLY REPORT
2
The Contract
The Employer:
The Employer’s Representative:
The Contractor:
Essential Terms Agreed: 1. Contract Sum :
RM Malaysian Ringgit :
2. Contract Sum Analysis :
To be provided by the contractor
3. Revised Contract Period :
4. Liquidated and Ascertained Damages :
RM ………… per calendar day.
PROJECT MONTHLY REPORT
3
INDEX
1.0
General
2.0
Progress against Schedule - Site progress - Manpower - Imported items - Submission - Next month schedule
3.0
Monetary report - Progress payment - Variation orders - Day works - Others
4.0
Information Requested - from authorities - from the employer - from the contractor
5.0
Important issues that might give rise to Contractual dispute in due course.
6.0
Progress photographs
7.0
Project Manager’s recommendations
8.0
Monthly Report submitted by Contractor 8.1 Contract Agreement : 8.2 Meetings & Site visit : 8.3 Works Completed : 8.4 Works Outstanding : 8.5 Pending Information :
OIL PALM MILL DESIGN BASIS F OR A 45 – 90 MT F F B P ER HOUR
The information herein contains strategies, trade secrets, intellectual properties and other confidential information and the protection of its secrecy is critical to the future financial well-being of Perunding AME. Accordingly, this document is provided on the conditions of confidentiality and non-disclosure and parties to whom this document is supplied by the document, acknowledge and agree to respect the sensitivity and exclusivity of the information, affirm that the document and its contents are confidential; and further, agree to hold and treat it in strictest confidence, not permit, directly or indirectly, the disclosure of the information contained herein to third parties, and if so required by Perunding AME to return the document without any photocopies or other duplications being made.
SPECIFIC GRAVITY
SPECIFIC GRAVITIES AND DENSITIES OF OIL PALM COMPONENTS & SUBSTANCE USED IN THE CALCULATION IN THE DESIGN BASIS SHEETS. ITEM / COMPONENTS / MATERIAL OR SUBSTANCE
Ash Bunch Cracked mixture Crude Palm Oil Diluted crude oil Fibre Fresh Fruit Bunch Fruitlets Palm Kernel Oil Palm Nuts Palm Olein Palm Stearin Press expelled cake Pure water without air at 30degC Shell Sludge Sterilized Fruit Vegetable oils Water at 4 deg.C max
Specific Gravity
Bulk Density Average weight
SG
mt / m3
0.550 0.628 0.535 0.8927 0.890 0.257 0.580 0.640 0.892 0.653 0.9015 0.8865 0.550 0.994 0.650 0.899 0.640 0.945 1
0.437 0.550 0.653 0.893 0.900 0.350 0.480 0.680 0.892 0.653 0.902 0.880 0.650 0.994 0.750 0.900 0.660 0.950 1
DESIGN OF LOADING RAMP ITEM : PROJECT:
OIL PALM MILL
CLIENT: POWER
230/415V 50Hz
CODE :
DATE:
Steel
Input data by:
Pressure
Nil
1st Ph
Mill Capacity Minimum Storage Period Capacity of each cage
90
mt FFB/hr hr Tonnes FFB
12 7
Bulk Density Of FFB Capacity Per Door Of Loading Ramp Number of loading ramps / hoppers Loading Ramp Slab: Assume Average storage Operating period Choose number of loading doors Number of doors required
2nd Ph
45
kg/m3 Tonnes 24 Nr. m m m hr/day doors per bay 48 Nr.
480 15 12 n/a n/a 0.45 24 2 24
Length Width depth
CALCULATE Total storage required Storage in the ramp / hopper Storage on slab Storage in cages Nr.of cages required
540
(Minimum)
Number of Loading Ramps with Hoppers
180 0 360 51
1,080 360 0 720 103
tonnes tonnes tonnes tonnes Nos
12
24
Nr.
Page 1 of 1
16-Jun-99 NW
Perunding AME Consulting Engineers
GIVEN DATA LOADING RAMP & HOPPERS
DESIGN BASIS 1.02
DESIGN OF CAGE TRANSFER CARRIAGE PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
DESIGN BASIS
ITEM :
1.4 16-Jun-99
CODE:
BS2654
DATE:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA
CAGE TRANSFER CARRIAGE Mill Capacity Tranfer cycle time Capacity of each cage CONSIDERATION Design for final phase
1st Ph
2nd Ph
45
90
mt FFB/hr min tonnes FFB
90
mt / FFB per hour
9 7
90
CALCULATE Transfer capacity required Nr.of cages required per transfer Number of transfer capacity
6.43 0.96
12.86 1.93
2
2
Page 1 of 1
cages/hr
cages per transfer
NW
DESIGN OF FFB STERILIZER PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
DESIGN BASIS
ITEM :
2.2 16-Jun-99
CODE:
BS2654
DATE:
Steel
ST 37
Input data by:
Pressure
3.16 Bar.g
Perunding AME Consulting Engineers
GIVEN DATA FFB STERILIZER Mill Capacity Capacity of each cage Nr.of cages per steriliser Cycle time
2nd Ph
1st Ph 45
90 7
7
7 120
mt FFB/hr tonnes FFB cages minutes
CALCULATE Nr.of steriliser required Nr.of units to be provided
1.84 2
Page 1 of 1
4
3.67 Nos units
NW
DESIGN OF FFB CAGE TIPPLER
DESIGN BASIS
ITEM :
3.1 16-Jun-99
PROJECT: OIL PALM MILL
CODE:
BS2654
DATE:
CLIENT:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
Power
230/415 V 50 Hz
GIVEN DATA CAGE TIPPLER Mill Capacity Capacity of each cage Nr.of Tippler
1st Ph
2nd Ph
45
90 7
1
mt FFB/hr tonnes FFB
2
CALCULATE Nr.of cages required to be tippled Time taken per tippling cage ACCEPTABLE
6
13 9.33
YES
Page 1 of 1
per hour minutes
NW
PERUNDING AME - Consulting Engineers
DESIGN OF FRUIT ELEVATOR (45MT /HR ) PROJECT:
OIL PALM MILL
CODE:
CLIENT: PowerPower
DESIGN BASIS
Steel 230/415 V 50 Hz
ITEM :
4.1
DATE:
16-Jun-99
Input data by:
Pressure
Nil
NW
Perunding AME Consulting Engineers
GIVEN DATA Mill Capacity MATERIAL BULK DENSITY CAPACITY, TF/ Material Ratio VERTICAL HEIGHT INCLINATION SPROCKET C/C SPROCKET TEETH SPROCKET PCD SPROCKET REV SPEED BUCKET SPACING CHAIN PITCH BUCKET THICKNESS
FRUIT ELEVATOR mt 45 mt/HR Sterilized Fruit 3 pf 640 kg/m M r H α t c
30 100% 14 60 15 12 0.2964 33.12 30.84 0.75 150 3
m C m T mm rpm m/min m mm mm 3 7200 kg/m
S z l t ps
STEEL DENSITY
mt/HR
o
CALCULATE MASS FLOW NO.OF BUCKETS WEIGHT OF material per bucket
Mf=rxMx1000
NET VOLUME OF BUCKET CHOOSE BUCKET SIZE:
Vb=Qf/pf
29,700 kg/hr 41 bucket/min 12 kg/bucket 3 0.0188 m /bucket
n=S/z Qf=Mf/(60*n)
width depth length
a d b
0.25 m 0.25 m 0.70 m 3
Vb=1/2xaxdxb
VOLUME OF BUCKET
0.021875 m 2
2 0.5
-3
WEIGHT OF BUCKET
wb=[ad+2b({a/2} +d ) ]tpsx1.1x10
10.78 kg
WEIGHT OF MATERIAL
Wm=Mfxc/(60xS)
240.8 kg
NO.OF BUCKET ON LOADED STRAND
Nb=c/z
WEIGHT OF MATERIAL PER BUCKET
wm=Wm/Nb
12.0 kg
DREDGING PULL
F1=20.12 x wm/z
323 kg
ESTIMATED WEIGHT OF BUCKET+CHAIN
Wb=wbx4xNb
863 kg
PRELIM CHAIN PULL
F2=(Wm+F1)f1+Wbxf1/2
995 kg
MIN.BREAKING STRENGTH
f1=
1.0
fs=
10
20
F3=F2xfs
Page 1 of 2
9,950 kg
86%
PERUNDING AME - Consulting Engineers
FINAL CHAIN PULL
( Renold conveyor chain booklet )
Choose: Chain: Pitch Strength: Weight:
150 mm 13,636 kg 11.68 kg/m
Total weight of chain, Total weight of bucket
Wc=wb x Nb
350 kg 431 kg
Total weight of chain + bucket,
Wt=Wc+Wb
782 kg
Final chain pull,
(Wm+F1)f2+Wt/2(f2+f3)
955 kg
f2=
1.0
f3=
0 fsa
Actual safety factor,
14
Power
5.32 KW f4=
1.2
f5=
0.03 1.5
S.F=
Installed motor
7.5 KW
Page 2 of 2
DESIGN OF DIGESTER PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 4.5 16-Jun-99
CODE:
BS2654
DATE:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA DIGESTER Mill Capacity Ratio of fruitlet / FFB Digestion time Bulk density
1st Ph
2nd Ph
45
90 66% 12 640
mt FFB/hr min kg/m3
CALCULATE Amount of fruitlets Volume of fruitlets Total volume of digester Nr of digester chosen to operate Nr. of stand-by digester Capacity per digester Choose digester capacity Number of units to be provided
30 46.41 9.28 3 1 3,094
59 92.81 18.56 6 2 3,094 3500
4
Page 1 of 1
8
mt/hr m3/hr m3
m3 litres
NW
DESIGN OF TWIN SCREW PRESS PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 4.6
CODE:
DATE:
16-Jun-99
Steel
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA
TWIN SCREW PRESS
1st Ph
2nd Ph
Mill Capacity Capacity of each press
45
90 15
mt FFB/hr mt FFB/hr
CALCULATE Nr.of presses required Nr.of presses as spare Number of units to be provided
3 1 4
Page 1 of 1
NW
6 2 8
Units
DESIGN OF SAND TRAP TANK PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 4.7 16-Jun-99
CODE:
BS2654
DATE:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA SAND TRAP TANK Mill Capacity Ratio of diluted oil/FFB Tank retention time
1st Ph
2nd Ph
45
90 60% 15
Density of diluted crude oil
mt FFB/hr min kg/m3
890 CALCULATE
Amount of diluted crude oil produced Volume of diluted crude oil produced Volume of sand trap required Use tank capacity Nr.of tank required Nr of sand trap tank to be provided
27 30.34 7.58
54 60.67 15.17 8
0.948 1
Page 1 of 1
1.896 2
mt/hr m3/hr m3/hr m3
NW
DESIGN OF OIL CLARIFIER PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 5.1 16-Jun-99
CODE:
BS2654
DATE:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA OIL CLARIFIER Mill Capacity Crued oil to FFB Density of crude oil Retention time
1st Ph
2nd Ph
45
90 60% 890 4
mt FFB/hr kg/m3 hr
CALCULATE Amount of diluted crrude oil produced Volume of Clarifer required Capacity per clarifier Nr.of clarifiers to be provided
27.00 121.3
54.00 mt/hr 242.7 m3 120
1
2
Page 1 of 1
m3 m3
NW
DESIGN OF OIL PURIFIER PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 5.15 16-Jun-99
CODE:
BS2654
DATE:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA OIL PURIFIER Mill Capacity Oil to FFB Density
1st Ph
2nd Ph
45
90 22% 890
mt FFB/hr kg/m3
CALCULATE Amount of oil produced equivalent to Choose purifier capacity Nr.of purifier required Nr.of purifiers to be provided
9.90 11,124
19.80 22,247 4,500 2.47 4.94 3 5
Page 1 of 1
mt/hr litres/hr litres/hr Nos Nos
NW
DESIGN OF VACUUM DRYER
DESIGN BASIS ITEM :
PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
CODE:
BS2654
DATE:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA VACUUM DRYER Mill Capacity Oil to FFB Density of oil
1st Ph
2nd Ph
45
90 22% 890
mt FFB/hr kg/m3
CALCULATE Amount of oil produced Use capacity per purifier Nr.of dryer required Nr.of dryer to be provided
9.90 19.80 12 0.83 1.65 1 2
Page 1 of 1
mt/hr mt/hr Nos Nos
16-Jun-99 NW
DESIGN OF PURE OIL TANK PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 5.2 16-Jun-99
CODE:
BS2654
DATE:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA PURE OIL TANK Mill Capacity Pure oil to FFB Density of oil Retention time
1st Ph
2nd Ph
45
90 22% 890 1
mt FFB/hr kg/m3 hr
CALCULATE Amount of oil produced Volume of pure oil tank required Use capacity per pure oil tank Nr.of tank required Nr.of tank to be provided
9.90 11.1
19.80 mt/hr 22.2 m3 15 m3 0.742 1.483 1 2
Page 1 of 1
NW
DESIGN OF SLUDGE TANK PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 5.3 16-Jun-99
CODE:
BS2654
DATE:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA SLUDGE TANK Mill Capacity Crued oil to FFB Density of crude oil Retention time
1st Ph
2nd Ph
45
90 35% 890 1
mt FFB/hr kg/m3 hr
CALCULATE Amount of sludge oil produced Volume of sludge tank required Use sludge tank capacity Nr.of sludge tank required Nr.of sludge tank to be provided
15.75 17.7 0.88 1
31.50 mt/hr 35.4 m3 m3 20 1.77 2
Page 1 of 1
NW
DESIGN OF CRUDE OIL TANK ITEM :
DESIGN BASIS 5.4 16-Jun-99
PROJECT: OIL PALM MILL
CODE:
BS2654
DATE:
CLIENT:
Steel
ST 37
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
Power
230/415 V 50 Hz
GIVEN DATA CRUDE OIL TANK Mill Capacity Ratio of diluted oil/FFB Tank retention time Density of diluted crude oil
1st Ph
2nd Ph
45
90 60% 15 890
mt FFB/hr min kg/m3
CALCULATE Amount of diluted crude oil produced Volume of diluted crude oil produced Volume of crude oil tank required Use tank capacity Nr.of tank required Nr of tank to be provided
27 30.34 7.58
54 60.67 15.17 8
0.948 1
1.896 2
Page 1 of 1
mt/hr m3/hr m3/hr m3
NW
DESIGN OF DECANTER PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
DESIGN BASIS
ITEM :
5.9
CODE:
DATE:
16-Jun-99
Steel
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA DECANTER Mill Capacity Sludge to FFB Density of sludge
1st Ph
2nd Ph
45
90 35% 890
mt FFB/hr kg/m3
CALCULATE Amount of sludge produced Volume of sludge produced Use capacity per decanter
15.75 31.50 mt/hr 17,697 35,393 18,000 liters/hr
Nr.of Decanter required Use Nr.of decanter
0.98 1
Page 1 of 1
NW
1.97 2
m3 Nos
DESIGN OF DEPARICARPER ITEM :
DESIGN BASIS 6.2 16-Jun-99
PROJECT: OIL PALM MILL
CODE:
DATE:
CLIENT:
Steel
Input data by:
Power
230/415 V 50 Hz
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA DEPARICARPER Mill Capacity Fibre to FFB Bulk density Air to fibre ratio Air density
1st Ph
2nd Ph
45
90 18.5% 257 6 1.177
mt FFB/hr kg/m3 kg/m3
CALCULATE Amount fo fibre produced Amount of air required Airflow rate required Use fan Nr.of fan required Nr.of units to be provided
NW
8.33 16.65 49,950 99,900 42,438 84,877 24,959 49,918 25,000 0.998 1.997 1 2
Page 1 of 1
mt/hr kg/hr m3/hr cfm cfm Units Units
DESIGN OF DESTONER PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 6.7
CODE:
DATE:
16-Jun-99
Steel
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA DESTONER
1st Ph
Mill Capacity Nut to FFB
45
Bulk density Air to nut ratio Air density
2nd Ph 90
mt FFB/hr
15.0% 535 2.75 1.177
kg/m3 kg/m3
CALCULATE Amount of nut produced Amount of air required Airflow rate required Select fan cfm Nr.of fan required Nr. Of units to be provided
6.75 13.50 18,563 37,125 15,771 31,542 9,275 18,551 11,000 0.84 1.69 1 2
Page 1 of 1
NW
mt/hr kg/hr m3/hr cfm cfm
DESIGN OF NUT HOPPER PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 7.2
CODE:
DATE:
16-Jun-99
Steel
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA NUT HOPPER Mill Capacity Nuts to FFB
1st Ph
2nd Ph
45
90
mt FFB/hr
15%
Bulk density Buffer time
653 1
kg/m3 hr
CALCULATE Amount of nuts produced Volume of Silo required Use hopper capacity per line Number of hopper required Number of hopper to be provided
6.75 10.3 1.03 1
NW
13.50 mt/hr 3 20.7 m 3 m 10 2.07 2
Page 1 of 1
PERUNDING AME - Consulting Engineers
DESIGN OF NUT ELEVATOR PROJECT:
DESIGN BASIS
OIL PALM MILL
CODE:
CLIENT: PowerPower
Steel 230/415 V 50 Hz
ITEM :
7.4
DATE:
16-Jun-99
Input data by:
Pressure
Nil
NW
Perunding AME Consulting Engineers
GIVEN DATA Mill Capacity MATERIAL BULK DENSITY CAPACITY, TF/ Material Ratio VERTICAL HEIGHT INCLINATION SPROCKET C/C SPROCKET TEETH SPROCKET PCD SPROCKET REV SPEED BUCKET SPACING CHAIN PITCH BUCKET THICKNESS
NUR ELEVATOR mt 45 PALM NUTS pf 653 M 11 r 100% H 11 α t 60 c 15 12 0.2964 33.12 S 30.84 z 0.75 l 100 t 3 ps 7200
STEEL DENSITY
mt/HR 3
kg/m
mt/HR m C m T mm rpm m/min m mm mm 3 kg/m
o
CALCULATE MASS FLOW NO.OF BUCKETS WEIGHT OF material per bucket
Mf=rxMx1000
NET VOLUME OF BUCKET CHOOSE BUCKET SIZE:
Vb=Qf/pf
11,250 kg/hr 41 bucket/min 5 kg/bucket 3 0.0070 m /bucket
n=S/z Qf=Mf/(60*n)
width depth length
a d b
0.22 m 0.23 m 0.30 m 3
Vb=1/2xaxdxb
VOLUME OF BUCKET
0.00759 m 2
2 0.5
-3
WEIGHT OF BUCKET
wb=[ad+2b({a/2} +d ) ]tpsx1.1x10
4.84 kg
WEIGHT OF MATERIAL
Wm=Mfxc/(60xS)
91.2 kg
NO.OF BUCKET ON LOADED STRAND
Nb=c/z
20
WEIGHT OF MATERIAL PER BUCKET
wm=Wm/Nb
4.6 kg
DREDGING PULL
F1=20.12 x wm/z
122 kg
ESTIMATED WEIGHT OF BUCKET+CHAIN
Wb=wbx4xNb
387 kg
PRELIM CHAIN PULL
F2=(Wm+F1)f1+Wbxf1/2
407 kg
MIN.BREAKING STRENGTH
f1=
1.0
fs=
10 F3=F2xfs
Page 1 of 2
4,070 kg
92%
PERUNDING AME - Consulting Engineers
FINAL CHAIN PULL
( Renold conveyor chain booklet )
Choose: Chain: Pitch Strength: Weight:
150 mm 13,636 kg 11.68 kg/m
Total weight of chain, Total weight of bucket
Wc=wb x Nb
350 kg 193 kg
Total weight of chain + bucket,
Wt=Wc+Wb
544 kg
Final chain pull,
(Wm+F1)f2+Wt/2(f2+f3)
485 kg
f2=
1.0
f3=
0 fsa
Actual safety factor,
28
Power
2.04 KW f4=
1.2
f5=
0.03 1.5
S.F=
Installed motor
3.3 KW
Page 2 of 2
DESIGN OF CM WINNOWING PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 7.10
CODE:
DATE:
16-Jun-99
Steel
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA CM WINNOWING Mill Capacity Cracked Mixture to FFB Bulk density Air to Cracked mixture ratio Air density
1st Ph
2nd Ph
45
90 11.0% 535 4 1.177
mt FFB/hr kg/m3 kg/m3
CALCULATE Amount fo cracked mixture produced Amount of air required Airflow rate required Use fan for each line Nr of fan required Nr. Of units to be provided
NW
4.95 9.90 19,800 39,600 16,822 33,645 9,894 19,787 10,000 0.99 1.98 1 2
Page 1 of 1
mt/hr kg/hr m3/hr cfm cfm units units
DESIGN OF KERNEL DRYER SILO PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 7.17
CODE:
DATE:
16-Jun-99
Steel
Input data by:
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA KERNEL DRYER SILO Mill Capacity Kernel to FFB Bulk density Drying time
1st Ph
2nd Ph
45
90 8% 653 30 1.3
mt FFB/hr kg/m3 hr days
CALCULATE Amount of kernel produced Volume of Silo required Capacity per silo Storage required
NW
3.60 165.4 83 2
Page 1 of 1
7.20 330.8 83 4
mt/hr m3 mt Nos
per hr
DESIGN OF PK STORAGE SILO ITEM :
DESIGN BASIS 7.20 16-Jun-99
PROJECT: OIL PALM MILL
CODE:
DATE:
CLIENT:
Steel
Input data by:
Power
230/415 V 50 Hz
Pressure
Nil
Perunding AME Consulting Engineers
GIVEN DATA PK STORAGE SILO Mill Capacity Kernel to FFB Bulk density Storage capacity required
1st Ph
2nd Ph
45
90 8% 653 5
mt FFB/hr kg/m3 days
CALCULATE Amount of kernel produced Capacity per silo Nr. Of storage silos required Nr. Of storage silos to be provided
3.60 432 83 5.20 6
NW
7.20 864 83 10.41 12
Page 1 of 1
mt/hr mt mt Nos Nos
DESIGN OF WATER TUBE BOILER PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 8.5
CODE:
DATE:
16-Jun-99
Steel
Input data by:
Pressure
Nil
NW
Perunding AME Consulting Engineers
GIVEN DATA WATER TUBE BOILER Mill Capacity Power requirement HP steam required for power @ 21 barg LP steam req'd for process @ 3 barg Total power required
1st Ph
2nd Ph
45
90 18 24 660
810
1620
mt FFB/hr kW/mt FFB kg/kWH kg/mt FFB KW
CALCULATE Total HP steam req'd for power Total LP steam req'd for processing Maximum steam required Choose operating capacity of boiler Boiler capacity required Choose boiler capacity Nr. Of boilers required Nr. Of boilers for spare Nr.of boiler to be provided
19,440 29,700 29,700
38,880 59,400 59,400
85% 34,941 69,882 35,000 0.998 1.997 0 0 1 2
Page 1 of 1
kg/hr kg/hr LP is higher than HP kg/hr of rated kg/hr kg/hr units units units
DESIGN OF STEAM TURBINE PROJECT:
OIL PALM MILL
CLIENT: Power
230/415 V 50 Hz
ITEM :
DESIGN BASIS 9.1
CODE:
DATE:
16-Jun-99
Steel
Input data by:
Pressure
18 / 3.16 Bar.g
Perunding AME Consulting Engineers
GIVEN DATA STEAM TURBINE Mill Capacity Power required for machinery Power required for housing ( Domestic ) Power required per house
1st Ph
2nd Ph
45
90 18
46 4
152 4
mt FFB/hr KW/mt FFB KW
CALCULATE Total power required for mill Total power required for housing Total power required Choose capacity of turbine Nr.of turbine required
810 184 994
1620 608 2,228 1,200 0.83 1.86
Turbine running at No. of units to be provided
83% 1
Page 1 of 1
93% 2
NW
KW KW KW KW Nos
units
CPO Storage Tank
DESIGN OF CRUDE PALM OIL STORAGE TANK PROJECT:
OIL PALM MILL
CODE:
CLIENT:
Steel
CAPACITY
Pressure
DESIGN BASIS
BS2652
ITEM :
10.1
ST 35
DATE:
16-Jun-99
Input data by:
GIVEN DATA CRUDE PALM OIL STORAGE TANK Mill Capacity Oil extraction rate Maximum storage period Maximum operating hour per day
1st Ph
2nd Ph
45
90 22% 15 24
mt FFB/hr days hrs
CALCULATE CPO produced CPO produced for 20 days Use tank capacity Nr.of tank required Choose Nr.of tank
238 3,564
475 7,128 2,000
1.78 2
Page 1 of 1
3.56 4
mt /day mt mt Nr Nr
NW
DESIGN CALCULATION FOR WATER SUPPLY DESIGN BASIS PROJECT:
OIL PALM MILL
CODE:
CLIENT:
Capacity
Pressure 3 Bar.g
ITEM
11.0
DATE
04-Mar-01
Input data by
GIVEN DATA
Mill Capacity Processing period Processing time Water consumption include quarters Clarifier retention time Reservoir retention time
10 25 24 2 2 3
mt FFB/hr days/month hr/day m3/mt FFB hr months
CALCULATE Total consumption Clarifier capacity Monthly capacity Reservoir volume
20 23 6,000 18,000
Page 1 of 1
m3/hr m3 mt FFB m3
NW
Energy Balance
DESIGN CALCULATION FOR ENERGY BALANCE ( Fuel / Steam / Power ) PROJECT
OIL PALM MILL
CLIENT CAPACITY
45-90 mt FFB per hour
CODE
ITEM
Steel
DATE
Pressure
DESIGN BASIS 13 a. 4-Mar-01
Input data by
NW
INPUT DATA Mill Capacity Specific power requirement for POM Specific steam requirement for POM Specific steam requirement for back pressure turbine Turbine load factor Boiler load factor Fibre Content Shell Content Empty Bunch Content Net Calorific Value Of Fibre Net Calorific Value Of Shell Net Calorific Value Of Empty Bunch
16.5% 7.7% 22%
45 17.5 550 25 80% 80% 7.44 3.48 9.90 10,000 15,900 6,000
90 17.5 550 25 80% 80% 14.89 6.96 19.80 10,000 15,900 6,000
mt FFB/hr KWh/mt FFB kg/mt FFB kg/KWh
mt/hr mt/hr mt/hr KJ/Kg KJ/Kg KJ/Kg
Steam Generation Energy required to raise 1 kg of water @ 60C, atm to @ 21 barg 35C superheat
2382
2382 KJ
Assume boiler thermal efficiency Actual energy required Steam can be produced by 1 kg of fibre Steam can be produced by 1 kg of shell Steam can be produced by 1 kg of EB Total steam can be produced by fibre Total steam can be produced by shell Total steam can be produced by fibre+shell Total steam can be produced by bunch
70% 3,403 2.94 4.67 1.76 21,877 16,253 38,131 17,456
70% 3,403 2.94 4.67 1.76 43,754 32,507 76,261 34,912
Total therotical steam can be generated
55,587
111,173 Kg/hr
Total steam can be generated by burning Fibre, Shell & Bunch
55,587
111,173 Kg/hr
Steam required for specified Boiler capacity Excess Total available steam Percentage of excess energy
35,000 20,587 59%
70,000 kg/h 41,173 kg/h 59% %
Total steam can be generated by burning Fibre & Shell only Steam required for specified Boiler capacity Excess Total available steam Percentage of excess energy
38,131 35,000 3,131 9%
76,261 70,000 6,261 9%
kg/h kg/h kg/h %
1,575 49,500 39,375 1,969
KW kg/h kg/h KW
KJ/Kg of water kg kg kg Kg/hr Kg/hr Kg/hr Kg/hr
Excess available Energy a
b
Energy Generation & Requirement Turbine capacity Total power required LP steam required for processing HP steam required for power generation Minimum turbine capacity
788 24,750 19,688 984
Specify Turbine Capacity
1,200
2 x 1,200 KW
Boiler capacity Total HP steam requirement Minimum boiler capacity
24,750 30,938
Specify Boiler Capacity
35,000
[Page] of 1
49,500 kg/h 61,875 kg/h 2 x 35,000 kg/h
PERUNDING AME
DESIGN CALCULATION FOR EMPTY BUNCH MULCHING AREA DESIGN BASIS
PROJECT
OIL PALM MILL
CLIENT CAPACITY
45 - 90 mt FFB per hour
CODE
ITEM
14
STEEL
DATE
04-Mar-01
Pressure
INPUT DATA
Symbol
Mill capacity
C
Ratio of empty bunch/FFB
r
Bulk density of crushed empty bunches
d
INPUT DATA BY
Formula
Value
45 25% 0.27
NW
Value
90 ton/hr 25% 0.27 ton/m3
Empty bunches decomposing period
T
90
90 days
Maximum operating period
t
24
24 hr
Width of mulching area
f
3
3m
Height of staking
h
1
1m
Distant between rows of palm trees
s
9
9m
CALCULATION Weight of empty bunches produced
w
Cxr
11.25
W
wxt
Volume of empty bunches produced
V
W/d
Nr. Of rows of mulching area for a 100m wide
n
100/s
11
A
n x 100 x f
3333
3333 m2/ha
L
A x 70%
2333
2333 m2/ha
Q
Lxh
2333
2333 m3/ha
Mulching capacity of empty bunch in 1 ha
K
Q/V
2.33
Total area required for 90 days cycle
H
T/K
38.57
270 1,000
22.5 ton/hr 540 ton/day 2,000 m3/day 11 rows
plantation Area available for mulching in 1 ha (100m W x 100m L) Assume only 70% can be used, net area available for mulching Net volume available for mulching based on 1m stack 1.17 days/ha 77.14 ha
Conclusion The total area required for mulching based on 90 days cycle time is:
40
80
HECTARES
A PALM KERNEL OIL MILL PROJECT Noel Wambeck / May 1999
PALM 1 .
KERNEL
OIL
MILL________
A PALM KERNEL OIL MILL PROJECT By N oe l Wa mbe ck / M a y 19 99 .
01. OUR UNDERSTANDING OF THE PROJECT Our understanding is that the client wishes to establish a Processing complex for the production of Palm kernel oil and PK meal. The client has acquired a suitable site for the project. The proposed Palm Kernel Oil Expeller Mill shall have capacity of 10 mt Palm Kernel per hour or approx. an average of 240 mt Palm Kernel per day. The proposed project processing plant will include facilities for: a.
Infrastructure & Buildings in the processing complex.
b.
The Storage of raw material for process and finished produce.
c.
Main process line machinery, equipment and plant will include the raw material reception and storage, oil extraction by expeller presses, oil filter station, bins, silos, conveyor elements, piping, pumps and storage of produce.
d.
Utilities such as electrical power, water supply and fire protection systems.
e.
Consideration for Environment Impact and treatment.
f.
Design considerations for future expansions.
This proposal is based on our engineering know-how and project management in accordance to the Turnkey Contract conditions for the proposed processing plant including the design, fabrication, the supply C & F port of entry into Indonesia, supervision of erection, commissioning and guarantee for 12 months after handing over of equipment, machinery and plant, manufactured in Malaysia and third country by experienced and proven good sub-suppliers with part supply of manufactured items or construction in buyer’s country under good supervision with drawings applied for erection at site.
PALM 2 .
KERNEL
OIL
MILL________
The equipment, machinery, plant and systems offered are essential and regarded as operation requirement process sections of a modern plant and recommend that the buyer gives serious consideration to the advantages the systems we have to offer.
PALM 2 .
KERNEL
OIL
MILL________
02. METHODOLOGY.
OVERALL APPROACH, based on our experience, we anticipate that the turnkey project work will be divided into 3 main stages and later, further sub-divided in accordance with the yet-to-bedetermined Phases of development.
We recommend that these work stages be as follows:Stage 1
:
Initial assessment of the proposed sites and preparation of a project site report that will include the compilation of additional information regarding soil conditions, survey and logistics data, earth works, local material and cost estimates, required for the preparation of the basic design by the turnkey contractor for submission by the client to and approval of the Authorities.
Stage 2
:
Detailed Engineering Design, Specifications and Drawings for client’s consideration and approval, the submission of the final turnkey contract price, the purchase of proprietary equipment, the manufacture and fabrication works and delivery to site.
Stage 3
:
Supervision at Site for construction, erection, commissioning, training of process operators and handing over project for commercial production.
The basic design, project requirements and schedule will be established with the Client in the very early stages of the project. We have always considered several factors as being extremely important in our design concept.
•
Maintenance and Operation.
This is a very important point to consider in the design concept. It depends very much on the level of the operation and maintenance staff that can be expected to operate and maintain the plant and availability of spare parts.
PALM 3 .
•
KERNEL
OIL
MILL________
Extraction Efficiency and Performance.
The extraction efficiency is a factor, which must be taken into consideration at all times during the design stage that will take into account an efficient plant in terms of extraction rate, throughput and operation cost.
•
Flexibility of Design.
Flexibility of the design is equally important factor to be considered although sometimes it means additional cost. In some cases, it may be necessary so that the plant can be operated even under adverse conditions. However in this respect, we would consult the Client to seek agreement.
PALM KERNEL OIL MILL
03.
4
PALM KERNEL OIL EXTRACTION PROCESS.
The Oil Palm Industry offers advantage of its resource base and to optimize its profit centres. One such profit centre is the Palm Kernel Oil extraction milling process.
Extraction of oil from palm kernel can be processed in three basic processes. 1. Mechanical pressing of palm kernel in high-pressure expeller screw presses are common for capacities between 10 mt PK to 300 mt per day. 2. Direct extraction after suitable preparation of the palm kernel in a solvent extraction plant should be considered for capacities above 300 Mt PK per day. 3. A combination of the above two basic systems whereby the palm kernel after suitable preparation is processed in a pre-pressed to extract 75% of the oil at a comparatively low barrel pressure in the press. The pre-press meal is treated in a solvent extraction plant to remove 23% of the oil with a high total yield of 98% of the total oil input raw material. The direct solvent extraction system is more efficient in terms of extraction yields and operating cost per ton process material, among the three systems for palm kernel oil extraction. Mechanical pressing can be carried out in single or double pressing system. Single pressing has certain drawbacks as to double pressing, as enumerated below : (a) The major portion of the oil ( 80%) will be extracted at the pre-pressing and as the cone pressures are kept low, the oil temperature will not exceed above 80 deg. C resulting in a better grade of oil in terms of FFA and PV increase during the extraction process.. (b) Extraction at lower temperature will reduce the electrical load, the amount of solid matter ( call foots ) discharged with oil that would result in better utilisation and life of the vibrating screen, oil pumps and filter press. (c) Thus, the system selected would intrinsically prolong and life of wear parts that would reduce the operating cost of the complete plant. (d) The 2nd pressing or finish press and associated conveying elements is better utilised because less fines ( foots ) are being recycled with possible excess than rated capacity of machinery and plant.
PALM KERNEL OIL MILL
5
(e) The finish press will extract the balance of the extractable oil ( say 20% ) from the prepress meal at a cone pressure as high as for a single pressing system but as the quantity is only 60% of the input raw material, therefore the cooling of the press shaft and barrel with water or oil is not required in turn would eliminate the use of heat exchangers and cooling equipment. (f) Deterioration in oil quality is eliminated by not using the extracted oil which is cooled and sprayed on the barrel to lower the temperature of the fresh extracted oil. Design features of double pressing system, which is common in Palm Kernel Mills in Malaysia, take into consideration the following :
•
Easy and lower maintenance.
•
Longer life of wear parts.
•
Higher yield of palm kernel oil and cake.
•
Eliminate or reduce the cost of utilities, such as steam and cooling water.
•
Lower investment cost.
The “double pressing system “ eliminates expensive preparation equipment such as roller mills, flakers and cookers. Take one more variable that if inadvertently the mill is not kept at peak efficiency would ruin the quality of the final products and loss of process capacity that could cause considerable embarrassment if not also monetary loss to the company.
PALM KERNEL OIL MILL
THE PROCESS DESCRIPTION. The general arrangement of the Palm Kernel Oil expeller extraction mill is relatively simple and can be followed by process flow schematic enclosed. Process lines are made up of a raw material reception area, two rows of expeller presses, each Press with a capacity of 10 mt palm kernel per day ( 24 hours ) and an oil clarification station, housed in a steel structure main process building. The appurtenance consists of the raw material and finished produces storage facilities.
Reception. Palm Kernel with 7% moisture and 5% dirt content are conveyed directly from the kernel silos of the palm oil mill or delivered in bulk or bags from outside source and unloaded in the reception area after being weight and stored in PK storage hoppers by conveyors. Each hopper can hold approximately 100mt palm kernel or provided with larger size silos in accordance to the design capacity of the plant. The raw material of palm kernel are evacuated by screw conveyors at the bottom of the loading storage hopper and thereafter the material is transferred to the milling section of the process. The receiving conveyor is fitted with permanent magnet for the removal of tramp iron, transports the PK into the pre-press buffer bins mounted on a steel structure of the main process building.
Pre-Pressing section. Palm Kernel or PK for short is fed into the pre-press, each with capacity of 10 mt PK per day (24 hours ) via a chute fitted with slide valve or feed screw provided for presses with such an arrangement. The pre-press cake or meal discharged is conveyed and fed into the silos of final press line, whilst the crude oil extracted ( approx. 80% of total oil ) flows into the screw conveying gutter and to the oil clarification section for further process.
Finish Press section. The pre-press material with an oil content of less than 20% is fed into the finish presses extruding two products, oil and meal. The meal as “finished product” is corrected with a moisture content of 10% and conveyed to the PK meal bulk storage silos or bagging area.
6
PALM KERNEL OIL MILL
Crude Oil section. The crude oil from the oil gutter flows onto the vibrating screen for removal of foots and stored in the head tank which feeds the filter press. Foots collected from the circular vibrating screen an filter press are recycled back to the finished press for the removal of residual oil in solid matter. The filtered oil is fed into the Vacuum dryer for the removal of moisture content and discharge into the security filter, filled with citric acid where by dosing of the finish oil to minimised the chance of oxidation and to enhance the stability of the PALM KERNEL PRODUCT.
Storage of Products. The clean and dry kernel oil with a moisture content of 0.09% is conveyed by stainless steel canpumps to the oil storage tank or filled into steel drums for delivery to BUYER.
PALM KERNEL OIL EXTRACTION PROCESS SCHEMATIC FLOW.
Perunding AME / May 1999 / NW.
7
PALM KERNEL OIL MILL ________
8 .
04. THE PROJECT BRIEF 4.1
SCOPE OF WORKS.
The contract will include the design, manufacture, fabricate, supply of proprietary equipment, delivery to site, unloading, safe keeping, construction , erection, installation, Authority inspection and approval, testing, commissioning, training of operators, handing over for commercial production and guarantee for 12 months after handing over of plant with the limits of the plant complex, Manufactured in Malaysia and third country by experienced and proven good sub-suppliers with part supply and manufactured items in buyer’s country under good supervision with drawings applied for erection at site.
4.2
PROPOSED PROJECT.
A 10 mt Palm Kernel Oil expeller extraction per hour mill complex including the following: ITEM. 1
2
3
DETAILS
QUANTITY
Civil & Structure Internal Roads & drains Guard & weighbridge house Office & Lab. Canteen Palm Kernel Mill Building Store & workshop Warehouse for Meal Storage and packing
20 m2 120 m2 72 m2 600 m2 200 m2 600 m2
Reception station Weighbridge Receiving Hopper & Feed conveyor Palm kernel silo or Bin ( 250 mt ) Pneumatic conveyor Crusher / Breaker Mill Screw Conveyor Bucket Elevator Horizontal Screw Conveyor & Feed chutes
1 1 1 1 2 1 1 1
Pre - Pressing station Kernel Hopper & Steel structure Vibro Feeder & Metal trap Pre - Press Expeller Scraper conveyor Breaker mill Cross Bucket conveyor Screw Conveyor
8 8 8 1 1 1 1
PALM KERNEL OIL MILL ________
ITEM. 4
5
6
7
8
9 .
DETAILS
QUANTITY
Finish - Pressing station Hopper & Steel structure No.2 Vibro Feeder & Metal trap No.2 Final Press Expeller Scrapper conveyor No.2 Breaker mill No.2
6 6 6 1 1
PK Meal Bulk Storage Bucket Elevator Screw Conveyor Meal Bulk Silo
1 1 1
PK Oil Clarification Oil Gutter Oil Transfer Tank & Pumps Filter Pressure Press Solids discharge tray and chute Circular Vibrating screen Oil Purifier Vacuum Dryer & pumps Piping, Valves, Fittings & insulation
1 2 2 2 2 1 1 Lot
Electrical works Main switch gear and MCC Cable & wiring to motors Lighting & power points Stand by Diesel generating set - 300 kw
Lot Lot Lot 1
Fire Protection System Alarm system Fire hose reel system Fire Hydrants Fire fighting equipment
Lot 4 4 Lot
9
Shipping & Insurance
600 mt
10
Commissioning & Training of operators
10 days
11
Operation & Maintenance Manuals
3 sets
12
As built Drawings
3 sets
PALM KERNEL OIL MILL ________
4.3
10 .
SPECIFIED OFFER.
The offer is based on the buyer’s invitation to bid for the specified requirement and does not include the following :
• • • • • • • • • • •
4.4
Application and approval for Authority Licenses. Land for the project site. Site soil investigation and surveys. Application and supply for site facilities such as Electrical power and water supply. Site preparation and earthworks. Port clearance, customs, SGS inspection. All insurance requirements in buyer’s country. All duties and taxes from or in buyer’s country. Inbound transport, haulage and forwarding charges and unloading at site. All raw material, lub-oils, fuel, management, staff and labour for commissioning & hand over of plant for commercial operation. All other supply and works outside the limits of the plant complex.
TIME OF DELIVERY.
We confirm a delivery time from the date of the contract award provide that all technical and financial obligations are finalized as follow: Eighteen months from the date of award of contract and provided we receive the proposed site three ( 3 ) months from the date of award of contract.
4.5
VALITY OF OFFER.
The price offered in this bid shall be valid for 60 days.
PALM KERNEL OIL MILL ________
4.6
11 .
PERFORMANCE AND GUARANTEE.
We guarantee that the complete equipment, machinery and plant supplied by us for the proposed project are brand new and of first class quality and workmanship that is proven in operation shall be supplied in the contract. We guarantee that the complete equipment, machinery and plant supplied by us in the proposed project will be able to process good quality Palm kernel in accordance to the accepted standards after an appropriate start up time in regular uninterrupted operation of the plant. Quality of raw material for process. Tenera type Palm kernel of normal standard will consist and based on 1,000 kg input material are as follows:
• • • •
Oil ( including FFA ) contents
43.15%
Dry substance
43.85%
Moisture
8%
Dirt ( impurities ) at Max.
5%
Quality & Quantity of Products.
• • • • • 4.7
FFA increase in process
0.25%
Moisture
0.09%
Dirt
0.10%
Filtered Kernel oil
42%
PK Meal ( Moist.9% Oil 7% )
58%
LIABILITY LIMITS.
We are not liable for personal injury and damage to property, equipment, machinery and plant or third party claims during the execution of the contract and outside the battery limits of our scope of supply and works and in particular will not pay for any loss of profit, compensation and production.
4.8
CONDITION OF SUPPLY.
PALM KERNEL OIL MILL ________
12 .
Conditions of supply shall be in accordance to the IEM conditions of turnkey contract for design, build and hand over of project.
MATRIX FOR PALM KERNEL OIL ( Expeller Press ) EXTRACTION.
04-Mar-01
x
1
2
3
4
5
6
7
PALM KERNEL PROCESSED mt Per hour mt / hr Per Day mt / day
Design Capacity
9
mt per 24 hr / day
1
2
4
10
12
16
20
24
48
96
240
288
384
480
25
50
100
250
300
400
500
100 50 60
200 100 120
400 200 250
1,000 500 600
1,200 600 700
1,600 800 1,000
2,000 1,000 1,100
42% 58% 42% 58%
0.42 0.58 10.08 13.92
0.84 1.16 20.16 27.84
1.68 2.32 40.32 55.68
4.20 5.80 100.80 139.20
5.04 6.96 120.96 167.04
6.72 9.28 161.28 222.72
8.40 11.60 201.60 278.40
mt
2%
0.48
0.96
1.92
4.80
5.76
7.68
9.60
UTILITIES Power Water
kwh m3
55 0.02
55 0.50
110 1
220 2
550 5
660 6
880 8
1,100 10
LAND AREA Diamensions Square area Hectares
m m2 ha
40 x 80 3,200 0.32
40 x 100 4,000 0.40
40 x 120 4,800 0.48
60 x 120 7,200 0.72
60 x 120 7,200 0.72
100 x 200 20,000 2
100 x 200 20,000 2
1 1 1 6 3 3 6 6 1 9 9
1 1 1 6 3 3 6 6 1 9 9
1 1 1 6 3 3 6 6 1 9 9
1 1 1 6 3 3 6 9 2 9 9
1 1 1 6 3 3 6 9 2 12 12
1 1 1 6 3 3 6 9 2 12 12
1 1 1 6 3 3 6 9 2 12 12
46
46
46
50
56
56
56
Raw material storage capacity PK Oil storage capcity PK Meal storage capacity
mt mt mt
4 days 4 days 4 days
PRODUCTION PKO per hour MEAL per hour PKO per Day MEAL per Day
mt mt mt mt
LOSSES Oil in Meal
MANPOWER Manager Admin. Accounts Assistant General clark Weighbridge clark Mill Supervisor Wireman Forklift Driver Fitter Welder Machine operator General worker TOTAL
8
24 hrs
PRODUCTION COST General charges Direct manufacturing charges Sales & Distribution cost total
INVESTMENT Infrastructure Civil & Structure Mechanical & PI Electrical Works Fire Protection system Lab. & Workshop equipment Shipping & Insurance Commissioning & Training Professional Fees Mobilisation & Contingency TOTAL IN RM
Persons 1 1 1 2 1 1 2 2 1 3 3
Shifts 1 1 1 3 3 3 3 3 1 3 3
18
RM / mt RM / mt RM / mt
4 29 3 36
Mill Capacity mt per day
5.5% 22.0% 51.0% 6.0% 2.0% 1.5% 3.0% 0.5% 3.5% 5.0%
96 696 72 864
192 1,392 144 1728
384 2,784 288 3456
960 6,960 720 8640
1,152 8,352 864 10368
1,536 11,136 1,152 13824
1,920 13,920 1,440 17280
25 82,500 330,000 765,000 90,000 30,000 22,500 45,000 7,500 52,500 75,000
50 137,500 550,000 1,275,000 150,000 50,000 37,500 75,000 12,500 87,500 125,000
100 220,000 880,000 2,040,000 240,000 80,000 60,000 120,000 20,000 140,000 200,000
250 412,500 1,650,000 3,825,000 450,000 150,000 112,500 225,000 37,500 262,500 375,000
300 544,500 2,178,000 5,049,000 594,000 198,000 148,500 297,000 49,500 346,500 495,000
400 792,000 3,168,000 7,344,000 864,000 288,000 216,000 432,000 72,000 504,000 720,000
500 1,072,500 4,290,000 9,945,000 1,170,000 390,000 292,500 585,000 97,500 682,500 975,000
2,500,000
4,000,000
7,500,000
9,900,000
100.0% 1,500,000 1500000
Perunding AME
2500000
3/4/01
4000000
7500000
9900000
14,400,000 14400000
19,500,000 19500000
220 M
WORKSHOP & STORE
60 M
SURAU
WATER TOWER CANTEEN & REST ROOMS
PARKING AREA PALM KERNEL SILOS
42 M CAR SHED
MAIN PROCESS BUILDING
MEAL STORAGE BUILDING
100 M OIL STORAGE TANKS
OFFICE & LAB.
GUARD HOUSE
OIL LOADING SHED WEIGHBRIDGE
TNB sub-station
P PR RO OP PO OSSE ED DP PA ALLM M KE ER RN NE ELL O OIILL M MIILLL –– TTYYP PIIC CA AL G GE EN NER RA ALL LLA AYYO OU UTT
VIEW OF A PALM KERNEL OIL MILL COMPLEX INCLUDING THE RAILWAY SYSTEM.
VIEW OF THE EXPELLER PRESSING STATION IN OPERATION.
PERUNDING AME / 24TH MAY 1999 / NW.
REFINING PROCESS
1
AN INTRODUCTION TO REFINING PROCESS FOR PALM OIL AND OTHER DOWNSTREAM PROCESSES. By Noel Wambeck 20th September 1997.
Introduction. Edible oils and fats have traditionally been refined by the process of neutralising the fatty acid with a base such as caustic soda or alkali refining plant. The disadvantages of such a process are the high cost of chemicals and the problem of soapstock, which requires expensive effluent treatment. Further, the percentage of oil loss and operational cost of production are advantages in favour of Physical refining process. Palm oil can be subjected advantageously to physical refining and dry fractionation processes to produce more diversified products at competitive prices.
REFINING PROCESS
2
Our view on the general approach to a Palm Oil refining project for palm oil and other downstream process whiles taking into consideration that the finished products will be bottled, packed and marketed to consumers in a competitive market will require careful planning and selection of the right process design and component equipment to process various qualities palm oil to produce the highest quality finish products to sustain a long self life. The process systems discussed in this paper, are as follows :
§ § § §
Pre- treatment and wet de-gumming process. Continuous Bleaching plant. Steam Refining cum Deodorization system. Dry Fractionation system.
The aim is to produce refined produces of high quality in terms of oil colour, odorless, blend taste, stability for long shelf life at a reasonable cost of production. Basic features required producing high quality products from crude palm oil and palm kernel oil. Basic features required to produce high quality products are as follows : It is well accepted that impurities and phospholipids that are present in the crude palm oil plays a great part in the stability of the refined product. Therefore it is impertinent that this impurity be removed to an absolute minimum in the pretreatment stage or de-gumming process. Although the dry pretreatment can handle the de-gumming process but the wet de -gumming offer a more reliable pretreatment process of lesser quality feed crude palm oil. To do this the crude oil needs to undergo treatment with the resultant gums washed out with diluted phosphoric acid in hot water and than separated through centrifuge. The pretreated oil is to be dried before the bleaching process under suitable temperature, retention period and vacuum conditions. A feature at the bleaching stage is to allow quick changeover of feed stock and complete drainage and having minimum chance of contamination. It is an established fact that steam refiner cum deodorizer process or “ Physical refining process combined with the wet de-gumming and continuous bleaching process“ will produce a better quality product where the feed material is heated and cooled down in the same column under similar vacuum condition and proper retention time in the refining process will produce a refined product of a reasonable high quality and stability. Dry fractionation process also known, as “winterisation process” has become a common feature in modern refineries with the introduction of the membrane filter press resulting in yields and quality better than the detergent process. Manufactured fat products are generally foreseen as a requirement to ensure that freshly refined oils are available as feed stock, which is also economical for such integration. Ideally, the plant is to be equipped with a suitable control system to reduce the use of manpower on its operation. Among the control systems, the distributed and monitoring computerized control system seems appropriate for such a plant.
REFINING PROCESS
3
A CONCEPTIONAL PROPOSAL FOR A PALM OIL REFINERY PROJECT This proposal in brief, aims to provide guidance to those who may be involved in or a new comer to the identification and preparation of a palm oil refinery complex project. Our understanding is that the management have made the decision to invest in the expansion of their manufacturing activities after having prepared a thorough project study or business plan for a target market but require clarification on the advantages of the Palm Oil Refinery complex. Our view on the general technical approach to the project, will require careful planning and selection of project site, the right process design, equipment component and system to process various quantities, added values palm oil products to sustain a long self life, that is in demand by the buyer. Arguments for its economic viability, marketing requirements and corporate strategy are not address in this paper. The proposed project for the time being is restricted to the integration of : A 500 mt per day (24 hours) physical refinery and 400 mt per day (24 hours) Fractionation Plant to process crude palm oil (CPO) with the option of Palm Kernel oil as raw material for process. The matching of the oil palm mill capacity with the refinery is of equal importance to the availability of the raw material for process when considering the integration. The project business plan should have scope and potential to diversify and expand in the area of production of various down stream palm oil based products.
1. The Products. The proposed physical refinery and fractionation complex shall produce basic product mix, as follows: Palm Oil based : Refined, Bleached and deodorized Palm Oil. Crude Palm Olien Crude Palm Stearin RBD Olien RBD Stearin High purity FAD Palm Kernel Based : Refined, Bleached and deodorized Palm Kernel Oil. Crude Palm Kernel Olien Crude Palm Kernel Stearin RBD PK Olien RBD PK Stearin High purity FAD
REFINING PROCESS
4
2. The Advantages for Project Integration. An integrated processing complex offers several advantages including the following : & Reduce cost in Management, administration, communication, maintenance and labour & Reduce capital cost with common buildings to house the above. & Reduce capital cost of plant and equipment, such as effluent treatment system, cooling
system and steam generators. & No cost of transportation and insurance premium between processes. & Security monitoring requirements.
The selection of a suitable processing complex site is an important exercise as it has direct effects on the capital cost and long-term operation requirements.
3. Factors to consider for Integration. The refinery complex should have incorporated in the initial design of the plant adequate facilities for:
• Suitable space to house the refinery, fractionation plant, infrastructure, tank farm and appurtenances.
• The proposed plant shall be designed with consideration for and incorporation of the latest technology available in the industry.
• The equipment, plant and process systems will be design for high efficiency, quality and yields.
• Consideration and the incorporation of safety aspects that comply with Occupational Safety and health act, such as to provide for good ventilation, working space, dust free and noise levels within permissible limits.
• Consideration and the incorporation operating procedures, equipment, plant and process systems to meet the ecological, hygienic and cleanliness of the plant on par with good food manufacturing industrial plants standards.
• The plant and process shall be environmentally friendly and that the environment Control act requirements will be addressed in accordance to the standards prescribed.
• The plant will be designed for cost effectiveness for operation and maintenance.
REFINING PROCESS
5
4. Estimated Cost of a Refinery. The estimated cost of a Refinery complex with optimum capacities, based on the project matrix and current ( Exchange rate at USD 1 : RM 3.80 November 1998 ) cost of material, equipment and plant in the year 1998, are as follows:
1.
PROCESS PLANT
NOTES:
Preliminaries. Soil Investigation, earth works, Piling works etc. Temporary site facilities
Input : 150,000 mt CPO per year. Exclude cost of land (6 Ha)
2.
Infrastructure, Civil & Struct. Works and Buildings
3.
Equipment, systems & plant Road weighbridge Physical refinery Dry Fractionation Mech. & PI Fire fighting Electrical works Tanks – Infeed / chemicals / buffer etc. Utilities & Auxiliaries – Boiler / Diesel gen-sets / cooling system Support services i.e. Lab equip & sundries SBR effluent treatment plant
4.
Bulking farm
5.
Professional fees
TOTAL
COST IN RM.
2,700,000 2,600,000
( 500mt CPO per day ) ( 400mt Oil per day )
200,000 7,400,000 6,600,000 4,500,000 600,000 1,500,000 100,000 1,800,000 900,000 600,000
( 6,000mt produce mix )
5,000,000 1,500,000
RM 36,000,000
Take note that estimates can vary extensively, depending on the location of the site, terrain, type of soil, accessibility, selection of quality of equipment and design factors applied. The proposed design of the complex will give a reliable, easy to operate with the best up-todate performances for maximum efficiency with minimum product losses and quality products. However, we must understand that each project, operation and commercial consideration will defer in the actual implementation of the design for processing needs to meet the changing requirements and conditions of management priority.
REFINING PROCESS
6
5. Selection of Process System. Edible oils and fats have traditionally been refined by the process of neutralising the fatty acid with a base such as caustic soda or alkali refining plant. The disadvantages of such a process are the high cost of chemicals, the percentage of oil loss and the problem of soap stock, which requires expensive treatment are advantages in favor of Physical refining process. It was in the early eighties that palm oil could be subjected advantageously to physical refining and dry fractionation processes to produce more diversified products at competitive prices. The search for new markets for its products and the rapid development in the industry, found demand of other down stream production of palm oil mid fractions, cocoa butter equivalent, hydrogenated oils, etc. The most complimentary extension can be in the area of valuable Red Palm Oil containing Tocopherols (VitaminE) and derivatives with high yielding carotenoids and tocopherols. It fulfills a vital role as a means of control on product cost without any loss of properties and loss of performance in the product. However, the refinery plant with the molecular distillation process required to produce such value added products is deferred from the conventional physical refinery process and should not be compared in terms of process utilization to produce a range of marketable products, operation requirements and cost of investment. Therefore the rational and final selection of process system will depend on the result of the project study or business plan target market which dictate the products to be produced for marketing economics and should not be based on the products that can be produced by the process system. The manufacturer is usually also the marketing organizer. Marketing is the first consideration; to manufacture is a tool of the marketing organization. The superior quality of Crude Palm Oil and its derivatives produced in the integrated process are the marketing organization assurance for the future of its products.
REFINING PROCESS
7
6. BRIEF PROCESS DESCRIPTION. Fig. 1 CONTINUOUS PRE-TREATMENT & BLEACHING SCHEMATIC FLOW.
1. 1A. 2. 3. 4. 5.
BLEACHING CLAY DOSING STATION ADDITIONAL ACTIVE CARBON DOSING VACUUM OIL DRIER RECUPERATIVE HEAT EXCHANGER FINAL HEATER RETENTION LINE.
6. 7. 8. 9.
COOLER FILTER STATION SAFETY FILTER STATION VACUUM EQUIPMENT
Fig. 2 CONTINUOUS PHYSICAL REFINING SCHEMATIC FLOW.
1. 2. 3. 4. 5. 6.
Recuperative heat exchanger Deareator Final heater Physical refiner / deodorizer Oil cooler Polishing filter
7. 8. 9. 10. 11.
Vacuum equipment High temperature generator Start heater / stop cooler Vapour scrubber Anti oxidant equipment
REFINING PROCESS
8
Crude oil is preheated and acid treated, allowing for sufficient holding time and washed with hot water. The gummy matter precipitates and preheated oil is separated through a self-flushing centrifuge. The pretreated oil is to be dried before undergoing the bleaching process under regulated temperature and vacuum conditions. Bleaching clay is dosed and mixed with pretreated oil in the reaction vessel. Sufficient retention period is to be allowed for maximum and stabilizing effects. The slurry is than filtered through one of the two alternative working Pressure leaf filters. The partly bleached oil is than filled into intermediate holding tank before being processed further at the Steam refiner. The bleached oil is dried before being fed into the refining column. In the column the oil is heated up to a low distillation temperature with the distillation and deodorization effects being enhanced by injecting stripping steam. Some heat economizing is carried out within the steam refiner. The distillation and deodorization of the oil is to be well defined in terms of homogeneous retention time while retaining the endogenous carotene and vitamin E in the Red Palm Oil being process. The refined product is cooled to storage temperature using heat exchangers internally after which ant-oxidants treatment of the product is an essential part of the process to prevent oxidation and to enhance its stability. Free fatty acid vapours omitted during the distillation and deodorization stage in the steam refiner is condensed and scrubbed through a highly efficient vapour scrubber,resulting in clean steam vapour being removed through the ejector vacuum system. The cooled refined oil is stored in the storage tank or transferred to the Fractionation process or to the bottling and packing before the delivery to buyer.
REFINING PROCESS
9
FEED STOCK INLET TO PROCESS
1. CRYSTALLIZERS
2. REFRIGERATION UNIT
4. COMPRESSED AIR GENERATOR
3. MEMBRANE FILTER PRESS
5. LIQUID OLEIN OUTLET
6. MELTED STEARIN OUTLET
Generally, RBD palm oil is seeded, ( crude palm oil can also be used ) preheated before being filled into one of several units of the crystallization tanks. On reaching the required volume, the filling is cut off automatically and the crysatallization process is activated with the programme required. Upon completion of the crystallization cycle with well defined and uniformed crystal formation, the slurry is filtered through the Florentine belt filter press and or membrane filter press. Crystallization slurry is filtered through each filtration cycle after which the press will be inflated with air automatically to squeeze and to released any remaining liquid oil from the solid stearine cake. The hydraulic system of the press will operate automatically upon reaching the required preset pressure the filter elements will open to discharge the solid stearine cake. the cake would drop into the stearine melting tank directly below the filter press and after which the melting stearine will be transferred to the cooler for storage in the air-conditioning storage area or the stearine could be used as a building block for other downstream processes. The liquid fraction of Olein is transferred to the storage tank pending delivery to customer. Sept 1999 Noel Wambeck.
APPENDIX
PORLA GUIDELINES.
PALM OIL REGISTRATION & LICENSING AUTHORITY CONTENTS • • • • • • • •
Introduction. PORLA's Role in Quality Assurance. Responsibilities of the Various Parties in the Export Chain. Responsibilities of the Producer/Supplier. Responsibilities of the Traders / Exporters. Responsibilities of the Bulking Installation Operators. Responsibilities of the Independent Chemist. Responsibilities of PORLA Port Stations
Enforcement of Quality Control Practices. • • • •
Regulation and Monitoring Monitoring of the Professional Services. Inspection of Bulking Installations at the ports. Inspection of Laboratories.
Implementation of Quality Control Programme • • • • •
Palm Oil Surveying Course Malaysian Palm Oil Surveyors Examination. Recommended Practices for Surveying Palm Oil Products Palm Oil Laboratory Accreditation. Malaysian Laboratory Accreditation Scheme (SAMM)
1
PORLA GUIDELINES.
2
GUIDELINES AND CHECKLIST ON QUALITY FOR THE EXPORT OF MALAYSIAN PALM OIL.
INTRODUCTION. The objective of this document is to provide the guidelines and checklist for promoting quality awareness among the exporters or suppliers of Malaysian palm oil. It will outline all the necessary actions and precautions to be taken in assuring that the quality of palm oil products meets the quality specifications specified in their contract of sales at the point of export. Quality assurance can be defined as `controlling the process to produce a product free of defects'. Instead of relying entirely on inspection to assure product quality by rejecting defects, inspection is focused on the process itself that can provide feedback so that the process can be improved and perfected, thereby ensuring quality product. The role of Palm Oil Registration and Licensing Authority (PORLA) is to conduct inspection programmes on the quality of oil palm products at their strategic points of processing and of the trade including at ports of export to ensure the users that only oil palm products with the appropriate quality delivered. PORLA undertakes quality control activities starting from the stage of planting materials right to the final point of export of palm oil products. The quality of palm oil products may suffer most damage at certain stages of processing, handling and transportation, the inspection programmes are designed in such a way that PORLA's Inspectors are present to conduct quality inspections at the critical point of processing, handling and transportation. PORLA'S ROLE IN QUALITY ASSURANCE PORLA's function in promoting and regulating quality practices in the palm oil industry is stipulated in its Act :-• • • •
to regulate and improve the manner of storing and shipping of oil palm products; to promote efficient handling of oil palm products; to promote measures toward attaining a high quality for oil palm products including the laying down of standards and the establishment of an efficient grading system; and generally to do everything for the betterment and proper conduct of the palm oil industry.
This Act also empowers PORLA to discharge the above function through the following means:-• • •
registration and licensing of persons in respect of all activities within the scope of functions of the Authority; provide standard practices to be observed or avoided in the palm oil industry; and specify and define the standards and grades of oil palm product and make provisions for giving effect to such standards and grades, including provisions for or relating to labelling; and prescribe records to be kept and returns to be submitted by licensees.
The Palm Oil Industry (Licensing) Regulations (Amendments) 1984 provides that any persons who move, sell, purchase, broker, export, import, store, survey or test any oil palm product must be licensed. . In issuing the license, PORLA imposes conditions and restrictions to regulate the trade and to promote quality practices to ensure the products or services rendered is of the highest quality.
RESPONSIBILITIES OF THE PARTIES IN THE EXPORT CHAIN. Palm oil proceeds through a series of parties namely producers or suppliers, traders and exporters before reaching the point of export. These parties may either be separate individuals or one individual who perform all the roles or part of it. Supplementing the export chain is the service sector namely bulk installation operators, independent surveyors and independent chemist. While installations provide bulking, handling and storage facilities at the export point; independent surveyor and chemist provide independent inspection and certification of product to determine the quantity, quality, loading superintendent and confirmation required in a commercial transaction.
PORLA GUIDELINES.
3
The parties in the chain of export are legally bound to perform their contractual commitment to one another unequivocally and efficiently. It is PORLA's policy to ensure that the palm oil products for export meet the buyer's requirements and reasonable expectations. If the chain of obligations and responsibilities are broken or abused by the parties concerned, it will lead to losses, disputes, arbitration or litigation and ultimately causes damage to the smooth trading of oil palm products. RESPONSIBILITY OF THE PRODUCER/ SUPPLIER Producers adopt proper harvesting practices so that only ripe palm fruits are harvested and delivered to the palm oil mills. The mills will inspect the quality of the raw materials (Fresh Fruit Bunch) using the " PORLA's Fresh Fruit Bunch Grading Manual" The fruits are processed with good care and efficienly so as not to damage the quality of oil during the process of extraction. It is the responsibility of the producer/supplier to ensure :-• • • • •
that the buyers' quality specifications are determined and confirmed before production begins. that the refining process employed will achieve the desired contracted specifications of the buyer. that the product has been laboratory tested and confirmed to conform to the contractual specifications for which it was intended. that the product is properly stored in such a manner that the product quality is maintained before being transferred or transported to the bulking installations at the port for export. that the movement, transport and handling of the product to the bulking installation at the port for export are carried out in a manner that will ensure that the product quality is maintained.
RESPONSIBILITY OF THE EXPORTER/TRADER From the mills, the palm oil products are channeled to the refiners, kernel crushers or oleochemical plants. Strict quality control programmes are implemented to ensure that the quality is maintained in their processing of the palm oil products. It is the responsibility of the Trader/Exporter to ensure :-• • • •
• • • • •
that all contracts of sales or purchases are registered with PORLA by telex or telegram not later than 4.00 p.m. a day after the date of transaction; followed by sending a copy of the contract to be received by PORLA not later than 30 days from the date of contract. that records of stock, sale and purchase of palm oil are properly maintained and kept for verification by PORLA Palm Oil Inspectors. that a monthly statement of stock, sale and purchase of palm oil is sent to PORLA not later than the seventh day of the following month. that the product supplied by the producer is delivered to the bulking installation at the port at least 24 hours before shipment takes place.
that the product has been laboratory tested and certified by the supplier to be conforming to the buyers' specifications. that the palm oil is free from any contamination and the quality conforms to the standard that is acceptable to PORLA. that the product has been laboratory tested and certified by an independent chemist to be conforming to the buyer specifications as specified in the sales contract at least 24 hours before shipment. that the exporter declares in the Customs Declaration (CD 2) prescribed by PORLA that the quality of palm oil to be exported conforms to the quality specifications specified in the contract of sale with the buyer. that a sample of the palm oil is send to PORLA when required, for quality determination and verification.
PORLA GUIDELINES.
4
RESPONSIBILITY OF THE BULKING INSTALLATIONS Bulking installation ( tank farm) operator is licensed exclusively for storing and facilitating bulk handling. It is the responsibility of the bulking installation operator to ensure :-• • • • • • • • • •
that the palm oil received at the installation by lorry tankers are securely sealed. In the case of pipeline transfer, the pipeline is clean, dry and free from any previous cargo before it was being used to transfer the oil to the installation at the port. that the tank used for the storage of palm oil is dry, clean, and free from any previous cargo before it was being used to store palm oil. that the Storage and Handling Practice as recommended by Palm Oil Research Institute of Malaysia (PORIM) are always complied with that a sample is drawn upon completion of bulking and is sent to an independent laboratory to determine its quality. that the palm oil quality conforms to the quality specifications required by the buyer before shipment. that the palm oil installation is kept clean and all its storage facilities are in good working condition at all times. that the oil palm product stored is free from contamination and its quality meets the standard acceptable to PORLA. that a sample of the oil palm products stored is send to PORLA as and when required, for quality determination and verification. that a monthly statement of stock, bulking and despatch of palm oil is send to PORLA not later than the seventh day of the following month. that the records of stock, bulking and despatch of palm oil are properly maintained and kept for verification of PORLA Palm Oil Inspectors.
Surveyor performs the final independent inspections and certifications before export. The surveyors will supervise the proper handling procedures to determine the quantity and to draw a representative sample for ascertaining the product quality. It is the responsibility of the palm oil surveyor to ensure:-• • • • • • • • • • • • • • •
that the superintendent and survey of palm oil are carried out in compliance with the practices recommended in the PORLA Standard Surveying Procedures And Practices For Palm Oil And Its Derivatives. that the survey is carried out in accordance to the standard imposed by the Malaysian Government and international bodies governing the surveying of palm oil products. that the survey must be conducted by a qualified palm oil surveyor under the Malaysian Palm Oil Surveyors Examination organized by PORLA. that all necessary precautions and actions have been taken to prevent any mishap by the parties involved in the loading of the palm oil from the bulking installation to the ship. that the equipment and instruments used in surveying and sampling of palm oil are not made from copper, brass or copper alloy that is detrimental to the quality of palm oil. that the three previous cargoes of the nominated ship's tank are acceptable to the terms of the contract with the buyer. that all allocated ship tanks are clean, dry and suitable in all respect for storage and carriage of palm oil. that the allocated ship tanks are free from any toxic or leaded material in the form of solid, liquid or gas, odor or any material that is detrimental to the quality of palm oil. that all samples drawn from the shore or ship tanks are kept in tightly sealed containers and are properly labelled before being send to the laboratory for analysis. that a sample of the palm oil is sent to PORLA when required for quality determination and verification. that any protest,rejection, objection or reservation on any consignment surveyed including the condition and suitability of ship's tank be reported to PORLA within 24 hours by telex or telephone and a copy of the letter of protest,rejection, objection or reservation is sent to PORLA not later than the seventh day from the date of survey. that the integrity and professionalism expected of a surveyor is uphold at all times. that the details of survey are recorded in a record book or documented in a manner that it can be easily verified by PORLA Inspector and are kept for two years from the date of survey. that the record of survey pertaining to quantity, product type, quality and details of shore and ship tanks' condition for each consignment is properly kept for verification by PORLA Palm Oil Inspector. that the palm oil survey report issued to the client is a true and accurate account of the survey and is substantiated by records and documents.
PORLA GUIDELINES.
• •
5
that a copy of the Palm Oil Survey Report is sent to PORLA not later than the seventh day from the date of survey. that a monthly statement of all the palm oil product surveyed is send to PORLA not later than the seventh day of the following month.
Qualified surveyors are registered with PORLA which forms another measure of control to enhance professionalism. A registered palm oil surveyor is required to comply to the following Surveyor's Professional Code of Ethics:-• • • • • • • •
• • • •
A registered surveyor shall conduct himself in such a manner to uphold the dignity, standing and reputation of the profession. A registered surveyor, in discharging his duty to his employer and to the profession shall have full regard to the public and national interest. A registered surveyor shall discharge his duty to his employer withcomplete fidelity and shall not accept any payment for services endered except from his employer or with his employer's permission A registered surveyor shall not injure or attempt to injure, whether indirectly the professional reputation, prospects or business of another registered surveyor or his company with which he is employed. A registered surveyor shall all times ensure that he is fully equipped with the necessary recommended tools (equipment) when conducting his work and shall always maintain a high level of technical competency, and a high degree of professional integrity. A registered surveyor shall not conduct any survey unless he is employed by a surveying company licensed by PORLA for such purpose. A registered surveyor may delegate part of his job to any person who is not a registered surveyor but under his full supervision, and shall be fully responsible for such work carried out by the non- registered surveyor. A registered surveyor, through his company shall not accept job appointment if such acceptance renders or would render it difficult for him to maintain his professional independence.
A registered surveyor shall not be influenced by the interest of his client in the conduct of the survey in so far as such interest is inconsistent with upholding the dignity, standing and reputation of the profession. A registered surveyor shall no issue any press statement in the capacity of a registered surveyor on any matters that is likely to injure the dignity and reputation of the profession. A registered surveyor shall not issue any press statement whether of facts or opinion pertaining to any dispute be tween parties in a pending arbitration action or suit of which his survey report is a relevant issue. A registered surveyor shall assist another registered surveyor in the conduct of any joint survey between them and shall not withhold any findings or information crucial to the survey.
RESPONSIBILITY OF INDEPENDENT CHEMIST The laboratory is required to conduct testing of samples of palm oil products impartially and professionally using up to date and mutually agreed methods of tests. It is the responsibly of the independent palm oil chemist to ensure :-• • • • • • •
that the sample received for analysis is contained in new container that is properly labelled and securely sealed. that the test methods applied in the analysis of palm oil samples are in accordance to the test method specified in the contract between the buyer and seller; otherwise to locally and internationally recognized test methods. that the worksheet details of analysis are recorded in a record book or documented in a manner that it can be easily retrieved and verified byPORLA Palm Oil Inspectors and are kept for 2 years from the date of analysis. that the integrity and professionalism expected of a chemist is uphold at all times. that the palm oil analysis report issued to the client is a true and accurate account of the analysis and is substantiated by records and documentary evidence. that a copy of the analysis report issued to the client is send to PORLA not later than the seventh day after the date of analysis. that a monthly statement of all the analysis carried out on palm oil product is send to PORLA not later than the seventh day of the following month.
PORLA GUIDELINES.
6
RESPONSIBILITY OF PORLA PORT STATIONS. PORLA Inspectors are based in five Regional Offices and Branch offices throughout the country to conduct periodic spot inspection on licensed premises within the respective regions. In addition, Port Stations equipped with labarotaries are set up at five major Malaysian ports to ensure that oil palm products exported stringently meet the buyers' specifications. The activities undertaken by PORLA's port stations are : • • • • • • •
to regularly conduct sampling of palm oil products at the port installations before they are exported. to take and test pre-shipment samples in PORLA laboratories located at the port stations so as to ensure that only quality palm oil products that meet contractual specifications before they are allowed to be exported. to advise exporters whose products fail to meet the contractual specifications to undertake immediate remedial actions to ensure that their products meet the contractual specifications before export to take random samples during loading (into vessels) for the purpose of enforcement of quality control declaration under Regulation 3 of PORLA Quality Control Regulations. to send samples taken to the laboratories and Chemistry Department for analysis so as to determine whether the quality conforms to the contractual specifications as declared in the Customs Declaration Form to monitor the analysis reports from the Chemistry Department in order to determine the monthly average quality and also to detect palm oil quality problems faced the industry generally to ensure that the handling, transferring, storing, transporting, surveying and shipping practices are always in accordance with the required quality practices.
ENFORCEMENT OF QUALITY CONTROL PRACTICES Regulation and Monitoring Given the legislation and the tools to implement them, it is therefore imperative for PORLA ensure that practices towards producing good quality oil palm products are promoted and good quality control activities are observed in all sectors of the industry. PORLA enforces the Palm Oil Industry Quality Control Regulations of 1983 that provide for quality control practices of oil palm products in the local trade and export: • • •
It prohibits the act of contamination of any oil palm product with any undesirable matter or any foreign matter detrimental to the quality of the oil palm product. In the case of export, the regulations provide that all exporters must declare the contractual quality specifications in the Custom Declaration Form From the monthly quality statement QC/MF/1 sent to PORLA, analysis is then made to identify mills that are producing poor quality crude palm oil.
Mills identified of this nature is given reminders to enhance their quality control process so that their products meet the stringent standards as required by the trade. •
• • •
PORLA palm oil inspectors conduct follow-up visits to the mills to check their quality records of production and take samples of the crude palm oil for quality verification as required under the Quality Control Regulation of 1983. Mills that fail to take corrective actions and instead, continue to produce crude palm oil not conforming to stringent standard trade specifications are taken stern action against . PORLA palm oil inspectors at the various regional levels also actively monitor the activity of sludge oil traders to ensure that they do not indulge in unhealthy practices of adulterating palm oil with sludge oil. Road blocks are regularly carried out by PORLA to check on palm oil tankers. During the check, the hatch covers and outlet valves and the seals are inspected. The PORLA Form PL3 as required under PORLA licensing regulations for such movements is also inspected. Regular surveillance is also conducted to identify, locate and ambush illegal storage premises used for unauthorized siphoning of palm oil from lorry tankers. Illegal storage premises were raided and disabled. Palm oil together with the equipment and facilities used in their operations were seized by PORLA.
PORLA GUIDELINES.
7
Monitoring of the Professional Services Inspection of Surveyors • • •
PORLA's inspectors regularly check on surveyors to ensure that the records and documentation of survey carried out are properly maintained and the reports issued fulfill the contractual requirements of the buyers/sellers. The monthly statement QC/SV/1 submitted to PORLA on the quality and quantity of palm oil products exported is also verified. PORLA's inspectors at the various port stations also observe / check on the surveyors at time of actual survey, so as ensure that they strictly follow the requirements stipulated by PORLA.
Inspection of Palm Oil Installations At The Ports •
•
checking the condition of facilities and the handling and storage activities. i.e. physical inspection of tanks and tank coatings The heating coils, pipelines and pumps are checked so that they are in proper working conditions and that they do not consist of any material made of copper or copper alloy which is detrimental to the quality of palm oil exported. check the records of oil temperature in the tanks so as to ensure that proper heating procedures are strictly applied during and prior to discharge of the oil from the tanks.
Inspection of Laboratories • • • •
the checking of reports of analysis issued for palm oil products. The monthly quality statement QC/CL/1 as submitted to PORLA is also verified for its accuracy. Collaborative test on methods of testing has been organized jointly with PORIM and FOSFA with the purpose of achieving consistency in the various test methods employed. licensees found not practicing quality practice in their activities or not conforming to the recommended quality practices are advised to do so. Those found to have contravened any conditions or restrictions of the licensing regulation are given reminders and warnings, compounded or prosecuted in court.
IMPLEMENTATION OF QUALITY CONTROL PROGRAMMES Ship/ Shore Surveyors Course The has been held since 1987. PORLA, in co-operation with PORIM conducts the Ship-Shore Surveyors Course annually with the objective of not only enhancing the efficiency and quality of palm oil surveying, but also promoting knowledge on the handling, transfer, storage and transportation of palm oil. Malaysian Palm Oil Surveyors Examination PORLA holds the Malaysian Palm Oil Surveyors Examination that is intended to enhance the professionalism of Malaysian palm oil surveyors. It is aimed at getting palm oil surveyors to be thoroughly knowledgeable in both palm oil survey practices as well as understanding the physical and chemical characteristics of all oil palm products. Recommended Practices For Surveying Of Oil Palm Products PORLA has established stringent surveying procedures to ensure that surveying of oil palm products, is carried out systematically and efficiently. This standard procedure covers surveying practices during loading and discharge both at the installation and ship as well as documentation of the survey. The standards provide a yardstick to measure the quality performance of the surveyors and to ensure that reports issued by them are supported by recorded facts obtained during surveying.
PORLA GUIDELINES.
8
Laboratory Accreditation PORLA in collaboration with PORIM introduced the Palm Oil Laboratory Accreditation scheme to evaluate the facilities and competency of palm oil laboratories. The evaluation is to ensure that laboratories are manned by qualified personnel, fully equipped to conduct tests under the normal parameters as specified in standard contracts, maintain proper records of analysis, conduct routine maintenance and calibration of equipment and observe strictly all safety standards and requirement during operations. Malaysian Laboratory Accreditation Scheme (SAMM) The Sectoral Committee on Oils And Fats of Malaysian Laboratory Accreditation Scheme housed in PORLA is entrusted with the objective of ensuring that local independent laboratories conduct their business according to the stipulated standards, recognized both locally and internationally.
Further Information. The legal liabilities and palm oil quality programmes are summarized in this document. For further information, please contact :
Palm Oil Registration And Licensing Authority Lot 6 SS 6 Jalan Perbandaran 47301 Kelana Jaya Tel : 03-7035544 Fax : 03-7033533
FFB GRADING MANUAL
1
PORLA FRESH FRUIT BUNCH GRADING MANUAL
INTRODUCTION This manual serves as a practical guide for the grading of fresh fruit bunch in the mills jointly prepared by a working committee which comprised of representatives from the palm oil industry and was based on a study carried out by PORLA on mills throughout Malaysia which practised fresh fruit bunch grading. OBJECTIVE The main aim of this manual is to improve the quality and quantity of crude palm oil and palm kernel productions in Malaysia. The specific objectives are as follow: • • • •
To improve the quality of fresh fruit bunch (FFB) received at the mills. To improve the quality of Malaysian crude palm oil. To improve the efficiency of oil and kernel extraction rates in the mills. To ensure that the suppliers and millers obtain a fair deal from their transactions.
IMPLEMENTATION OF THE GRADING SCHEME Site of Grading Grading can be done anywhere inside the premises of the mill or its agent. Normally, it is best done on a platform beside the loading ramp. Who Can Perform The Grading Grading can only be done by the Grading Staff of the mills or an agent appointed by the mill who has the capability and experience in the grading of fresh fruit bunch (FFB). Documents Required Documents that are required for grading are the Grading Report Form (APPENDIX Xll), weighbridge ticket and suppliers agreement documents (if any). Only fruits received from suppliers with a valid PORLA license are to be graded.
GRADING PROCEDURES Sampling Procedures Select about 50-100 bunches at random as sample from each consignment to be graded. The sample taken should represent the top, middle and bottom portion of the consignment.
The minimum sample size of each consignment to be graded should be determined based on the following criteria :
FFB GRADING MANUAL
2
• of the net weight of the consignment is less than 5 tonnes, the minimum sample size should be 50 bunches. • If the net weight of the consignment is 5 tonnes or more, the minimum sample size should be 100 bunches. The sample size should be economical, practical and able to detect any change in the bunch quality especially the degree of ripeness at 95% level of confidence. Separate the bunches that have been sampled for grading from the rest of the bunches. Grading Frequency The minimum grading frequency for each supplier of fresh fruit bunch (FFB) with long term contract should not be less than 10% of the total consignments or at a ratio of 1:10 lorries. If there is variation in the quality of fresh fruit bunches supplied or doubts regarding the bunch quality, the grading frequency should be increased to fifty percent (50%) of the total consignments or at a ratio of 1:2 lorries. For suppliers without a long term contract, grading should be done on all consignments. Bunch Classifications Fresh fruit bunch (FFB) can be classified and graded according to the following criteria: • Ripe Bunch Ripe bunch is a bunch which has reddish orange colour and the outer layer fruitlet's mesocarp is orange in colour. This bunch has at least 10 fresh sockets of detached fruitlets and more than fifty percent (50%) of the fruits still attached to the bunch at the time of inspection at the mill. The bunch and the loose fruits are to be sent to the mill within 24 hours after harvesting. • Underripe Bunch Underripe bunch is a bunch which has reddish orange or purplish red colour and the outer layer fruit's mesocarp is yellowish orange in colour. This bunch has less than 10 fresh sockets of detached fruitlets at the time of inspection at the mill. The bunch and the loose fruits are to be sent to the mill within 24 hours after harvesting.
• Unripe Bunch Unripe bunch is a bunch which has black or purplish black fruits and the outer layer fruit's mesocarp is
yellowish in colour. This bunch does not have any fresh sockets of detached fruitlets at the time of inspection at the mill. The sockets(if any) on the bunch is not due to normal ripening process. • Overripe Bunch Overripe bunch is a bunch which has darkish red colour fruits and has more than fifty percent (50%) of detached fruitlets but with at least ten percent (10%) of the fruits still attached to the bunch at the time
FFB GRADING MANUAL
3
of inspection at the mill. The bunch and the loose fruits are to be sent to the mills within 24 hours after harvesting. • Empty Bunch Empty bunch is a bunch which has more than ninety percent (90%) of detached fruitlets at the time of inspection at the mill. • Rotten Bunch Rotten bunch is a bunch partly or wholly and together with its loose fruits have turned blackish in colour, rotten and mouldy. • Long Stalk Bunch Long stalk bunch is a bunch which has a stalk of more than 5 cm in length (measured from the lowest level of the bunch stalk). • Unfresh Unfresh bunch is a bunch which has been harvested and left at the field for more than 48 hours before being sent to the mill. The whole fruit or part of it together with its stalk has dried out. Normally, this type of bunch is dry and blackish in colour. • Old Bunch Old bunch is a bunch which has been harvested and left at the field for more than 7 days before being sent to the mill. The fruitlets still remaining on the bunch are dry and brownish black in colour. The stalk is also dry, soft, fibrous and blackish in colour. • Dirty Bunch Dirty bunch is a bunch with more than half of its surface covered with mud, sand, other dirt particles and mixed with stone or other foreign matters. • Small Bunch Small bunch is a bunch which has small fruits and weight less than 2.3 kg. (5 lbs.) • Pest Damaged Bunch Pest damaged bunch is a bunch with more than thirty percent (30%) of its fruits damaged by pest attack such as rat etc.
FFB GRADING MANUAL
• Diseased Bunch Diseased bunch is a bunch which has more than fifty percent (50%) parthenocarpic fruits and is not normal in terms of its size or its density. • Dura Bunch Dura bunch has fruits with the following characteristics: • Shell thickness - 2-8 mm • Ratio of shell to fruit - 25-50% • Ratio of mesocarp to fruit - 20-60% • Ratio of kernel to fruit - 4-20% • No fibre ring around the shell • Loose Fruit Loose fruit is a fruit detached from a fresh bunch because of ripeness and is reddish orange in colour. All loose fruits have to be sent to the mill within 24 hours after harvesting. • Wet Bunch Wet bunch refers to a consignment of fresh fruit bunches (FFB) which has excessive free water.
GRADING METHODS The sample that has been selected will be graded to determine the quality of the bunches and the extraction rate that can be given to the supplier. During grading the following practices should be carried out: • • • • •
Inspection and assessment of the bunch quality. Calculation of penalty for poor quality bunch. Determination of the basic extraction rate. Calculation of the awarded extraction rate. Inspection And Assessment of the Bunch Quality
The grading of the consignment of fresh fruit bunches should be done in the presence of the supplier or his representative such as the lorry driver or his attendant. The lorry with the consignment of fresh fruit bunches (FFB) which has been selected to be graded is directed to unload on the platform near the loading ramp. Ensure that the bunches are evenly laid out and no overlapping or layering should occur. Count the number of bunches in the consignment and calculate the average bunch weight with the following formula:
4
FFB GRADING MANUAL
5
Average Bunch............Net Weight (kg) as per Weight.....................= Weighbridge .................................=================. ..................................Total Number of Bunches From these bunches, select at random 50-100 sample bunches and separate them from the rest of the bunches. Selection of the minimum sample size should be based on the net weight of the consignment. Grade, classify and count the sampled bunches into 5 groups based on the criteria of bunch classifications: • • • • •
Ripe Bunch Underripe Bunch Unripe Bunch Empty Bunch Rotten Bunch
Inspection and assessment of the bunch quality should be done quantitatively. Record the number and the percentage of each group in the Grading Report Form as shown in APPENDIX. The total percentages of the 5 groups must be hundred percent (100%).
Grade, classify anf count agein all the sampled bunches into 5 groups as follows :• • • • •
Long Stalk Bunch Dirty Bunch Dura Bunch Old Bunch Wet Bunch
The grading should be based on the criteria of bunch classifications. Record the number and percentage of each group in the Grading Report Form as shown in APPENDIX Xll. The percentages of the 3 groups of bunch quality are calculated based on the total number of sampled bunches. • Calculation of Penalty For Poor Quality Bunch A penalty based on the discount system as shown in APPENDICES III to XI, will be imposed on the poor quality bunches. The penalty imposed will depend on the results of the grading as stated in the Grading Report Form. Check these results with the Penalty Appendices (APPENDIX III - APPENDIX XI) and from there get the actual penalty value that can be imposed on each category of poor quality bunches. Book for reference :Refer to Fresh Fruit Bunch - Grading Manual. •
Consignment of fresh fruit bunches (FFB) that has poor quality bunches and exceeding:
FFB GRADING MANUAL
• •
6
the 20% of maximum allowable limit for empty bunches or; the 30% of maximum allowable limit for dirty bunches should be rejected and return back to the supplier the whole load.
In practice, it is not possible to obtain hundred percent good quality bunches and hence a reasonably good quality consignment should comprised of the following combination of bunch quality : Bunch Category
Limit
Ripe Bunch
> 90%
Underripe Bunch
< 10%
Long Stalk Bunch
< 5%
Unripe Bunch
0%
Dura Bunch
0%
Empty Bunch
0%
Rotten Bunch
0%
Dirty Bunch
0%
Old Bunch
0%
Wet Bunch
0%
• Determination of The Basic Extraction Rate The basic extraction rate is the theoretical extraction rate which is also the maximum extraction rate of the oil and kernel. This extraction rate can be determined in 2 ways that is by the age of the palm and the bunch weight. • Determination of The Basic Extraction Rate Based On The Age of The Palm The basic extraction rate can be determined by the age of the palm provided that the information regarding the year when the oil palm was planted is known (Refer to APPENDIX I). This method is suitable for mills that receive fruits from their own estates. • Determination of The Basic Extraction Rate Based On The Bunch Weight This method is suitable for mills that receive their supplies from outside estates and dealers who do not have information regarding the age of the oil palm (Refer to APPENDIX II). The average bunch weight can be calculated by dividing the net weight (as stated in the weighbridge slip) with the total number of bunches.
GRADING REPORT • Sample Grading Report All observations and calculations during grading must be recorded in the Grading Report Form as shown in APPENDIX XII. Particulars that have to be recorded are as follow:
FFB GRADING MANUAL
• • • • • • • • • • • • • •
Net weight Number of bunches Number and percentage of unripe bunch Number and percentage of underripe bunch Number and percentage of ripe bunch Number and percentage of empty bunch Number and percentage of rotten bunch Number and percentage of long stalk bunch Number and percentage of dirty bunch Number and percentage of Dura bunch Number and percentage of old bunch Number and percentage of wet bunch Observations on bunch quality Name and signature of Grading Officer
Use separate Grading Report Form (APPENDIX ) for each grading consignment. This form is to be filled in duplicates. The original copy is to be kept by the mill and the second copy to be given to the supplier or its representative.
• Monthly Grading Summary Report All observations and calculations recorded in the Grading Form have to be summarised and recorded in the Monthly Grading Summary Form The particulars that have to be recorded are as follows: • • • • •
Amount of fresh fruit bunches received Amount and percentage of fresh fruit bunches graded Crude palm oil produced Oil and kernel extraction rates achieved Average bunch weight and age of palm
• • • • • • • • • • • •
Percentage and penalty (if any) for unripe bunch Percentage and penalty (if any) for underripe bunch Percentage of ripe bunch Percentage and penalty (if any) for empty bunch Percentage and penalty (if any) for rotten bunch Percentage and penalty (if any) for long stalk bunch Percentage and penalty (if any) for dirty bunch Percentage and penalty (if any) for Dura bunch Percentage and penalty (if any) for old bunch Percentage and penalty (if any) for wet bunch Awarded extration rate for oil and kernel given to the supplier Name and signature of the mill manager
7
FFB GRADING MANUAL
Only one copy of this form is to be filled for record and retention by the mill.
8
APPENDIX I
GRADING FORM
NAME OF SUPPLIER PHASE / LOT PORLA LICENCE NO DATE VEHICLE NO
:____________________________________________________ :____________________________________________________ :____________________________________________________ :____________________ TIME :_________________________ :______________ WEIGHBRIDGE TICKET NO :___________
PARTICULARS Nett Weight
Tones
Total Bunches Average Bunche Weight FFB Grading (1) Unripe Bunches
Kilograms NUMBER
PERCENTAGE ( % )
(2) Underripe Bunches (3) Ripe Bunches (4) Rotten Bunches (5) Empty Bunches TOTAL (1) Long Stalk Bunches (2) Dirty Bunches (3) Dura Bunches (4) Old Bunches (5) Wet Bunches TOTAL
Remarks
:___________________________________________________ ____________________________________________________ ____________________________________________________
SIGNATURE :____________________ NAME :_________________________
100%
BASIC EXTRACTION RATE FOR OIL PALM MILL TABLE I
BASIC EXTRACTION RATE FOR OIL AND KERNEL BASED ON THE YEAR PLANTED (AGE OF PALM) TENERA (DXP) * PROGENY
YEAR PLANTED 1.5 Motor:Power: Type:
3.75 kw TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent.
Motor: Gear reducer: Coupling: Conveyor & Transmission chain, sprocket Bearing:
Crompton Parkinson, ABB Brook, Brush SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold Renold, Tsubaki SKF, FAG, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at both end of the conveyor 4. Conveyor shall be mounted on rollers and able to slide sideway for easy removal during maintainance 5. Contractor to provide detail drawing and specification of equipment offered.
Page 1 of 1
D 3. 1
HORIZONTAL E.B.C
SPECIFICATION SHEET PROJECT NAME
DATE: 13-May-00 MACHINE NAME HORIZONTAL EMPTY BUNCH CONVEYOR
OIL PALM MILL
PROJECT CODE
PREPARED BY
DELIVERY
NW
REVISION No. LOCATION THRESHING STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manufacture, delivery & installation commissioning, handing over and guarantee .
Function:
To convey empty bunches from THRESHER to EMPTY INCLINED BUNCH CONVEYOR
SPECIFICATIONS Quantity
One (1) unit Horizontal Empty Bunch Conveyor suitable for handling 90MT FFB per hour as follows:
Type: Capacity: General Arrangment:
Conveyor chain c/w scrapper plate 30,000 kg / hr of empty bunches As per drawing
CONSTRUCTION MATERIAL Chain: Drag Plate: Frame: Sprocket: Wear Plate:
Steel c/w hardened steel rollers, 100 mm pitch, 8,000 kg breaking load Mild steel or equivalent Mild steel or equivalent 12T, 100 mm pitch, grey iron Mild steel 6 mm minimum thickness or equivalent
Basic Dimension: Width: Length: Inclination: Conveying Section: Shaft Speed: Transmission Sprocket Ratio: Drive:
760
mm mm
Horizontal Top 25 rpm 1.00 Geared motor coupled conveyor shaft by transmission chain & sprocket
Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer:
Specified or Equivalent. Crompton Parkinson, ABB Brook, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectroPower
Coupling:
Fenner (Fenaflex) , Renold
Conveyor & Transmission
Renold, Tsubaki, PC
chain, sprocket Bearing:
SKF, FAG, NTN
1450 25 2865 <
rpm rpm Nm (min) 1.5
OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings Page 1 of 2
D4 1
HORIZONTAL E.B.C
SPECIFICATION SHEET PROJECT NAME PROJECT CODE
DATE: 13-May-00 OIL PALM MILL
MACHINE NAME HORIZONTAL EMPTY BUNCH CONVEYOR
DELIVERY DRAWING NO.
PREPARED BY
NW
REVISION No. LOCATION THRESHING STATION
ITEM No. QUANTITY / UNITS
4. Non-drive end shaft to be fitted with chain tensioning devises c/w take-up bearings
Page 2 of 2
D4 1
UNSTRIPPED BUNCH ELEVATOR
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME
UNSTRIPPED BUNCH ELEVATOR
OIL PALM MILL
PROJECT CODE
PREPARED BY
DELIVERY
NW
REVISION No. LOCATION THRESHING STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
D5 1
GENERAL Scope
Scope of works include the manufacture, delivery & installation commissioning handing over and guarantee.
Function:
To convey unstripped bunches from H.E.B Conveyor to Thresher No.2
SPECIFICATIONS Quantity Type: Capacity: General Arrangement: Construction Details:
One ( 1 ) unit Unstripped Bunches Conveyor as follows : Double conveyor chain c/w buckets 90 MT FFB per hour. As per drawing As per drawing
CONSTRUCTION MATERIAL Casing: Sprocket Bucket: Chain rail: Wear plate: Chain: Drive: Shaft Speed: Transmission Sprocket Ratio:
Mild steel with 6mm minimum thickness 12T, 150 mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 150mm pitch 15000 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 25 rpm 1
Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:
1450 25 2865 >
rpm rpm Nm (min) 1.5
Power: Type:
7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Motor:-
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
Crompton Parkinson, ABB Brooks, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS 1. Miantenance door shall be provided at the elevator booth 2. Top cover shall be bolted for ease of maintenance 3. Take-up bearing with adjustable bolt and screw shall be provided at the bottom booth for chain tightening 4. Mild steel outlet chute shall be provided 5. Plumber block bearing shall be fixed at the top booth
Page 1 of 1
THRESHER No. 2
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME OIL PALM MILL
PROJECT CODE
PREPARED BY
THRESHER MACHINE No.2
DELIVERY
NW
REVISION No. LOCATION THRESHING STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
D6 1
Scope of works include the manufacture, delivery & installation, commissioning, handing over and guarantee.
Function:
To thresh unstripped bunches
SPECIFICATIONS Quantity
One ( 1 ) unit Thresher No.2 for Unstipped Bunches as follows:
Type: Capacity: General Arrangement: Construction Details:
Rotating Drum 90MT FFB per hour As per drawing As per drawing
CONSTRUCTION MATERIAL Shaft: Boss: Rim: Frame & Structure: Drum Speed: Drum Basic Dimension: Drive System:
Gear box: Input speed: Output speed: Output torque: Overhung load: Design Service Factor:
EN 16 Steel Carbon steel Carbon steel Carbon steel 22 rpm 2,200 mm diameter 5,000 mm length Motor coupled to gear reducer by fliud coupling and gear reducer output shaft connected to the thresher shaft by triplexchain / sprocket system
1450 rpm 25 rpm 8404 Nm (min) To be within the permissible limit depending on the sprockets used for further speed reduction < 1.5 (min)
Sprocket:Ratio: Type:
1.14 Triplex
Power: Type:
15 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Motor:-
APPROVED MAKES Motor: Gear reducer: Coupling:
Specified or Equivalent Crompton Parkinson, ABB Brook, Brush Elektrim SEW, HANSEN, SEW, Renold, EPG ElectroPower. Fenner (Fenaflex) , Renold
Conveyor & Transmission chain, sprocket Bearing:
Renold, Tsubaki SKF, FAG, NTN
OTHER REQUIREMENTS:1. Vendor to furnish selection of gear reducers, fluid coupling, chain and sprockets 2. Inlet and outlet chute made from 6mm thk. m.s plate shall be provided Page 1 of 4
BOTTOM FRUIT CONVEYOR
SPECIFICATION SHEET PROJECT NAME PROJECT CODE
DATE: OIL PALM MILL
MACHINE NAME BOTTOM FRUIT CONVEYOR FOR THRESHER No.2
DELIVERY DRAWING NO.
PREPARED BY
ITEM No.
GENERAL Scope
Scope of works include the manufacture, delivery & installation, commissioning, handing over and guarantee.
Function:
To convey fruitlets from Unstripped Bunch Thresher to the fruit Elevator Via Bottom cross conveyor.
SPECIFICATIONS Quantity
One (1) Bottom Fruit Conveyor as follows :
Type: Size: General Arrangement: Construction Details:
Full flight screw 600 mm dia. As per drawing As per drawing
Screw Shaft: Hanger bearing: Conveyor Speed: Drive System:
NW
REVISION No. LOCATION THRESHING STATION
QUANTITY / UNITS
CONSTRUCTION MATERIAL Casing: Wear plate:
13-May-00
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L, Gr.B Sch 80 pipe Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled with flexible coupling to the shaft.
Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
5.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Conveyor & Transmission
Crompton Parkinson, Brook, Brush SUMITOMO, HANSEN, Renold Fenner (Fenaflex) , Renold Renold, Tsubaki
chain, sprocket Bearing:
SKF, FAG, NTN
1450 rpm 56 rpm 938 Nm (min) > 1.5
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at both end of the conveyor 4. Conveyor shall be mounted on rollers and able to slide sideway for easy removal during maintainance
Page 1 of 1
D7 1
BOTTOM CROSS FRUIT CONVEYOR
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED BY
BOTTOM CROSS CONVEYOR
DELIVERY
NW
REVISION No. LOCATION
THRESHING STATION
DRAWING NO.
ITEM No.
D8
QUANTITY / UNITS
GENERAL Scope
Scope of works include the manufacture, delivery & installation, commissioning, handing over and guarantee 12 months.
Function:
To convey fruitlets from Thresher bottom fruit conveyor to fruit elevator
SPECIFICATIONS Quantity
One ( 1 ) unit Bottom Cross Fruit Conveyor as follows :
Type: Size: General Arrangement: Construction Details:
Full flight screw 600 mm dia. As per drawing As per drawing
Construction Material: Casing: Wear plate:
Screw Shaft: Hanger bearing: Conveyor Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughoutthe conveyor extended a least 100mm above the centerline of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L, Gr.B Sch 80 pipe Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled with flexible coupling to the shaft. 1450 56 938 <
rpm rpm Nm (min) 1.5
5.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent.
Motor: Gear reducer:
Crompton Parkinson, ABB Brook, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectrolPower
Coupling:
Fenner (Fenaflex) , Renold
Conveyor & Transmission
Renold, Tsubaki
chain, sprocket Bearing:
SKF, FAG, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at both end of the conveyor 4. Conveyor shall be mounted on rollers and able to slide sideway for easy removal during maintainance
Page 1 of 1
1
INCLINED E.B.C
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
INCLINE EMPTY BUNCH CONVEYOR
DELIVERY
PREPARED BY
NW
REVISION No. LOCATION
EMPTY BUNCH DISPOSAL SYSTEM
DRAWING NO.
ITEM No. QUANTITY / UNITS
E1 1
GENERAL Scope
Scope of works include the manufacture, delivery & installation commissioning, handing over and guarantee.
Function:
To convey empty bunches from the horizontal bunch conveyor to the empty bunch hoppers.
SPECIFICATIONS Quantity
Type: Capacity: General Arrangment: Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate: Inclination: Conveying Section: Shaft Speed: Transmission Sprocket Ratio: Drive:
One ( 1 ) unit Inclined Empty Bunch Conveyor complete with covered walkway, handrails, chutes, steel structure and drive shall be suitable for handling 90mt FFB per hour opration.
Conveyor chain with scrapper plate 25,000 kg / hr of empty bunches As per drawing
Flanged roller chain of 150mm pitch of Cast steel or equivalent, 8000 kg breaking load Mild steel section Mild steel 12T, 150mm pitch grey cast iron Mild steel 6 mm minimum thickness 15 deg. Top 15 rpm 1.67 Geared motor coupled conveyor shaft by tarnsmission chain & sprocket
Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
11 KW Vendor to advise TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Drag Chain: Bearing:
Crompton Parkinson, Brush, ABB Brook, Elektrim SEW, HANSEN, Renold, EPG Electropower Fenner (Fenaflex) or equivalent Renold, Tsubaki, PC Chain SKF, FAG
1450 25 4202 <
rpm rpm Nm (min) 1.5
OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devises c/w take-up bearings
Page 1 of 1
UNSTRIPPED BUNCH ELEVATOR
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME OIL PALM MILL
PROJECT CODE
PREPARED BY
UNSTRIPPED BUNCH ELEVATOR
DELIVERY
NW
REVISION No. LOCATION EMPTY BUNCH DISPOSAL SYSTEM
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
E2 1
Scope of works include the manufacture, delivery & installation, commissioning handing over and guarantee.
Function:
To convey unstripped bunches from H.E.B Conveyor to Thresher No.2
SPECIFICATIONS Quantity
One ( 1 ) unit Unstripped Bunches Conveyor as follows :
Type: Capacity: General Arrangement: Construction Details:
Double conveyor chain c/w buckets 90 MT FFB per hour. As per drawing As per drawing
Construction Material: Casing: Sprocket Bucket: Chain rail: Wear plate: Chain:
Mild steel with 6mm minimum thickness 12T, 150 mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 150mm pitch 15000 kg breaking load
Drive: Geared Motor coupled to elevator shaft by chain & sprocket Shaft Speed: 25 rpm Transmission Sprocket Ratio: 1 Speed Reducer: Input speed: 1450 rpm Output speed: 25 rpm Output torque: 2865 Nm (min) Design Service Factor: > 1.5 Motor:Power: Type:
7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer:
Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower
Coupling: Transmission Chain: Conveyor Chain: Bearing:
Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS 1. Miantenance door shall be provided at the elevator booth 2. Top cover shall be bolted for ease of maintenance 3. Take-up bearing with adjustable bolt and screw shall be provided at the bottom booth for chain tightening 4. Mild steel outlet chute shall be provided 5. Plumber block bearing shall be fixed at the top booth
Page 1 of 1
BUNCH CRUSHER
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED BY
BUNCH CRUSHER
DELIVERY DRAWING NO.
NW
REVISION No. LOCATION EMPTY BUNCH DISPOSAL SYSTEM
ITEM No.
E3
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the manufacture, supply, installation, erection, testing commissioning, handing over and guarantee
Function:
Crushing of the bunches for the removal of fruitlets and dewatering of bunches
SPECIFICATIONS Quantity
One ( 1 ) unit Bunch Crusher complete with support, chutes and drive, as follows:
Unit Capacity
12MT Bunches per hour. ( 45mt FFB per hour )
Diamension Weight
Approx 2,500 kg
CONSTRUCTION MATERIAL Construction
Drive system
Robust construction with parts in contract with bunch from special wear resistance steel. The drive system shall consist of a motor coupled to gearmotor with pulley and belt transmission. An arrangement with the use of a fluid coupling can also be considered.
Motor
Approx. 22kw 415 V 3 Ph 50 HZ TEFC IP55 Class F
APPROVED MAKES Motor: Gear reducer: Coupling: Conveyor & Transmission chain, sprocket Bearing:
Specified or Equivalent. Crompton Parkinson, ABB Brook, Brush, Elektrim Sew, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold Renold, Tsubaki SKF, FAG, NTN
OTHER REQUIREMENTS:1. Vendor to furnish details drawing and specifications of selection of gear reducers, fluid coupling, chain and sprockets 2. Inlet and outlet chute made from 6mm thk. m.s plate shall be provided
Page 1 of 1
TOP EMPTY BUNCH CONVEYOR
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME OIL PALM MILL
PROJECT CODE
PREPARED BY
TOP EMPTY BUNCH CONVEYOR
DELIVERY
NW
REVISION No. LOCATION EMPTY BUNCH DISPOSAL SYSTEM
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manufacture, delivery & installation commissioning, handing over and guarantee.
Function:
To convey empty bunches from Inclined EB Conveyor to the EB Hoppers.
SPECIFICATIONS Quantity
One (1) unit Top Empty Bunch Conveyor suitable for handling 90MT FFB per hour as follows:
Type: Capacity: General Arrangment: Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate: Basic Dimension: Width: Length:
Conveyor chain c/w scrapper plate ### kg / hr of empty bunches As per drawing
Steel c/w hardened steel rollers, 100 mm pitch, 6800 kg breaking load Mild steel or equivalent Mild steel or equivalent 12T, 100 mm pitch, grey iron Mild steel 6 mm minimum thickness or equivalent
Inclination:
mm mm Horizontal
Conveying Section:
Top
Shaft Speed:
25
Transmission Sprocket Ratio: Drive:
1.00 Geared motor coupled conveyor shaft by tarnsmission chain & sprocket
Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:
760
rpm
1450 rpm 25 rpm 2865 Nm (min) < 1.5
Motor:Power: Type:
7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Page 1 of 2
E4 1
TOP EMPTY BUNCH CONVEYOR
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
TOP EMPTY BUNCH CONVEYOR
DELIVERY DRAWING NO.
PREPARED BY
NW
REVISION No. LOCATION EMPTY BUNCH DISPOSAL SYSTEM
ITEM No. QUANTITY / UNITS
E4 1
Sheet 2. APPROVED MAKES Motor: Gear reducer: Coupling: Conveyor & Transmission chain, sprocket Bearing:
Crompton Parkinson, ABB Brook, Brush, Elektrim SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex) , Renold Renold, Tsubaki, PC SKF, FAG, NTN
OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devises c/w take-up bearings
Page 2 of 2
Empty bunch Hoppers
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
EMPTY BUNCH HOPPERS STRUCTURE
&
PREPARED BY
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
EMPTY BUNCH DISPOSAL SYSTEM
ITEM No.
E5
QUANTITY / UNITS
16
GENERAL Scope
Scope of works include the design, manufacture, delivery & installation commissioning, handing over and guarantee.
Function:
To receive, store and unload empty bunches into trucks.
SPECIFICATIONS Quantity
Sixteen ( 16 ) bay Empty Bunch hoppers as follows : The hopper shall be of mild steel construction and doors will be operated hydraulically.
Type: Capacity: Slope: Construction Material: Construction Details: Door operation:
Sloping ramp c/w hydraulic operated doors 10,000 kg per Hopper 27 deg
Hydraulic type, vertical stroke( top down) c/w individual lever control located at hopper's platform as per drawings
Hydraulic System:
Consist of hydraulic pump, oil tank, cylinders, tubing, lever control, releif valve, pressure gauges, pump strainer, check valve and all the necessary accessories for completion operation of each 16 sets of doors. The tank shall be interconnected.
Powerpack: Reservoir: Pump
Double unit 80 litres capacity with epoxy coating Fix displacement low noise gear type, 23 litres/min @ 250 Bar
Relief valve
Direct acting type, 120 litres/min adjustable from 0-100 Bar
Cylinder:
piston type, 915mm stroke 200 bar rated pressure 300 bar static pressure Heavy duty construction with welded cap and easily removable head with air bleeding plugs at both end
Piston road: Mounting: Directional Control Valve: Tubing:
38mm diameter rod heat treated steel hard chrome plated Female clevis both ends.
Motor:
Individual valve for each door seamless cold drawn hydraulic tubing, 235 N/m2 minimum yeild strength. Flaxible hoses to be 2 -wire braided high pressure type. 2 x 5.25 kw TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Detail Drawings
Contractor to provide detail drawing for approval by the consultant Page 1 of 2
FRUIT ELEVATOR
SPECIFICATION SHEET PROJECT NAME
DATE: 13-May-00 MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED BY
FRUIT ELEVATOR
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
PRESS STATION
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee 12 months.
Function:
To convey loose fruits from THRESHER CONVEYOR to TOP DISTRIBUTING CONVEYOR
SPECIFICATIONS Quantity
Two ( 2 ) unit Fruit Elevator.
Type: Capacity: General Arrangement: Construction Details:
Double conveyor chain c/w buckets 45 MT FFB per hour. As per drawing As per drawing
Construction Material: Casing: Sprocket Bucket: Chain rail: Wear plate: Chain:
Mild steel with 6mm minimum thickness 12T, 150 mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 150mm pitch, 15000 kg breaking load
Drive: Shaft Speed: Transmission Sprocket Ratio:
Geared Motor coupled to elevator shaft by chain & sprocket 25 rpm 1
Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:
1450 25 2865 >
rpm rpm Nm (min) 1.5
Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent. Crompton Parkinson, Brush, ABB Brooks , Elektrim SEW, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS 1. Miantenance door shall be provided at the elevator booth 2. Top cover shall be bolted for ease of maintenance 3. Take-up bearing with adjustable bolt and screw shall be provided at the bottom booth for chain tightening 4. Mild steel outlet chute shall be provided 5. Plumber block bearing shall be fixed at the top booth
Page 1 of 1
F1 2
FRUIT FEED CONVEYOR
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
FRUIT FEED CONVEYOR
PREPARED BY
DELIVERY DRAWING NO.
NW
REVISION No. LOCATION PRESS STATION
ITEM No. QUANTITY / UNITS
F 2. 1
GENERAL Scope
Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee.
Function:
To convey loose fruit from FRUIT ELEVATOR to Digesters
SPECIFICATIONS Quantity Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:
One ( 1 ) unit Fruit feed conveyor as follows : 45 MT FFB per hour. Full flight screw 600 mm dia. As per drawing As per drawing Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor
Screw Shaft: Shaft joint: Hanger bearing:
Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup
Conveyor Speed: Drive System:
56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
5.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent.
Motor: Gear reducer: Coupling: Bearing:
Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold,HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
1450 rpm 56 rpm 938 Nm (min) > 1.5
OTHER REQUIREMENTS:1. Four ( 4 ) mild steel outlet chutes c/w rack & pinion sliding doors with chain operated to be provided at inlet to 3 digesters and blank space. 2. One mild steel chute to be provided at the end of the conveyor to recycle the excess fruit to FRUIT ELEVATOR 3. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 4. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust Page 1 of 2
FRUIT FEED CONVEYOR
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
FRUIT FEED CONVEYOR
DELIVERY DRAWING NO.
PREPARED BY
NW
REVISION No. LOCATION PRESS STATION
ITEM No. QUANTITY / UNITS
5. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 2 of 2
F 2. 1
RETURN FRUIT CONVEYOR
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED BY
RETURN FRUIT CONVEYOR
DELIVERY
REVISION No. LOCATION PRESS STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, manufacture, delivery installation, commissioning, handing over and guarantee.
Function:
To convey excess loose fruit from Fruit Feed Conveyor to Fruit Elevator
SPECIFICATIONS Quantity Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
NW
One (1) unit Return Fruit Conveyor as follows : 45 MT FFB per hour. Full flight screw 600 mm dia. As per drawing As per drawing
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling 1450 56 640 >
rpm rpm Nm (min) 1.5
3.75 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer:
Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold,HANSEN, EPG ElectroPower
Coupling: Bearing:
Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. One inlet appreture for the overflow of digested material to be conveyed to the fruit elevator. 2. One MS chute flange to be provided at the end of the conveyor for attachment of the return fruit chute to the elevator. 3. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 4. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust Page 1 of 2
F 3. 1
RETURN FRUIT CONVEYOR
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
RETURN FRUIT CONVEYOR
DELIVERY DRAWING NO.
PREPARED BY
NW
REVISION No. LOCATION PRESS STATION
ITEM No. QUANTITY / UNITS
5. Top of the conveyor shall be covered with 3mm thk m.s plate cover.
Page 2 of 2
F 3. 1
Recycle Chute
SPECIFICATION SHEET PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
RECYCLE CHUTE
DELIVERY
PREPARED BY
NW
REVISION No. LOCATION
DRAWING NO.
PRESS STATION
ITEM No.
F 4.
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the Design, manufacture, delivery, installation, commissioning, handing over and guarantee
Function:
To convey excess loose fruit from Fruit Feed Conveyor to Fruit Elevator
SPECIFICATIONS Quantity
One ( 1 ) unit Recycle Chute of mild steel
General Arrangement: Construction Details: Construction Material: Casing: Supports :
As per drawing As per drawing Mild steel of 6mm minimum thickness M. S. Channels & Angle iron
Page 1 of 1
DIGESTER
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
DELIVERY DRAWING NO.
PREPARED
DIGESTER ( 3500 m3 )
REVISION No. PRESS STATION
ITEM No. QUANTITY / UNITS
GENERAL Scope
Function: SPECIFICATIONS Quantity Unit Capacity
Diamension CONSTRUCTION MATERIAL Construction
F5 3
Scope of works include the unloading at site, safe keeping installation, assist in testing and commissioning. Digestion of loose fruitlets before screw press oil extraction.
Three ( 3 ) units Digesters as follows : 15MT Fresh Fruit Bunches ( FFB ) per hour. or not less than 3,500 liters per hour. approx. 4000 mm H x 1300 mm D
The cylindrical portion shall have a 12mm thick mild steel shell with a 9mm thick mild steel liner. The shell insulated with rockwool at density of 90 kg / m2 and covered with 22 gauge embossed stainless steel sheet. Heating by steam injection and control by a thermostatic valve. Chute from digester to screw press to be fabricated from 4 mm thick stainless steel sheet with sight glass, flanged door oil filled pocket for temperature gauge.
Drive system
Motor is connected to a fluid drive coupling and then to the vertically mounted gear reducer as shown in the drawing.
Motor
approx. 22kw 4 pole, TEFC, IP 55 class F 415 V 3 phase 50 Hz.
Gear reducer
Ratio 40:1 service factor 1.5 ( min )
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Bearing:
Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold,HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
Page 1 of 1
TWIN SCREW PRESS
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
TWIN SCREW PRESS ( TYPE P15)
DELIVERY
REVISION No.
DRAWING NO.
ITEM No.
PRESS STATION
QUANTITY / UNITS
F 6. 3
GENERAL Scope
Scope of works include the unloading at site, safe keeping, insatallation assist in testing and commissioning.
Function:
The extraction of crude palm oil by screw pressing.
SPECIFICATIONS Quantity
Three ( 3 ) units Twin Screw Presses as follows :
Unit Capacity
15MT Fresh Fruit Bunches ( FFB ) per hour.
Diamension Weight
Approx. 4600mm L x 1100mm W x 1400mm H Approx 4,500 kg
CONSTRUCTION MATERIAL Construction
Robust construction with parts in contract with press mash & fibre from special wear resistance steel.
Strainer & Cage
The holes of the strainer and press cage shall have taper holes no larger than 3 x 2 mm with 6 mm C/C and the cage plate of 12 mm thickness supported by ribs.
Drive system
The drive system of he twin screw press shall consist of a motor directly coupled to a gearmotor with pulley and belt transmission to the drive shaft of the screw press. An arrangement with the use of a fluid coupling can also be considered.
Motor
Approx. 22kw 415 V 3 Ph 50 HZ TEFC IP55 Class F
Hydraulic Cone Control
The hydraulic cone control shall be automatic with the cones sliding in and out, maintaining a consistent pressure. The feedback of the pressure in the main hydraulic motor drive shall be used to control the hydraulic cylinder driving the adjustable cones and its motion shall stepless.
Preformance
a. b. c. d.
Oil loss on press fibre shall not exceed 7% Oil / Dry matter Oil loss on Nuts shall not exceed 1% Oil / Dry matter Broken Nuts in press fibre shall not exceed 12% NOS in Sludge shall not exceed 10% Oil / Dry matter.
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Bearing:
Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold,HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
Page 1 of 1
PRESS STRUCTURE
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PRESS STRUCTURE
DELIVERY DRAWING NO.
PREPARED REVISION No.
'PRESS STATION
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, manufacture, delivery Installation, commissioning, handing over and guarantee.
Function:
To support equipment which include 4 presses, 4 digesters, digester feed conveyor, fruit return conveyor, Hot water tank and Oil launder.
SPECIFICATIONS Quantity
Lot - Press Structure with platform and necessary stairways.
Plateform
The chequered plates for the platform shall be 6 mm thick and toe plate of 100mm x 6 mm
Stairways
The chequered plates are to be secured to the supporting structure by stitch welding and all necessary stairways shall be provided as shown in the drawing.
Chain Block
At the top of the structure a cross beam with a 3 ton chain block shall be provided for maintenance of the digester & Press.
General Arrangment: Construction Details: Construction Material: Structures: Plaform Handrail: Structure bolts & nuts:
As per drawing As per drawing
Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe High tensile
OTHER REQUIREMENTS 1. Handrail of 40 mm black pipe shall be 900mm high with intermediete poles at 2000 c/c 2. 100mm high kick plate to be provided around the platform 3. Hoist beam and 3 ton chain block shall be installed as shown in the relevant drawings
Page 1 of 2
F 7. 3
CRUDE OIL COLLECTION GUTTER
SPECIFICATION SHEETS PROJECT NAME
DATE:
2-Oct-98
MACHINE NAME PROJECT CODE
OIL PALM MILL
CRUDE OIL GUTTER
DELIVERY
PREPARED NW REVISION No.
LOCATION PRESS STATION
DRAWING NO.
ITEM No.
F 8.
QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, manufacture, delivery, installation, commissioning, handing over and guarantee .
Function:
To collect crude oil ex-SCREW PRESSES and channel it to Sand trap
SPECIFICATIONS Quantity
One ( 1 ) Crude Oil Collection Gutter as follows : The cude oil pipe shall be a stainless steel pipe of 200 mm dia. It shall have sufficient gradient to allow a full flow and drainage of the crude oil mixture. The outlet oil drain from the digester and press drain funnel and interconnecting pipes to crude oil gutter shall be included. Provision for hot water and steam blowing of the crude oil gutter.
General Arrangment:
As per drawing
Construction Details:
As per drawing
Construction Material:
PIPE S.S AISI 304
Thickness:
4.5 mm
Size:
200 mm Dia.
Page 1 of 1
1
SAND TRAP
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
SAND TRAP TANK
DELIVERY
REVISION No.
DRAWING NO.
ITEM No.
PRESS STATION
QUANTITY / UNITS
GENERAL Scope Function:
NW
F 9. 1
Scope of works include the Design, manufacture, delivery, installation, testing, commissioning and guarantee. To receive oil from CRUDE OIL GUTTER and trap the sand
SPECIFICATIONS Quantiry
One ( 1 ) Sand Trap as follows : The sand trap tank shall have a capicity of approximately 7 m 3 and of vertical cylindrical construction. Internal buffling shall be provided to allow for non-turbulent flow of crude oil to the top of the tank whereby allowing the sand and heavy solid particles to settle to the bottom. The crude oil overflow pipe shall be connected to the crude oil tank.
Capacity: Basic Dimensions:
7 m3 As per drawing
Construction Material:Tank:
Mild steel
Close Steam Coil:
50mm dia. S.S 304 seamless sch 10S
Nozzles:Protrusion qty 1 1 1 1 1
Purpose Drain Overflow Steam inlet Cond.Outlet Hot water
Size (mm) 80 150 50 50 25
Tank plate thickness: Flanges:
6 mm Raised face to BS 4504
Page 1 of 1
(mm) 150 150 150 150 150
Flange PN 10 PN 10 PN 16 PN 16 PN 10
Material API 5L Gr B Sch 40 API 5L Gr B Sch 40 SS 304 Sch 10S SS 304 Sch 10S GI Class C BS 1387
CIRCULAR VIBRATING SCREEN
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OILPALM MILL
PREPARED
CIRCULAR VIBRO SIEVE SCREEN
DELIVERY
NW
REVISION No. 'PRESS STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
F 10 2
GENERAL Scope
Scope of works include the Design, manufacture, delivery, installation, testing commissioning and guarantee.
Function:
Screening of crude oil before clarification process.
SPECIFICATIONS Quantity
Two ( 2 ) units Circular Vibrating screens as follows :
Type
Double deck circular vibro sieve screens.
Screen area
not less than 1.6 m2
Diameter
60 inchs.
Unit Capacity
:
CONSTRUCTION AND MATERIAL. Construction
Diluted crude oil of equivalent to 16 m3 / h
Bottom supporting assembly supported by springs which shall give the required vibrations.
The cylindrical deck body (wetted part) to fabricated from stainless steel 304 (EN 58B) or equivalent. The first and second deck shall be equipped with mesh 20 and 40 stainless steel screen respectively Variable weights at the lower end of the motor shaft for varying the amplitude of vertical vibration. Variable weights at the upper end of the motor shaft for varying the horizontal conveying so as to screen solids to the periphery for discharge
The design fittings of the sieve screen shall be so as to facilitate easy assembling and dismantling of the screen box for screen cloth changes, cleaning and inspection
Contractor shall provide details of and specify vibrating screen make, type, model, country of origin, capacity , motor etc… Vibro Motor.
3.75 kw 415 V, 3 phase 50 Hz TEFC, IP 55 Class F
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Bearing:
Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold,HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
Page 1 of 1
VIBRATING SCREEN STRUCTURE
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
VS STRUCTURE
DELIVERY DRAWING NO.
REVISION No. LOCATION PRESS STATION
ITEM No. QUANTITY / UNITS
GENERAL
Scope of works include the design, fabrication, delivery, installation, testing, commissioning and guarantee.
Function:
To support 2 circular vibrating screens
SPECIFICATIONS General Arrangment: Construction Details: Construction Material: Structures: Plaform Handrail:
NW
As per drawing As per drawing Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe
OTHER REQUIREMENTS 1. Handrail shall be of 40mm black pipe, 900mm high with intermediete poles at 2000 c/c 2. 100mm high kick plate to be provided around the platform
Page 1 of 1
F 11. 2
SCREEN WASTE CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
SCREEN WASTE CONVEYOR
DELIVERY
NW
REVISION No. LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
F 12
QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, manufacture, delivery installation, commissioning, handing over and guarantee.
Function:
To convey vibrating screen reject of solid waste to FRUIT ELEVATOR.
SPECIFICATIONS Quantity
One ( 1 ) unit Screen Waste Conveyor as follows :
Type: Size: General Arrangement: Construction Details:
Full flight screw 300 As per drawing As per drawing
Construction Material: Casing: Wear plate:
Screw Shaft: Hanger bearing: Conveyor Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
mm dia.
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Stainless steel 304 of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Motor directly coupled to speed reducer by flexible coupling 1450 56 375 >
rpm rpm Nm (min) 1.5
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer:
Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold, HANSEN
Coupling: Bearing:
Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at drive end of the conveyor 4. Roller thrust bearing shall be fitted at discharge end
Page 1 of 1
1
CRUDE OIL TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
CRUDE OIL TANK
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
PRESS STATION
ITEM No.
F 13.
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the Design, manufacture, delivery, installation commissioning, handing over and guarantee.
Function:
To receive oil from VIBRATING SCREEN
SPECIFICATIONS Quantity
One ( 1 ) unit Crude oil tank as follows :
Capacity: Basic Dimensions: Construction Details:-
7 m3 As per drawing As per drawing
Construction Material:Tank: Close Steam Coil: Live steam injection: Insulation: Nozzles:-
Stainless steel 4.5mm plate 25mm dia. S.S 304 seamless sch 10S 25mm dia. S.S 304 seamless sch 10S 80mm thk Rockwool c/w 0.7mm thk aluminium cladding
Purpose drain pump suction vent hot water inlet crude oil inlet steam inlet steam condensate recycle Flanges:
Size (mm) 80 80 150 25 200 50 50 50
Qty 3 3 1 3 1 3 3 1
Raised face to BS 4504
Page 1 of 1
Protrusion Flange PN 10 PN 10 PN 10 PN 10 PN 10 PN 16 PN 16 PN 10
(mm) 150 150 150 150 150 150 150 150
Material API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 SS 304 SCH10S SS 304 SCH10S API 5L SEAMLESS SCH40
CRUDE OIL PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE: 13-May-00 MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CRUDE OIL PUMP DELIVERY
REVISION No. LOCATION PRESS STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, manufacture, delivery installation, commissioning, handing over and guarantee.
Function
To transfer the crude oil to the clarification station
SPECIFICATIONS Quantity
Two ( 2 ) units Crude Oil Pump as follows :
Type Connection
Centrifugal, End-suction Raised face flange to BS 4504 PN 10
OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Deleivery Head Speed NPSH available
45 Crude Oil 90 0.9 0.1425 35 1450 3
MT / hr o
C
Ns / m2 m liquid RPM (Max) m liquid
CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling Level Switches:
Cast Iron GG25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Magnetic type, with stainless steel float & rod and counter weight Motor directly coupled with flexible coupling to the pump
Drive: Motor:Power: Type:
approx. 3.75 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
OTHER REQUIREMENTS
1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 1
F 14 2
OVERHEAD HOT WATER TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
HOT WATER TANK
DELIVERY DRAWING NO.
NW
REVISION No. LOCATION PRESS STATION
ITEM No. QUANTITY / UNITS
F 15 1
GENERAL Scope
Scope of works include the Design, manufacture, delivery installation, commissioning, handing over and guarantee.
Function:
Heating tank of water for extracted crude oil dilution
SPECIFICATIONS Quantity
One ( 1 ) unit Overhead Hot water tank as follows :
Capacity: Basic Dimensions: Construction Details:-
4 m3 As per drawing As per drawing
Construction Material:Tank: Close Steam Coil: Live steam injection: Insulation: Level switch Control
Stainless steel 4.5mm plate 25mm dia. S.S 304 seamless sch 10S 25mm dia. S.S 304 seamless sch 10S 80mm thk Rockwool c/w 0.7mm thk aluminum cladding Level limit switch for feed water inlet Thermostatic control valve for steam coil
Nozzles:Purpose vent hot water inlet and outlet steam inlet
Flanges:
Size (mm) 150 25 50 25
Qty 1 3 1 3
Raised face to BS 4504
Page 1 of 1
Flange PN 10 PN 10 PN 10 PN 16
Protrusion (mm) 150 150 150 150
Material API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 API 5L SEAMLESS SCH40 SS 304 SCH10S
SAND TRAP CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE: 13-May-00 MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
SAND TRAP CONVEYOR
DELIVERY
REVISION No. LOCATION PRESS STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
TO convey trap sand for disposal
SPECIFICATIONS Quantity
One ( 1 ) unit Sand trap Conveyor No. 1 as follows :
Capacity: Type: Size: General Arrangement: Construction Details:
1,000 kg / hr of sand material Full flight screw 200 mm dia. As per drawing As per drawing
Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
NW
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling 1450 56 375 >
rpm rpm Nm (min) 1.5
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent.
Motor: Gear reducer:
Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold, HANSEN, EPG ElectroPower
Coupling: Bearing:
Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate Page 1 of 2
F 16 1
STRAINER BUCKET ELEVATOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
BUCKET ELEVATOR
DELIVERY
PREPARED
NW
REVISION No. LOCATION
PRESS STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Function:
F 17. 1
Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee. Conveyor to drain the solid waste in buckets, while in motion and thereafer unloading onto trailer or truck for field disposal.
SPECIFICATIONS Quantity
One (1) Bucket Elevator ( strainer ) complete with drive as folows:
Type: Capacity: General Arrangement: Construction Details:
Double conveyor chain c/w buckets 1,000 kg material per hour. As per drawing As per drawing
Construction Material: Casing: Sprocket Bucket: Chain rail: Wear plate: Chain: Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
Mild steel with 6mm minimum thickness 12T, 100mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 100mm pitch. 3600 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 25 rpm 1 1450 25 1000 >
rpm rpm Nm (min) 1.5
3.75 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer:
Specified or Equivalent. Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, HANSEN, Renold, EPG ElectroPower
Coupling: Transmission Chain: Conveyor Chain: Bearing:
Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS 1. Miantenance door shall be provided at the elevator booth 2. Top cover shall be bolted for ease of maintenance 3. Take-up bearing with adjustable bolt and screw shall be provided at the bottom booth for chain tightening 4. Mild steel outlet chute shall be provided 5. Plumber block bearing shall be fixed at the top booth
Page 1 of 1
AUTO DILUTION SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
CRUDE OIL DILUTION SYSTEM
DELIVERY
NW
REVISION No. LOCATION PRESS STATION
DRAWING NO.
ITEM No.
F 18.
QUANTITY / UNITS
GENERAL Scope
Scope of works include the unloading, safe keeping, installation supervision assist in the testing and commissioning.
Function
Controlled dilution of raw CPO and water for effective clarification
SPECIFICATIONS Quantity
One (1) Crude Oil Dilution System as follows:-
Construction
The Automatic Crude Oil Dilution system shall handle viscous slurry nature of crude oil at temperature range: 70 C - 90 C. It shall be of proven make and currently in operation. The Automatic Crude Oil Dilution System consists of PID controller that automatically modulates 50mm hot water valve to dilute crude oil to pre-set density. Crude oil from buffer tank is gravity feed and pass through density cell for continuously crude oil density.
Scope of supply shall include: 1
Density cell c/w positive cell fluid retainer and signal conditioning.
2
Microprocessor based controller with PID control and I/P conversion.
3
50mm dia. modulating control valve for hot water.
4
Crude Oil R.S.G. recorder.
5
Installation & Operating instructions, service manual and buffer tank drawing.
6
Testing and commissioning.
Page 1 of 1
1
WATER COLLECTION TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
WATER COLLECTION TANK
DELIVERY
NW
REVISION No. LOCATION
PRESS STATION
DRAWING NO.
ITEM No.
F 19.
QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, manufacture, delivery, installation commissioning, handing over and guarantee.
Function:
Tank to collect condensate water from all equipment and piping system
SPECIFICATIONS Quantity
One ( 1 ) unit Water Collection tank as follows :
Capacity: Basic Dimensions:
2.25 As per drawing
Construction Details:-
As per drawing
m3
Construction Material:Tank: Insulation: Level switch
Mild steel 5mm plate 80mm thk Rockwool c/w 0.7mm thk aluminum cladding Level limit switch for level control
Nozzles:Purpose
Size (mm)
Qty
Flange
Protrusion (mm)
Material
Water inlet
50
3
PN 10
150 API 5L SEAMLESS SCH40
and outlet
50
1
PN 10
150 API 5L SEAMLESS SCH40
Flanges:
Raised face to BS 4504
Page 1 of 1
1
PUMP SET - WATER COLLECTION TANK.
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PUMP FOR WATER COLLECTION TANK
DELIVERY
PREPARED
NW
REVISION No. LOCATION PRESS STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
F 20 2
GENERAL Scope
Scope of works include the Design, manufacture, delivery , installation commissioning, handing over and guarantee.
Function
To recycle the condensate water to the Hot water tank crude oil dilution tank, vibrating screen and clarification station.
SPECIFICATIONS Quantity
Two ( 2 ) Pump set with level switch for water collection tank as follows : Note : One unit on standby.
Type Connection Control
Centrifugal, End-suction Raised face flange to BS 4504 PN 10 Level switch
OPERATING DATA Capacity Medium Temperature Specific Gravity Deleivery Head Speed NPSH available
15 WATER 100 1 30 1450 3
MT / hr o
C
m liquid RPM (Max) m liquid
CONSTRUCTION Casing Impeller Shaft Coupling Level Switches:
Cast Iron GG25 S.S AISI 304 S.S AISI 304 Flexible Magnetic type, with stainless steel float & rod and counter weight Motor directly coupled with flexible coupling to the pump
Drive: Motor:Power: Type:
approx. 3.75 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
OTHER REQUIREMENTS 1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 2
VERTICAL CLARIFIER
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
VERTICAL CLARIFIER
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
CLARIFICATION STATION
ITEM No. QUANTITY / UNITS
G 1. 1
GENERAL Scope
Scope of works include the Design, Fabrication, delivery, installation, testing commissioning and guarantee.
Function:
Static separation of crude oil from sludge
SPECIFICATIONS Quantity
One ( 1 ) unit Vertical Clarifier Tank as follows :
Capacity: Basic Dimensions : Construction Details:-
120 As per drawing As per drawing
Construction Material:Tank body: Close Steam Coil: Open Steam Coil: Skimmer: Sludge Underflow Pipe: Hot water Coil: Stirrer: Baffles: Supporting Structures: Insulation:
Mild steel cylindrical section and SS 304 conical section 50mm dia. S.S 304 seamless sch 10S 50mm dia. S.S 304 seamless sch 10S S.S 304 S.S 304 seamless sch 10S 50mm dia. S.S 304 seamless sch 10S S.S 304 S.S 304 Mild steel 50mm thk Rockwool c/w 0.7mm thk aluminium cladding
Nozzles:Users Drain Sudge Overflow Oil outlet Vent Hot water in Steam in Cond. out crude oil in Rec.oil in Temp.Gauge Temp.Controller
Size mm 100 150 150 100 50 50 50 80 65 3/4" BSP 3/4" BSP
Qty 1 1 1 1 1 2 1 1 1 1 1
Manhole
as per drawing
Stirrer
as per drawing
Flanges:
m3
Raised face to BS 4504
Page 1 of 2
Flange Protrusion Material mm PN 10 150 API 5L Gr B, seamless Sch 40 PN 10 150 SS 304 Sch 10S PN 10 150 API 5L Gr B, seamless Sch 40 PN 10 150 API 5L Gr B, seamless Sch 40 PN 10 150 SS 304 Sch 10S PN 16 150 SS 304 Sch 10S PN 16 150 SS 304 Sch 10S PN 10 150 SS 304 Sch 10S PN 10 150 SS 304 Sch 10S 100 100
PURE OIL TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
PURE OIL TANK
DELIVERY
NW
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
G 2. 1
GENERAL Scope
Scope of works include the Design, Fabrication, delivery installation, testing, commissioning and guarantee.
Function:
To receive oil from VERTICAL CLARIFIER
SPECIFICATIONS Quantity Capacity: Basic Dimensions: Construction Details:-
One ( 1 ) Unit Pure Oil Tank as follows : 30 m3 As per drawing As per drawing
Construction Material:Tank body: Steam Coil: Cover: Insulation:
Mild steel 50mm dia. API 5L,Gr B seamless sch 40 Mild steel 50mm thk Rockwool c/w 0.7mm thk aluminium cladding
Nozzles to be provided:Users drain oil inlet vent steam inlet cond.oulet oil outlet temp.gauge temp.control
Size (mm) 100 150 100 50 25 100 3/4" BSP 3/4" BSP
Qty 1 1 1 1 1 1 1 1
Flange PN 10 PN 10 PN 10 PN 16 PN 16 PN 10
Protrusion (mm) Material 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 80 API 5L, Gr B Sch 40 seamless 80 API 5L, Gr B Sch 40 seamless
Flanges:
Raised face to BS 4504
Level Indicator:
Mechanical type with SS float and string
Page 1 of 1
SLUDGE TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
SLUDGE OIL TANK
DELIVERY
NW
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL
Scope of works include the Design, Fabrication, delivery installation, testing , commissioning and guarantee
Function:
To receive Sludge phase from VERTICAL CLARIFIER
SPECIFICATIONS
One ( 1 ) unit Sludge Tank as follows :
Capacity: Basic Dimensions: Construction Details:-
30 As per drawing As per drawing
Construction Material:Tank body: Steam Coil: Cover: Insulation:
Mild steel SS AISI 304 seamless sch 10S Mild steel 50mm thk Rockwool c/w 0.7mm thk aluminium cladding
G 3. 1
m3
Nozzles to be provided:Users drain sludge inlet vent steam inlet cond.oulet sludge outlet temp.gauge temp.control Flanges: Level Indicator:
Size (mm) 100 150 100 50 25 100 3/4" BSP 3/4" BSP
Qty 1 1 1 1 1 1 1 1
Flange PN 10 PN 10 PN 10 PN 16 PN 16 PN 10
Protrusion (mm) Material 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 SS 304 seamless Sch 10S 150 SS 304 seamless Sch 10S 150 SS 304 seamless Sch 10S 80 API 5L, Gr B Sch 40 seamless 80 API 5L, Gr B Sch 40 seamless
Raised face to BS 4504 Mechanical type with SS float and string
Page 1 of 1
DESANDING CYCLONE
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
MULTI DESANDING CYCLONE
DELIVERY
NW
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No.
G 4.
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the design, manufacture, delivery installation supervision, testing, commissioning and guarantee. The installation on elevated platform will be provided by others.
Function:
desanding of crude oil before clarification process.
SPECIFICATIONS Quantity
One ( 1 ) Desanding cyclone system, delivered in module assembly, mounted in a m.s. frame complete with 3 cyclones control valves, connecting pipes, booster pump, solids collecting tank and control unit to be link with PLC and Central Control station via the LAN networking. The starter board, local switch and air supply will be provided by others
Capacity
45 m3 Sludge mixture per hour with solid contents of 15%
Performance
Removal of sand and solid mattter above 50 micron of not less than 75% of the total input sand and solid matter, operating at full capacity. Vendor to provide details on wear parts and running hours
Discharge head Scope of supply
3 kg / cm3 a. b. c. d. e. f. g. h. I. j. k.
Desanding cyclone assembly, mounted in m.s. frame Auto program control unit Set of control valves Solid matter collecting tank with water flushing system. Booster feed pump Set of piping connections and fixtures. Set of standard tools Set of standard spares Flow indicator Installation & Operation instruction, service and parts manuals Testing, commissioning and training of 3 operators
Page 1 of 2
DESANDING CYCLONE
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
MULTI DESANDING CYCLONE
DELIVERY DRAWING NO.
PREPARED
NW
REVISION No. LOCATION CLARIFICATION STATION
ITEM No.
G 4.
QUANTITY / UNITS
1
Sheet 2.
Material for Cyclones
Abrasion resistance ceramic
System for discharge of dirt
Discharge via a stainless steel collecting tank
Control Panel
Control panel using microprocessor- based control for operation.
Control Valve
Mark Control, Valtac, Keystone, bailey, Kitasawa or equivalent
Booster pump motor
3.75 kw 415V / 3-Ph / 50Hz Contractor to provide detail requirements
Test on completion :
Samples shall be taken for the inlet feed and outlet discharged material and analysed for quality and quantity of solid matter. The results shall be statistically analysed by taking the mean average and standard deviation.
Approved Makes
Specified or Equivalent.
Valves
Mark Control, Valtac, bailey, Kitasawa, Keystone, Klinger
Motor
Brook Crompton, ABB, Brush, Marelli
Pump
SIHI, Vogel, KSB, Grundfos, Robuschi, Allen Gwynnes, Ajax
Requirement
Contractor to provide design details of equipment offered for consultant's approval before fabrication.
Page 2 of 2
PRE - CLEANER PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
SLUDGE OIL TRANSFER PUMP
DELIVERY DRAWING NO.
REVISION No. LOCATION CLARIFICATION STATION
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the Purchase, delivery, installation testing, commissioning and guarantee.
FUNCTION
To pump the sludge oil from the sludge oil tank to the multi desanding cyclone
SPECIFICATIONS. Quantity Type Connection
Two ( 2 ) units Sludge Oil Transfer Pumps as follows: Centrifugal, End-suction BS 4504 PN 10
OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Deleivery Head Speed NPSH available
45 Sludge Oil 105 0.86 0.1425 30 1450 3
CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling DriveSystem: Motor:Power: Type:
APPROVED MAKES Pump: Motor: Coupling: Bearing: Mechanical seal:
NW
m3 per hour of Sludge Oil o
C
Ns/m2 m liquid RPM (Max) m liquid
Cast Iron GS-C25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling approx. 3.75 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent KSB, SIHI, Robuschi, Warman or equivalent Crompton Parkinson, Brush, ABB Brooks, Elektrim Fenner (Fenaflex), Renold SKF, FAG, NTN Crane, Burgman
OTHER REQUIREMENTS:1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 1
G 5. 2
SLUDGE BUFFERTANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
SLUDGE OIL TANK
DELIVERY
NW
REVISION No. LOCATION
CLARIFICATION STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
G 6. 1
GENERAL Scope
Scope of works include the Design, Fabrication, delivery, installation, testing commissioning and guarantee.
Function:
Buffer tank to feed the decanter or sludge separator
SPECIFICATIONS Quantity Capacity: Basic Dimensions: Construction Details:-
One ( 1 ) unit Sludge buffer tank as follows : 3 4 m As per drawing As per drawing
Construction Material:Tank body: Steam Coil: Cover: Insulation:
Stainless steel 304, 3mm thick SS AISI 304 seamless sch 10S Mild steel 50mm thk Rockwool c/w 0.7mm thk aluminium cladding
Nozzles to be provided:Uses drain sludge inlet vent steam inlet cond.oulet sludge outlet temp.gauge temp.control Flanges: Level Indicator:
Size (mm) 100 80 100 50 25 100 3/4" BSP 3/4" BSP
Qty 1 1 1 1 1 1 1 1
Flange PN 10 PN 10 PN 10 PN 16 PN 16 PN 10
Raised face to BS 4504 Mechanical type with SS float and string
Page 1 of 1
Protrusion (mm) Material 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 API 5L, Gr B Sch 40 seamless 150 SS 304 seamless Sch 10S 150 SS 304 seamless Sch 10S 150 SS 304 seamless Sch 10S 80 API 5L, Gr B Sch 40 seamless 80 API 5L, Gr B Sch 40 seamless
SLUDGE SEPARATOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
SLUDGE SEPARATOR
DELIVERY
PREPARED
NW
REVISION No. LOCATION
CLARIFICATION STATION
DRAWING NO.
ITEM No.
G 7.
QUANTITY / UNITS
GENERAL Scope
1
Scope of works include the unloading at site, safe keeping, installation assist in testing and commissioning. Centrifugal Separation and recovery of Oil from Sludge from the under flow of the sludge tank or working in series with the decanter.
Function:
SPECIFICATIONS Quantity
One ( 1 ) Sludge Separator in module form complete with interconnecting pipes, valves and fittings ready for start up.
Material to process Capacity
Sludge with 15% NOS from underflow of CS tank 36 m3 per hour ( Rate at 0.8 of 45 MT FFB per hour )
Capacity of each Separator Input feed rate
Performance will be based on operating without Decanter. 9 m3 Crude oil & Sludge mixture per hour
Discharge head
3 kg / cm3
CONSTRUCTION All bowl parts in contact with oil or sludge shall be in stainless steel. System for Cleaning:
The nozzle holders shall be easily removable from the outside without dismantling the centrifuge. A cleaning system shall be provided that the bowl internals can be cleaned by intermittent flushing without dismantling the unit.
Scope of supply: a. b. c. d. e. f. g.
Motor complete with fluid coupling Set of flexible connections 2 Sets of Special tools for maintenance Set of standard spares Complete automated cleaning system Flowmeter for incoming sludge 3 Sets of Installation, Operation & Service Manual
Operation of the automated cleaning system at regular intervals shall necessitate cleaning of the bowl parts by dismantling of the centrifuge after only 150 hours of operation. For sludge as the processing medium the waste water ex separator shall have an oil loss not exceeding 12% oil/Nos. Motor
11kw 415V, 3Ph, 50 HZ 4-pole, TEFC, Class F, IP 55 ( Vendor to advise )
Page 1 of 1
3 PHASE DECANTER
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
DECANTER ( 3 PHASE )
DELIVERY
PREPARED
NW
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No.
G 8.
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the unloading at site, safe keeping, installation, assist in testing and commissioning.
Function:
Separation of Oil, Light phase and Sludge from Raw Sludge oil from the underflow of the CS tank
SPECIFICATIONS Quantity
One ( 1 ) unit 3 Phase Decanter System complete in module form as follows : The unit shall be supplied complete with inter-connecting pipes, valves and fittings ready for start up.
Capacity
15 m3 Sludge oil with 20% NOS per hour
Discharge head
3 kg / cm3
CONSTRUCTION MATERIAL Construction:
All decanter parts in contact with oil or sludge shall be in s.s. AISI 306 and scroll conveyor with tips protected with tungsten carbide tiles. The works for the Mechnical Contractor shall also include the following : a. b. c. d. e. f. g. h.
Mounting and Installation of the decanter equipment Flow meter and regulated with an isolating valve. A 75mm solenoid valve to shut off the feed when power is cut Connections of a 50mm socket for hot water feed. Steel structure with platform, handrailings, stairways and ladder. A 3 ton chain block mounted on a overhead I-beam for maintenance Suitable discharge chutes for solid waste to conveyor. Drawing and detail specification of mounting platform & structure
Power
45kw 415V 3phase 50 HZ TEFC IP55 Class F Vendor to advise details of power requirements.
Requirements
Contractor to co-ordinate with equipment supplier for full details
Page 1 of 1
DECANTER WASTE CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
CONVEYOR ( DECANTER SOLID )
DELIVERY
PREPARED
NW
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No.
G 9.
QUANTITY / UNITS
GENERAL Scipe
1
Scope of works include the Design, Fabrication, delivery, installation, testing, commissioning and guarantee
Function:
To convey decantered solid waste material to hopper for field disposal.
SPECIFICATIONS Qunatity Capacity Type: Size: General Arrangement: Construction Details:
One (1) unit Screw Conveyor for decanter solid waste as follows: 6000 kg solid waste per hour ( 90mt FFB per hour ) Full flight screw 300 mm dia. As per drawing As per drawing
Construction Material: Casing: Wear plate:
Screw Shaft: Hanger bearing: Conveyor Speed: Drive System:
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Stainless steel 304 of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Motor directly coupled to speed reducer by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 56 640 >
rpm rpm Nm (min) 1.5
Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
3.75 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Crompton Parkinson, Brush, ABB Brooks, Elektrim SEW, Renold, HANSEN, EGP ElectoPower Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearings to be fitted at drive end of the conveyor 4. Roller thrust bearing shall be fitted at discharge end
Page 1 of 1
DECANTER LIGHT PHASE TRANSFER PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
LIGHT PHASE TANK & PUMP DELIVERY
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No.
G 10.
QUANTITY / UNITS
GENERAL Scope
1
Scope of work include the Design, Fabrication, delivery, installation, testing, commissioning and guarantee.
Function
To receive the underflow from the decanter
SPECTIFICATION Quantity Tank Volume Material Construction
One ( 1 ) units Decanter Light Phase Tank & Transfer Pump 200 litres Stainless Steel As per drawing
Pump Type Connection
Centrifugal, End-suction Raised face flange toBS 4504 PN 10
OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Deleivery Head Speed NPSH available
15 M3 per hour. Sludge Oil - Light phase o 99 C 0.9 Ns/m2 0.0798 20 m liquid 1450 RPM (Max) 3 m liquid
CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling DriveSystem:
Cast Iron GS-C25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling
Motor:Power: Type: APPROVED MAKES Pump: Motor: Coupling: Bearing:
approx. 3.75kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent. KSB, SIHI, Robuschi, Warman Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, FAG, SKF
OTHER REQUIREMENTS:1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 1
DECANTER HEAVY PHASE TRANSFER PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
DECANTER HP TRANSFER PUMP DELIVERY
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No.
G 11.
QUANTITY / UNITS
GENERAL Scope
Scope of work include the Design, Fabrication, delivery installation, testing, commissioning and guarantee.
Function
To receive the heavy phase liquid from the decanter
SPECTIFICATION Quantity Type Connection
Two ( 2 ) units Decanter Heavy Phase Transfer Pump Centrifugal, End-suction Raised face flange toBS 4504 PN 10
OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Deleivery Head Speed NPSH available
15 Sludge Oil 90 0.9 0.0798 20 1450 3
CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling DriveSystem:
Cast Iron GS-C25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling
M3 per hour. o
C
Ns/m2 m liquid RPM (Max) m liquid
Motor:Power: Type: APPROVED MAKES Pump: Motor: Coupling: Bearing:
approx. 3.75kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Robuschi, Warman Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, FAG, SKF
OTHER REQUIREMENTS:1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 1
2
SLUDGE SETTLING TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
SLUDGE SETTLING TANK DELIVERY
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
G 12. 1
GENERAL Scope
Scope of works include the Design, fabrication, delivery installation, testing, commissioning and guarantee.
Function:
To receive sludge from various tank for recovery of Oil
SPECIFICATIONS Quantity Capacity: Basic Dimensions: Construction Details:-
One ( 1 ) unit Sludge / Oil recovery settling Tank as follows : 3 m 20 As per drawing As per drawing
Construction Material:Tank body: Steam Coil: Open channel:
Mild steel API 5L Gr B seamless Sch 40 Mild steel
The following nozzles to be provided:-
Users drain pump inlet steam inlet
Size (mm) 80 80 50
Qty
Flange PN 10 PN 10 PN 16
Protrusion (mm) Material 150 API 5L Gr B seamless Sch 40 150 API 5L Gr B seamless Sch 40 150 API 5L Gr B seamless Sch 40
Flanges:
Raised face toBS 4504
Requirement
Contractor to provide full details for approval by consultant.
Page 1 of 1
SLUDGE SETTLING TANK PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
SETTLING TANK PUMP
DELIVERY
NW
REVISION No. LOCATION
CLARIFICATION STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, fabrication, delivery installation, testing, commissioning and guarantee
Function
To pump the recovered oil from the Sludge settling tank
SPECIFICATIONS Quantity Type Connection
Two ( 2 ) units Recovery Oil Pump as follows: Centrifugal, End-suction BS 4504 PN 10
OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Deleivery Head Speed NPSH available
15 Crude Oil 90 0.86 0.1425 20 1450 3
mt/hr o
C
Ns/m2 m liquid RPM (Max) m liquid
CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling DriveSystem: Level Switch:
Cast Iron GS-C25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling Mercury type with SS float and rod
Motor:Power: Type:
2.2 kw ( Vendor to advice ) TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent
Pump: Motor: Coupling: Bearing: Mechanical seal: Level switch:
Robuschi, Warman or equivalent Crompton Parkinson, Brush Fenner (Fenaflex), Renold SKF, FAG, NTN Crane, Burgman Mobrey, BESTA
OTHER REQUIREMENTS:1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 2
G 13. 2
OIL HEATER TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
OIL HEATER TANK
DELIVERY
NW
REVISION No. LOCATION
CLARIFICATION STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
G 14. 1
GENERAL Scope
Scope of works include the Design, Fabrication, delivery installation, testing, commissioning and gurantee.
Function:
To heat the Clean CPO before Vacuum drying process.
SPECIFICATIONS Quantity Capacity: Basic Dimensions:
One ( 1 ) unit Oil heater Tank as follows: 3 1.5 m 1 m (W) x 1 m (L) x 1.5 m (H)
Construction Material:Contruction Tank body: Steam Coil: Level switch
Stainless steel 4mm thick sheet ( AISI 304 ) API 5L Gr.B Seamless Sch 40 Mercury type with ss float and rod.
The following nozzles to be provided:Users drain steam inlet cond.outlet pump inlet Flanges:
Size (mm) 50 50 25 50
Flange PN 10 PN 16 PN 16 PN 10
Protrusion (mm) 150 150 150 150
Raised face to BS 4504
Page 1 of 1
Material API 5L Gr.B Seamless Sch 40 API 5L Gr.B Seamless Sch 40 API 5L Gr.B Seamless Sch 40 API 5L Gr.B Seamless Sch 40
OIL PURIFIER
SPECIFICATION SHEETS PROJECT NAME
DATE:
10-Oct-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
OIL PURIFIER
DELIVERY
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the unloading at site, safe keeping installation, assist in testing and commissioning.
Function:
Clarification of the crude oil by removing dirt from oil.
SPECIFICATIONS Quantity
Two ( 2 ) unit Oil Purifiers as follows :
Unit capacity
:
6,000 liters per hour of crude palm oil
System for separation
High speed centrifuge with solids ejecting disc stack type
Discharge system
Sliding bowl bottom automated to discharge at regular intervals by a discharge programme. The intervals for discharge shall be easily variable by setting the timing device.
Material of construction
All parts in contact with oil shall be in stainless steel.
Scope of supply
Unit shall be completed with the following:Flanged motor Built-on feed pump Set of flexible connections Set of standard tools Set of standard spares Flow indicator Thermometer Strainer Automatic discharge system Installation instruction, service and operation manuals
Test on completion :
Samples shall be taken for the inlet feed and outlet waste water and analysed for oil content. The results shall be statistically analysed by taking the mean average and standard deviation.
Performance
Dirt content of purified oil not more than 0.01%
Motor
NW
:
Approx. 7.5kw 4 pole TEFC, IP55 Class F 415V, 3-Ph , 50Hz
OTHER REQUIREMENTS : 1. Vendor to provide technical details, catalogues, performance curve etc ……..
Page 1 of 1
G 15. 2
OIL HEATER PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
CPO TRANSFER PUMP
DELIVERY
NW
REVISION No. LOCATION
CLARIFICATION STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of work include the Design, Fabrication, delivery, installation, testing, commissioning and guarantee.
Function
To heat the Oil before Vacuum drying process
SPECIFICATION Quantity
Two( 2 ) unit CPO Transfer Pump as follows :
Type Connection
Centrifugal, End-suction Raised face flange toBS 4504 PN 10
OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Deleivery Head Speed NPSH available
15 Sludge Oil 90 0.9 0.0798 20 1450 3
CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling DriveSystem:
Cast Iron GS-C25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling
M3 per hour. o
C
Ns/m2 m liquid RPM (Max) m liquid
Motor:Power: Type: APPROVED MAKES Pump: Motor: Coupling: Bearing:
approx. 3.75kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Robuschi, Warman Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, FAG, SKF
OTHER REQUIREMENTS:1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 1
G 16. 2
VACUUM OIL DRYER
SPECIFICATION SHEETS PROJECT NAME
DATE:
10-Oct-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
VACUUM OIL DRYER DELIVERY
REVISION No. LOCATION
DRAWING NO.
CLARIFICATION STATION
ITEM No.
G 19.
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the unloading at site, safe keeping installation, assist in testing and commissioning.
Function:
Drying of Purified CPO by removing the moisture
SPECIFICATIONS Quantity
One ( 1 ) Vacuum Oil Dryer as follows :
Capacity
15 metric ton per hour of Crude Palm Oil
CONSTRUCTION MATERIAL Construction
Constructed from mild steel and conforming to the latest standards for pressure vessels standards for and Factories & Machinery Regulations. Vacuum provided by means of mechnical pump.
Vacuum Pump
Motor Scopeof supply
Type: Multi-stage centrifugal, horizontal Contruction: cast iron casing and impeller Sealing: mechanical seal Capacity: As per vaccum dryer Head: shall be able resistance of 100 mm pipe, 300m long, 4 elbows, 11kw 415V/3Ph/50Hz, S.C TEFC, Class F Ins., IP 55 Vacuum dryer vessel with spray nozzle assembly, sight glasses, vacuum pressure gauge, float type liquid level control valve, illumination of the intervals of the dryer Feed tank with stainless steel float. Multi-stage Vacuum Pump Transfer oil pump c\w motor, coupling and base plate. Certification from the Factories and Machinery Department.
Performance
Moisture content in dried oil does not exceed 0.09% at 90oC.
Tests on completion
Samples shall be taken at hourly interval for inlet and outlet oil and analysed for moisture content. The results shall be statistically analysed by taking the mean average and standard deviation
Page 1 of 1
HOT WATER TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
10-Oct-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
HOT WATER TANK
DELIVERY
NW
REVISION No. LOCATION
CLARIFICATION STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
G 20 1
GENERAL Scope
Scope of works include the Design, fabrication, delivery installation, testing, commissioning and guarantee
Function:
To provide hot water for dilution purposes
SPECIFICATIONS Quantity
One ( 1 ) unit Hot Water Tank as follows :
Capacity: Basic Dimensions: Construction Details:-
15 As per drawing As per drawing
Construction Material:Tank: Steam Coil: Insulation:
Mild steel Carbon steel seamless Sch 40 50mm thk Rockwool c/w 0.7mm thk aluminium cladding
m3
The following nozzles to be provided:Users
Size
Protr'n
Qty
Flange
1 1 1 1
PN 10 PN 10 PN 10 PN 10
Material
mm Water inlet Water outlet Overflow Drain Temp.gauge Temp.controller Flanges:
100 150 100 150 80 150 80 150 3/4" BSP with copper pocket 3/4" BSP with copper pocket Raised face to BS 4504
Page 1 of 2
GI Class C to BS 1387 GI Class C to BS 1387 GI Class C to BS 1387 GI Class C to BS 1387
CLARIFICATION STRUCTURE
SPECIFICATION SHEETS PROJECT NAME
DATE: 10-Oct-99 MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
CLARIFICATION STRUCTURE DELIVERY DRAWING NO.
REVISION No. LOCATION CLARIFICATION STATION
ITEM No. QUANTITY / UNITS
G 21 1
GENERAL Scope
Scope of works include the Design, fabrication, delivery installation, testing, commissioning and guarantee
Function:
To support equipment, tanks and vessels
SPECIFICATIONS Quantity
General Arrangment: Construction Details: Construction Material: Structures: Plaform Handrail: Structure bolts & nuts: Chain block beam
One ( 1 ) unit Clarification Steel structure with Chain block, and roller for maintenance of centrifugal equipment, stairways platform, walkways, handrails and ladder. As per drawing As per drawing
Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe High tensile steel Mild steel I beam to suit
OTHER REQUIREMENTS 1. Handrail shall be 40 mm black pipe 900mm high with intermediete poles at 2000 c/c 2. 100mm high kick plate to be provided around the platform 3. A 3 ton Chain block c/w I-beam shall be provided for maintenance of Separators and Purifier
Page 1 of 1
SLUDGE PIT PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE: 10-Oct-99 MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
SLUDGE PIT PUMP DELIVERY
REVISION No. LOCATION CLARIFICATION STATION
DRAWING NO.
ITEM No.
G 22
QUANTITY / UNITS
GENERAL Scope
Scope of works include the purchase, delivery, installation testing, commissioning and guarantee.
Function:
To pump Oil from Sludge pit to the Sludge recovery tank
SPECIFICATIONS Quantity Type Connection
Two ( 2 ) units Sludge pit pump as follows : Centrifugal, self-priming, Vertical mount Raised face flange to BS 4504
OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Deleivery Head Speed NPSH available
30 Crude Oil 100 0.9 0.0798 200 1500 3
CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling DriveSystem:
Cast Iron GG-25 S.S AISI 304 S.S AISI 304 Mechanical seal S.S AISI 304 Flexible Motor directly coupled with flexible coupling
MT/hr o
C
Ns/m2 Kpa RPM (Max) m liquid
Motor:Power: Type: APPROVED MAKES Pump: Motor: Coupling: Bearing:
approx. 3,75 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Robuschi, Warman, CK Pump Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, SKF, FAG
OTHER REQUIREMENTS 1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 1
2
SLUDGE RECOVERY TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
10-Oct-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
SLUDGE OIL RECOVERY TANK DELIVERY
REVISION No. LOCATION
CLARIFICATION STATION
DRAWING NO.
ITEM No.
G 23.
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the Design, fabrication, delivery installation, testing, commissioning and guarantee
Function:
To recover oil from clarification and other process waste water
SPECIFICATIONS Quantity
One ( 1 ) unit Sludge Oil Recovery Tank as follows : A conical bottom and cylindrical top section supported by steel sections, elevated from ground level. An adjustable skimmer is to be provided for skimming oil at the top layer. Overflow pipe for sludge underflow to be provided.
Capacity: Basic Dimensions: Construction Details:
150 As per drawings As per drawings
m3
Construction Material:Tank: Skimer Funnel: Skimer Handle: Skimer Pipe: Overflow Pipe: Ladder & Catwalk: Heating coils: Support:
Mild steel Mild steel Mild steel S.S 304 Sch 40 Pipe (inside tank only) API 5L Gr.B Sch 40 Mild steel S.S 304 Sch 10S Pipe Mild steel
Nozzles:Users skimmed oil drain overflow steam in steam out steam in steam out hot water in Flanges:
Size (mm)
100 80 150 50 50 25 25 25
Qty 2 2 2 1 1 1 1 1 Raised face to BS 4504
Page 1 of 1
Flange
Protrusion
PN 10 PN 10 PN 10 PN 16 PN 16 PN 16 PN 16 PN 10
(mm) 150 150 150 150 150 150 150 150
Material API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40 API 5L Gr.B Sch 40
CAKE BREAKER CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
CAKE BREAKER CONVEYOR DELIVERY
REVISION No. LOCATION DEPARICARPER STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manufacture, delivery & installation testing, commissioning, handing over and guarantee
Function:
To break up pressed cake from SCREW PRESSES and convey to the DEPRICARPING COLUMN
SPECIFICATIONS Quantity
One ( 1 ) unit Cake Breaker Conveyor complete with supports and inspection walkway with handrails and ladders.
Type:
Paddle c/w short section of auger conveyor at the end of the conveyor to act as airlock 45 MT FFB per hour. 700 mm
Capacity: Diameter: Construction Material: Shaft:
Paddle: Casing: Top cover: Hanger Bearing:
SANVIK low alloy steel pipe, supported by thrust roller bearing at lower end and hanger bearing at 2.5m c/c along the conveying section Mild steel paddle with H.T.S rod or equivalent Mild steel minimum thickness 6mm or equivalent Steel mesh for the entire conveyor Railko bush c/w cast iron housing, grease nipple and cup protuding out of the conveyor casing
Thrust Bearing:
To be fitted at the drive-end
Shaft to shaft jointer:
Solid mild steel
Screw (auger):
Mild steel screw 6mm minimum thickness welded to mild steel solid shaft
Connecting piece to Depricarper Column: Inclination: Conveyor Speed: Drive: Variable Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:
Canvas c/w mild steel holder rings o 6 69 rpm Geared motor directly coupled by flexible coupling 1450 69 1038
rpm rpm Nm (min)
<
1.5
Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
7.5 KW Vendor to advise. TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, SEW, EPG ElectroPower Fenner (Fenaflex), Renold SKF, FAG, NTN
OTHER REQUIREMENTS:1. Wear plate thickness 6mm minimum to be provided 2. Side plate of minimum 300mm high to be provided for the entire length of the conveyor except at the full flight screw section 3. Conveyor supporting structures c/w platform , walkways, stairways and handrails are to be provided 4. Detail design by the contractor shall be first approved by the consultant before fabrication.
Page 1 of 1
H 1. 1
DEPRICARPING SYSTEM
SPECIFICATION SHEETS PROJECT NAME PROJECT CODE
DATE: OIL PALM MILL
MACHINE NAME DEPARICARPER WINNOWING SYSTEM
PREPARED
DELIVERY
13-May-00 NW
REVISION No. LOCATION DEPARICARPER STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee.
Function:
To separate the nut and fibre using air separation method
SPECIFICATIONS Quantity
One ( 1 ) Depericarping system complete with : Separation column, support, ducting and adjustable damper, fibre cyclone, airlock, fan
Separation capacity:
45 MT FFB per hour.
Depricarping Column General Arrangement: Construction Details: Construction Material:
As per drawing As per drawing Mild steel
Ducting General Arrangement: Construction Details: Construction Material: Basic Dimensions:
As per drawing As per drawing Mild steel Diameter: Thickness
600 6
mm mm
Fibre Cyclone General Arrangement: Construction Details: Construction Material:
As per drawing As per drawing Mild steel
Wear liner:
4.5mm thk to be provided at the inlet volute of the cyclone
Page 1 of 2
H 2. 1
DEPRICARPING SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
PROJECT CODE
OIL PALM MILL
MACHINE NAME DEPARICARPER WINNOWING SYSTEM
PREPARED
DELIVERY
13-May-00 NW
REVISION No. LOCATION DEPARICARPER STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
H 2. 1
Sheet 2. Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:
Rotary vane 1 As per drawing As per drawing Mild steel 600 mm 30 rpm Motor directly coupled to speed reducer by flexible coupling
Motor:Power: Type:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Fan Type: Flowrate: Static Pressure:
Cetrifugal 42,000 150
Construction Material: Casing: Impeller: Shaft: Pulley:
Mild steel Carbon steel (self-cleaning type) Carbon steel Cast iron
Speed: Drive System:
m3/hr mm wg
Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by fluid coupling then to belt and pulley To be provided Floor Common baseframe to be provided
Belt guard: Type of Mounting: Baseframe: Motor:Power: Type:
approx. 36 kw - Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent
Motor: Fan: Coupling: Bearing:
Crompton Parkinson, Brush Novenco, James Hawden, Chicago Transfluid, Renold, Fenner NTN, SKF, FAG
OTHER REQUIREMENT Contractor to provide detail design for approval by consultant.
Page 2 of 2
DEPERICARPER CONTROL SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
DAMPER CONTROL SYSTEM
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
DEPARICARPER STATION
ITEM No.
H 3.
QUANTITY / UNITS
GENERAL Scope
Function
SPECIFICATIONS Quantity
1
Scope of works include the unloadfing, safe keeping, assisting in the testing installation and commissioning. System to monitor and control of kernel or Nuts losses in the fibre cyclone by controlling the air flow rate in the Depericarper Column.
One (1) Depericarper Damper Control System as follows:-
The control shall be based on the following process variables : a. Number of Presses in operation b. Predetermined separation air velocity in the Depericarper column.
The supply shall consist of : 1. PLC unit system. The PLC shall be link to the Central control station via LAN networking 2. Damper pneumatic actuator 3. Air flow meter. The air flow meter shall measure the air flow rate and compare it with the set value. It will sent a signal to the PLC which in turn automatically adjust the damper accordingly to the set value of the air flow rate. 4. Installation & Operating instructions, service manual and buffer tank drawing. 5. Testing, commissioning and training of operator.
Manuals
Equipment drawings, installation and operating instruction, spare parts list and specification shall be provide upon commissioning.
General
Contractor shall provide design details of the equipment for the consultant's approval before fabrication.
Page 1 of 1
NUT POLISHING DRUM
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
NUT POLISHING DRUM DELIVERY
REVISION No. LOCATION
DEPARICARPER STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the design, fabrication, delivery installation, testing and guarantee.
Function:
To polish nuts from DEPERICARPER COLUMN
SPECIFICATIONS Quantity
One ( 1 ) unit Nut Polishing Drum complete as follows :
Type: Capacity: General Arrangement: Construction Details:
Rotating Drum 9,000 kg/hr of nuts As per drawing As per drawing
Construction Material: Shaft: Hub: Drum Casing: Frame & Structure: Basic Dimensions: Drum Speed: Drive System: Gear box: Input speed: Output speed: Output torque: Design Service Factor:
EN 16 Steel Carbon steel Carbon steel Carbon steel 1,200 mm dia. 4,500 mm long 25 rpm Geared motor coupled to drum shaft by spocket and chain drive 1450 25 2101 <
rpm rpm Nm (min) 1.5 (min)
Motor:Power: Type:
5.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Bearing:
Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, SEW, EPG ElectroPower Fenner (Fenaflex), Renold SKF, FAG, NTN
Page 1 of 1
H 4. 1
INCLINE NUT CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
INCLINED NUT CONVEYOR
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
DEPARICARPER STATION
ITEM No. QUANTITY / UNITS
H5 1
GENERAL Scope
Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee.
Function:
To transfer nuts from NUT POLISHING DRUM to destoning system
SPECIFICATIONS Quantity
One ( 1 ) unit Inclined Nut Conveyor as follows :
Type:
Full flight screw with round casing only at the end of the conveyor
Capacity General Arrangement: Construction Details:
7,500 As per drawing As per drawing
Construction Material: Diameter: Conveyor Speed: Drive System:
Mild steel 300 mm 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
1450 56 375 <
kg nuts per hour.
rpm rpm Nm (min) 1.5 (min)
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, SEW, Renold, Benzler SALA Fenner (Fenaflex), Renold NTN, SKF, FAG
OTHER REQUIREMENTS : 1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing 3. Flange bearing to be fitted at drive end of the conveyor. 3. Roller thrust bearing to be fitted at discharge end of the conveyor 4. Saddle supports to be provided
Page 1 of 1
DESTONING SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
DESTONING SYSTEM
DELIVERY
PREPARED
NW
REVISION No. LOCATION
DEPARICARPER STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
H 6. 1
GENERAL Scope
Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee
Function:
To separate the nut and stone using air separation method
SPECIFICATIONS Quantity
One ( 1 ) Destoning System consisting of : Expansion column, support, ducting, nut discharge chute, cyclone, airlock and fan
Capacity: Separation & Expansion Column General Arrangement: Construction Details: Construction Material:
9,000 kg / hr of nut
As per drawing As per drawing Mild steel
Ducting General Arrangement: Construction Details: Construction Material: Basic dimensions: Diameter: Thickness:
450 6
Cyclone General Arrangement: Construction Details: Construction Material: Basic dimensions:
As per drawing As per drawing Mild steel As per drawing
Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Speed: Drive System: Motor:Power: Type:
As per drawing As per drawing Mild steel mm mm
Rotary vane 1 As per drawing As per drawing Mild steel 300 mm 30 rpm Motor directly coupled to speed reducer by spocket & chain 2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Page 1 of 2
DESTONING SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
DESTONING SYSTEM
DELIVERY
NW
REVISION No. LOCATION
DEPARICARPER STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
H 6. 1
Sheet 2. Fan Type:
Centrifugal 20,404 m3/hr 250 mm wg
Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System:
Mild steel Carbon steel Carbon steel Cast steel Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by fluid coupling then by belt and pulley To be provided
Belt guard:
Type of Mounting: Baseframe: Motor:-
Floor Common baseframe to be provided Power: Type:
Approx. 22 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Supporting Structures Construction details: Material:
as per drawing mild steel
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer:
Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, SEW, EPG Electropower
Fluid Coupling: Bearing: Fan: Transmission Belt:
Fenner (Fenaflex), Renold, Transfluid NTN, SKF, FAG Novenco, James Hawden, Chicago Fenner
Page 2 of 2
DESTONER DAMPER CONTROL SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
DESTONER DAMPER CONTROL SYSTEM
DELIVERY
PREPARED
NW
REVISION No. LOCATION
DRAWING NO.
DEPARICARPER STATION
ITEM No. QUANTITY / UNITS
H 7. 1
GENERAL Scope
Scope of works include the unloading, safe keeping, assisting in the testing, installation and commissioning
Function
System to monitor and removal of stones from the transported Nuts by controlling the air flow rate in the Destoner Column.
SPECIFICATIONS Quantity
The control shall be based on the following process variables : a. Number of Presses in operation b. Predetermined separation air velocity in the Destoner column.
The supply shall consist of : 1. PLC unit system. The PLC shall be linked to the Central control station via LAN networking. 2. Damper pneumatic actuator 3. Air flow meter. The air flow meter shall measure the air flow rate and compare it with the set value. It will sent a signal to the PLC which in turn automatically adjust the damper accordingly to the set value of the air flow rate. 4. Installation & Operating instructions, service manual and buffer tank drawing. 5. Testing, commissioning and training of operator.
Manuals
Equipment drawings, installation and operating instruction, spare parts list and specification shall be provide upon commissioning.
General
Contractor shall provide design details of the equipment for the consultant's approval before fabrication.
Page 1 of 1
NUT ELEVATOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NUT ELEVATOR
DELIVERY
NW
REVISION No. LOCATION
DEPARICARPER STATION
DRAWING NO.
ITEM No.
H 8.
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the manfacture, erection & installation Testing, commissioning, handing over and guarantee
Function:
To convey Nuts onto the NUT BIN
SPECIFICATIONS Quantity
One ( 1 ) unit Nut Elevator as follows :
Type: Capacity: General Arrangement: Construction Details:
Conveyor chain c/w buckets 9,000 kg Nuts per hour As per drawing As per drawing
Construction Material: Casing: Sprocket Bucket: Chain rail: Chain: Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:
Mild steel with 6mm minimum thickness 12T, 100mm pitch, grey iron Mild steel Mild steel angle Steel c/w hardened steel flanged rollers, 100 mm pitch, 6800 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 30 rpm 1 1450 30 955 >
rpm rpm Nm (min) 1.5
Motor:Power: Type:
3 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold , EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS 1. Miantenance door shall be provided at the bottom booth 2. Take-up bearing c/w tensioning devices to be provided at the bottom sprockets & shaft 3. Top booth cover to be bolted construction for ease of maintenance 4. Outlet chute to be provided Page 1 of 2
Nut Conveyor No.1
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NUT CONVEYOR No.1
DELIVERY
NW
REVISION No. LOCATION
DEPARICARPER STATION
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee
Function:
To convey Nuts from the Nut Elevator to the Nut Silo.
SPECIFICATIONS Quantity Capacity: Type: Size: General Arrangement: Construction Details:
One ( 1 ) unit Nut Conveyor No. 1 as follows : 9,000 kg / hr of cracked micture Full flight screw 300 mm dia. As per drawing As per drawing
Construction Material: Casing: Wear plate:
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor
Screw Shaft: Shaft joint: Hanger bearing:
Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup
Conveyor Speed: Drive System:
56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 56 375 >
rpm rpm Nm (min) 1.5
Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent. Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 1 of 1
H 9. 1
PALM OIL STORAGE TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
CPO STORAGE TANK DELIVERY
REVISION No. LOCATION
CPO STORAGE
DRAWING NO.
ITEM No. QUANTITY / UNITS
I 1. 2
GENERAL Scope
Scope of works include the Design, fabrication, delivery, Installation testing, commissioning and guarantee.
Function:
To store and heat palm oil prior to despatch
SPECIFICATIONS Quantity Capacity: Construction Details:-
Two ( 2 ) units Palm Oil Storage Tanks as follows : 2000 tons. As per drawing and in accordance with BS 2654
Construction Material:Tank Shell Tank Bottom Tank Roof Steam Coil: Roof trusses: Handrailing:
Mild steel Mild steel Mild steel 50mm dia. seamless API 5L Gr B Sch 40 Mild steel Black pipe Class B
Nozzles to be provided:Users Oil inlet Oil outlet Drain Vent Steam inlet Cond.outlet Oil recycle Sounding temp. gauge Flanges:
Size (mm)
Qty
100 150 100 150 50 50 80 150 1/2 " BSP
1 1 1 1 2 2 1 1 1
Protrusion (mm) 150 150 150 150 150 150 150 600 80
Flange PN 10 PN 10 PN 10 PN 10 PN 16 PN 16
Material Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40 Seamless API 5L Gr B Sch 40
To BS 4504
Other Accessories:Spiral staircase c/w handrailing Mechanical level indicator c/w stainless steel float, steel guide wire for float Bottom manhole of 600mm diameter Top manhole of 600mm diameter Internal monkey ladder Interconnecting platform Painting:Internal External
crude palm oil 2 coats of MIO zinc chromate, followed by 2 coats of gloss finish
Testing:
Water testing to full level for a duration of at least 2 weeks. Water to be supplied by contractor
Calibration:
In accordance with local authority's requirements
Page 1 of 1
CPO DESPATCH PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
CPO DISPATCH PUMP DELIVERY
REVISION No. LOCATION CPO STORAGE
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the purchase, delivery, installation testing, commissioning and gurantee
Function
To convey Crude Palm Oil from the Storage Tanks and loading into Oil Tanker.
SPECIFICATIONS Quantity Type Connection
Two ( 2 ) units Palm Oil Despatch Pumps as follows: Gear or screw positive displacement BS 4504 PN 10 flange
OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Deleivery Head Speed NPSH available
90 Crude Palm Oil 60 0.9 0.0798 120 500 6
CONSTRUCTION Casing Gear or screw Shaft Sealing Coupling Drive:
MT crude palm oil per hour. o
C
Ns/m2 kPa RPM (Max) m liquid
Cast Iron GG25 Cast Iron GG25 Carbon steel Mechanical seal Flexible Motor directly coupled with flexible coupling to gearbox and pump
Motor:Power: Type: APPROVED MAKES Pump: Motor: Gear reducer: Coupling: Bearing:
approx. 7.5kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415 V / 3-Ph / 50 Hz Specified or Equivalent Tuthill, Viking, IMO, Leistritz Crompton, Brook SUMITOMO, Renold, HANSEN Fenner (Fenaflex), Renold SKF, FAG, NTN
OTHER REQUIREMENTS 1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 1
I 2. 2
NUT CONVEYOR No.2
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NUT CONVEYOR No.2
DELIVERY
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee
Function:
To convey nuts from Destoner to Nut Buffer Silo
SPECIFICATIONS Quantity
One ( 1 ) unit Nut Conveyor No.2 as follows :
Capacity: Material Type: Size: General Arrangement: Construction Details:
9,000 kg per hour Wet Nuts Full flight screw 300 mm dia. As per drawing As per drawing
Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 56 375 >
rpm rpm Nm (min) 1.5
Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
2.2 KW Vendor to advise TEFC 4-pole, S.C, IP 55, Class F Ins., 415V / 3-Ph / 50 Hz Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectoPower Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 1 of 1
J 1. 1
NUT BUFFER HOPPER
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NUT BUFFER HOPPER
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No.
J 2.
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To receive nuts and act as buffer storage before feeding into the nut ripple mills or crackers.
SPECIFICATIONS Quantity
One ( 1 ) unit Nut Buffer Hooper as follows :
Capacity: Basic Dimensions: Construction Details:Construction Material:-
12 m3 (comprising of 3 hoppers for nut discharge) As per drawing As per drawing Mild steel
Requirements
a. Steel supporting structure of mild steel angles and channels of size detail in the drawings. b. Discharge apperture fitted with flanged stop sluce & chute. c. A supporting frame shall be provide for mounting of a Vibro-feeder and magnetic metal trap to detail design.
Page 1 of 1
NUT FEEDER
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NUT FEEDER
DELIVERY
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No.
J 3.
QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To feed nuts by a vibrating tray from nut buffer hopper into the ripple mills.
SPECIFICATIONS Quantity
Three ( 3 ) units Nut Feeder with Magnetic Trap as follows :
Type: Material to convey Capacity Each: Drive: Motor:-
Magnetic vibratory feeder Palm Nuts 3,000 kg per hour. Vibratory motor Power: Type:
approx. 0.33 Vendor to advice Electro-magnetic, 415V or 220V @ 50Hz
Magnetic Trap
One Magnetic Plate of 200 x 200 mm x 20 mm thick
MATERIAL DESCRIPTION Material Bulk Density: Average Nut Diameter: Condition Of Material:
Palm Nuts 700 25 loose
Temperature:
APPROVED MAKES
40
kg/m3 mm o
Eriez or equivalent
Page 1 of 1
C
3
RIPPLE MILL
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
RIPPLE MILL
DELIVERY
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
J 4. 3
GENERAL Scope
Scope of works include the unloading at site, safe keeping installation, assist in testing and commissioning.
Function:
Cracking of Palm Nuts
SPECIFICATIONS Three ( 3 ) Ripple Mill as follows : Unit Capacity
6,000 kg per hour
Material
Palm Nuts
CONSTRUCTION MATERIAL Construction
a.
Each ripple mill shall be driven by a motor with adjustable variable speed vee rope drive.
b.
The ripple plates will be hard faced, heavy duty, and reversible to prolong the operational life between rebuilding of the cracking faces.
c.
Solid alloy steel rotating ripple bars will be fitted to the wear resistant rotor discs.
d.
The motor, vee rope drive and guard will be mounted on a rigid fabricated steel baseplate designed to allow the ripple mill to discharge into the cracked mixture screw conveyor mounted below.
Performance Guarantee:
Each ripple mill shall have cracking efficiency of not less than 97%.
Motor
approx. 5.25kw 4-pole, TEFC, Class F, IP 55
Power Supply
415V 3 phase 50Hz
Page 1 of 2
C.M CONVEYOR NO.1
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
CM CONVEYOR No.1
DELIVERY
PREPARED
NW
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No.
J 5.
QUANTITY / UNITS
GENERAL Scope
Function: SPECIFICATIONS Quantity Material to convey Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee To convey cracked micture from RIPPLE MILLS to CRACKED MIXTURE ELEVATOR One ( 1 ) unit Cracked Mixture Conveyor as follows: Palm Nut Cracked Mixture 9,000 kg per hour Full flight screw 300 mm dia. As per drawing As per drawing Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56
rpm
Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
1450 56 375 >
rpm rpm Nm (min) 1.5
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 1 of 1
1
C.M CONVEYOR NO.2
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
CM CONVEYOR No.2 DELIVERY
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To convey cracked micture from Winnowing System to C.M Conveyor No.3
SPECIFICATIONS Quantity
One ( 1 ) Cracked Mixture Conveyor No.2
Material to be conveyed Capacity: Type: Size: General Arrangement:
Palm Nuts cracked mixture 9,000 kg per hour. ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing
Construction Details:
As per drawing
Construction Material: Casing: Wear plate:
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:
56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 56 375 >
rpm rpm Nm (min) 1.5
Motor:Power: Type:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent.
Motor: Gear reducer:
Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower
Coupling: Bearing:
Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated Page 1 of 2
J 6. 1
C.M CONVEYOR NO.2
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
CM CONVEYOR No.2 DELIVERY
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No. QUANTITY / UNITS
3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 2 of 2
J 6. 1
CRACKED MIXTURE ELEVATOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
CM ELEVATOR
DELIVERY
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No.
J 7.
QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee 12 months.
Function:
To convey cracked mixture from CM CONVEYOR to PRIMARY WINNOWING COLUMN
SPECIFICATIONS Quantity Type: Material to Convery Capacity:
One ( 1 ) Cracked Mixture Elevator as follows : Conveyor chain c/w buckets Palm Nut Cracked Mixture 9,000 kg per hour.
General Arrangement:
As per drawing
Construction Details:
As per drawing
Construction Material: Casing: Sprocket
Mild steel with 6mm minimum thickness 12T, 100 mm pitch, grey iron
Bucket: Chain rail: Chain:
Mild steel Mild steel angle Steel c/w hardened steel flanged rollers, 100 mm pitch, 6800 kg breaking load
Drive: Shaft Speed: Transmission Sprocket Ratio:
Geared Motor coupled to elevator shaft by chain & sprocket 30 rpm 1
Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:
1450 30 1194 >
rpm rpm Nm (min) 1.5
Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
3.75 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS 1. Miantenance door shall be provided at the bottom booth 2. Take-up bearing c/w tensioning devices to be provided at the bottom sprockets & shaft 3. Top booth cover to be bolted construction for ease of maintenance Page 1 of 2
1
CRACKED MIXTURE ELEVATOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
CM ELEVATOR
DELIVERY
PREPARED
NW
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No. QUANTITY / UNITS
4. Outlet chute to be provided
Page 2 of 2
J 7. 1
VIBRATING TROUGH
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
VIBRATING TROUGH DELIVERY
REVISION No. LOCATION KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
Separating of un-cracked nuts and feeder to Winnowing column
SPECIFICATIONS Quantity
One ( 1 ) unit Vibrating Trough as follows :
Type: Material to convey Capacity Each: Drive: Motor:-
Magnetic vibratory feeder PK cracked mixture 9,000 kg per hour. Vibratory motor Power: Type:
approx. 0.33 Vendor to advice Electro-magnetic, 415V or 220V @ 50Hz
MATERIAL DESCRIPTION Material Bulk Density: Average Nut Diameter: Condition Of Material: Temperature:
Palm Nuts Cracked mixture 3 700 kg/m 10 mm loose kernel and broken shell o 40 C
APPROVED MAKES
Eriez or equivalent
Page 1 of 1
J 8. 1
PRIMARY WINNOWER SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PRIMARY WINNOWER
DELIVERY
PREPARED
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No.
J 9.
QUANTITY / UNITS
GENERAL Scope
1
Scope of works include the manfacture, erection & installation Testing, commissioning, handing over and guarantee
Function:
To separate the cracked mixture from light particles using air separation method
SPECIFICATIONS Quantity
One ( 1 ) Primary Winnowing System sa follows :
System consist of:
Adjustable damper, expension column, support, ducting, nut discharge chute, cyclone, airlock and fan
Material to process Separation Capacity:
Palm nut cracked mixture 9,000 kq per hour.
Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:
Rotary vane 2 As per drawing As per drawing Mild steel 300 mm 45 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 45 212 >
rpm rpm Nm (min) 1.5 (min)
Power: Type:
1 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Motor:-
Ducting General Arrangement: Construction Details: Construction Material: Basic dimensions: Diamater: Thickness: Cyclone 1 stage General Arrangement: Construction Details: Construction Material: Basic dimensions:
As per drawing As per drawing Mild steel 400 6
mm mm
As per drawing As per drawing Mild steel 1,350 mm dia.
Page 1 of 2
PRIMARY WINNOWER SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PRIMARY WINNOWER
DELIVERY
PREPARED
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No.
J 9.
QUANTITY / UNITS
1
Sheet 2. Airlock for Cyclone Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:
Rotary vane 1 As per drawing As per drawing Mild steel 600 mm 45 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 45 467 >
rpm rpm Nm (min) 1.5 (min)
Power: Type:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Motor:-
Fan Type: Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System: Belt guard: Type of Mounting: Baseframe: Motor:-
Centrifugal 24,000 m3/hr 375 mm wg Mild steel Carbon steel Carbon steel Cast steel Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by belt and pulley To be provided Floor Common baseframe to be provided
Power: Type:
approx. 30 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent.
APPROVED MAKES Motor: Fan: Coupling: Gear reducer: Bearing: Transmission Belt:
Crompton Parkinson, Brush Novenco, James Hawden, Chicago Renold, Fenner SUMITOMO, HANSEN, Renold, EPG ElectroPower. NTN, SKF, FAG Fenner
Page 2 of 2
WINNOWING COLUMN DAMPER CONTROL SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
WINNOWING DAMPER CONTROL
PREPARED
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No.
J 10.
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the unloading, safe keeping, assisting in the testing, installation and commissioning.
Function
System to monitor and control of kernel losses in the cyclone by controlling the air flow rate in the Primary Winnowing Column.
SPECIFICATIONS Quantity
One (1) Primary Winnowing Damper Control System as follows:The control shall be based on the following process variables : a. Number of Presses in operation b. Pre-determined separation air velocity in the Primary Winnowing column.
The supply shall consist of : 1. PLC unit system. The PLC shall be link to the Central control station via LAN networking 2. Damper pneumatic actuator 3. Air flow meter. The air flow meter shall measure the air flow rate and compare it with the set value. It will sent a signal to the PLC which in turn automatically adjust the damper accordingly to the set value of the air flow rate. 4. Installation & Operating instructions, service manual and buffer tank drawing. 5. Testing, commissioning and training of operator.
Manuals
Equipment drawings, installation and operating instruction, spare parts list and specification shall be provide upon commissioning.
General
Contractor shall provide design details of the equipment for the consultant's approval before fabrication.
Page 1 of 1
SECONDARY WINNOWER
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
SECONDARY WINNOWER DELIVERY
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the Design, Fabrication, delivery installation, testing, commissioning and guarantee.
Function:
To separate the cracked mixture from light particles using air separation method
SPECIFICATIONS Quantity System consist of:
One ( 1 ) Secondary Winnowing system as follows : Adjustable damper, expension column, support, ducting, nut discharge chute, cyclone, airlock and fan
Material for Process Separation Capacity:
Palm Nut Cracked Mixture 9,000 kq per hour.
Separation Column General Arrangement: Construction Details: Construction Material: Column size:
As per drawing As per drawing Mild steel 600
Ducting General Arrangement: Construction Details: Construction Material: Basic dimensions: Diamater: Thickness: Cyclone General Arrangement: Construction Details: Construction Material: Cyclone diameter:
mm dia.
As per drawing As per drawing Mild steel 400 6
mm mm
As per drawing As per drawing Mild steel 1,350 mm
Page 1 of 2
J.11 1
SECONDARY WINNOWER
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
SECONDARY WINNOWER DELIVERY
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
J.11 1
Sheet 2. Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:
Rotary vane 1 As per drawing As per drawing Mild steel 300 mm 45 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 45 467 >
rpm rpm Nm (min) 1.5 (min)
Motor:Power: Type: Fan Type: Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System: Belt guard: Type of Mounting: Baseframe: Motor:Power: Type:
APPROVED MAKES Motor: Fan: Coupling: Gear reducer: Bearing: Transmission Belt:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins.,415V/3-Ph/50 Hz
Centrifugal, 18,000 m3/hr 280 mm wg Mild steel Carbon steel Carbon steel Cast steel Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by belt and pulley To be provided Floor Common baseframe to be provided approx. 22kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Crompton Parkinson, Brush Novenco, James Hawden, Chicago Renold, Fenner SUMITOMO, HANSEN, Renold, EPG ElectroPower NTN, SKF, FAG Fenner
Page 2 of 2
SECONDARY WINNOWER DAMPER CONTROL
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
SECONDARY WINNOWER DAMPER CONTROL
PREPARED
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No.
J.12
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the design, manufacture, assembly, delivery testing, installation supervision, commissioning and guarantee.
Function
System to monitor and control of kernel losses in the cyclone by controlling the air flow rate in the Secondary Winnowing Damper Column.
SPECIFICATIONS Quantity
One (1) Secondary Winnowing Damper Control System as follows:The control shall be based on the following process variables : a. Number of Presses in operation b. Predetermined separation air velocity in the Secondary Winnowing column.
The supply shall consist of :
1. PLC unit system. The PLC shall be link to the Central control station via LAN networking 2. Damper pneumatic actuator 3. Air flow meter. The air flow meter shall measure the air flow rate and compare it with the set value. It will sent a signal to the PLC which in turn automatically adjust the damper accordingly to the set value of the air flow rate. 4. Installation & Operating instructions, service manual and buffer tank drawing. 5. Testing, commissioning and training of operator.
Manuals
Equipment drawings, installation and operating instruction, spare parts list and specification shall be provide upon commissioning.
General
Contractor shall provide design details of the equipment for the consultant's approval before fabrication.
Page 1 of 1
C.M CONVEYOR NO.2
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
CM CONVEYOR 3
DELIVERY
PREPARED
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No.
J 13.
QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To convey cracked micture from Winnowing System to C.M Conveyor No.4
SPECIFICATIONS Quantity Material to be conveyed Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:
One ( 1 ) Cracked Mixture Conveyor No.3 Palm Nuts cracked mixture 9,000 kg per hour. ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:-
Power: Type:
1450 56 512 >
rpm rpm Nm (min) 1.5
3 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 1 of 1
1
C.M CONVEYOR NO.2
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
CM CONVEYOR 4
DELIVERY
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To convey cracked micture from Winnowing System to C.M Conveyor No.3
SPECIFICATIONS Quantity Material to be conveyed Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:
One ( 1 ) Cracked Mixture Conveyor No.3 Palm Nuts cracked mixture 9,000 kg per hour. ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 56 512 >
rpm rpm Nm (min) 1.5
Motor:Power: Type:
3 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer:
Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower
Coupling: Bearing:
Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 1 of 1
J 14. 1
HYDROCYCLONE
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
HYDROCYCLONE 3 STAGE
DELIVERY
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee
Function:
To separate kernel and shell from cracked mixture
SPECIFICATIONS Quantity Description:
Two ( 2 ) Hydroclone Kernel Recovery system as follows : The system consists of 1 shell cyclone c/w vortex finder, 2 kernel cyclone c/w vortex finder, 1 shell pump, 2 kernel pumps, dripping drum, water tank, intergral piping.
Type: Capacity: General Arrangement:
2-stage separation system 9,000 kg/hr cracked mixture As per drawing
Shell Pump:
Units Type: Make/model: Capacity: Discharge Head: Construction: Speed: Drive:
Kernel Pump:
Units. Type: Make/model: Capacity: Discharge Head: Construction: Speed: Drive:
Cyclone material:
One ( 1 ) Centrifugal, open impeller, vertical split casing Warman 4/3, Robuschi 95.34 m3/hr 11 m w.g Cast iron impeller, ni-hard casing liner < 1200 rpm TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz c/w to pump via belt and pulley Two ( 2 ) Centrifugal, open impeller, vertical split casing Warman (Aust) 6/4, Robuschi 136.2 m3/hr 11 m w.g Cast iron impeller, ni-hard casing liner < 1200 rpm TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz c/w to pump via belt and pulley mild steel with manganese cone liners
Dripping drum screen:
stainless steel mesh 40
APPROVED MAKES
Motor: Gear reducer: Transmission Belt: Transmission Chain: Bearing:
Crompton Parkinson SUMITOMO, HANSEN, RENOLD, EPG ElectroPower. Fenner (Fenaflex) Renold, Tsubaki NTN,SKF, FAG
Page 1 of 1
J 15. 2
WET SHELL TRANSPORT
SPECIFICATION SHEETS PROJECT NAME
DATE: 13-May-00 MACHINE NAME
PROJECT CODE
OIL PALM MILL
WET SHELL TRANSPORT SYSTEM
DELIVERY
PREPARED
NW
REVISION No. LOCATION KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
J.16 1
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee
Function:
To transport wet shell from Hydrocyclone to SHELL BUNKER
SPECIFICATIONS Quantity System consist of: Transport Capacity:
One (1) Lot Wet Shell Transport system ducting, cyclone, airlock and fan 4,500 kg/hr of wet shell
Ducting General Arrangement: Construction Details: Construction Material: Diameter:
As per drawing As per drawing API 5L Gr B Sch 40 pipe 150 mm
Cyclone General Arrangement: Construction Details: Construction Material: Diameter:
As per drawing As per drawing Mild steel mm
Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:
Rotary vane 1 As per drawing As per drawing Mild steel 300 mm 45 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: 1450 Output speed: 45 Output torque: 467 Design Service Factor: >
rpm rpm Nm (min) 1.5
Motor:Power: Type:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Page 1 of 2
WET SHELL TRANSPORT
SPECIFICATION SHEETS PROJECT NAME
DATE: 13-May-00 MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
WET SHELL TRANSPORT SYSTEM
DELIVERY DRAWING NO.
NW
REVISION No. LOCATION KERNEL RECOVERY PLANT
ITEM No. QUANTITY / UNITS
J.16 1
Sheet 2. Fan Type: Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System: Belt guard: Type of Mounting: Baseframe: Motor:Power: Type: APPROVED MAKES Motor: Fan: Coupling: Gear reducer: Bearing: Transmission Belt:
High Pressure Blower 4,500 m3/hr 750 mm wg Mild steel Carbon steel Carbon steel Cast steel Vendor to advice (not more than 2900 rpm) Motor directly coupled to fan To be provided Floor Common baseframe to be provided Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Crompton Parkinson, Brush Novenco, James Hawden, Chicago Renold, Fenner SUMITOMO, HANSEN, Renold NTN, SKF, FAG Fenner
Page 2 of 2
WET KERNEL TRANSPORT SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE: 10-Oct-99 MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
WET KERNEL TRANSPORT SYSTEM DELIVERY
REVISION No. LOCATION KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To convey Wet Kernel from the recovery station to feed the battery of kernel dryers
SPECIFICATIONS Quantity Material to be conveyed Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:
One ( 1 ) unit Wet Kernel Conveyor as follows : Wet Kernel 4,500 kg per hour ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 56 640 >
rpm rpm Nm (min) 1.5
Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
3.75 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate Page 1 of 2
J. 17 1
SHELL BUNKER STRUCTURE
SPECIFICATION SHEETS PROJECT NAME
DATE: 13-May-00 MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
SHELL BUNKER & STRUCTURE DELIVERY
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee
Function:
To store shell material from the various separation systems and Structure to support the shell bunker, cyclones & fans
SPECIFICATIONS Quantity
General Arrangment:
One ( 1 ) unit Shell Bunker of 4 compartments and Structure as follows : As per drawing
Volumn Construction Details:
Construction Material: Structures: Plaform Handrail: Structure bolts & nuts:
As per drawing
Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe High tensile
OTHER REQUIREMENTS 1. Handrail shall be 900mm high with intermediete poles at 2000 c/c 2. 100mm high kick plate to be provided around the platform 3. Hoist beam shall be installed on building roof trusses as shown in the relevant drawings
Page 1 of 1
J 18. 1
WET KERNEL ELEVATOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
WET SHELL ELEVATOR DELIVERY
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee
Function:
To convey wet kernel from Hydrocyclone to the Kernel Silo
SPECIFICATIONS Quantity Type: Capacity: General Arrangement: Construction Details:
One ( 1 ) Wet Kernel Elevator. Conveyor chain c/w buckets 4,500 kg/hr dry kernel As per drawing As per drawing
Construction Material: Casing: Sprocket Bucket: Chain rail: Chain: Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
Mild steel with 6mm minimum thickness 12T, 101.6 mm pitch, grey iron Mild steel Mild steel angle Steel c/w hardened steel rollers, 101.6 mm pitch, 6800 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 30 rpm 1 1450 30 700 >
rpm rpm Nm (min) 1.5
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS 1. Miantenance door shall be provided at the bottom booth 2. Take-up bearing c/w tensioning devices to be provided at the bottom sprockets & shaft 3. Top booth cover to be bolted construction for ease of maintenance 4. Outlet chute to be provided
Page 1 of 1
J 19. 1
WET KERNEL CONVEYOR NO.2
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
WET KERNEL CONVEYOR 2.
DELIVERY
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL
Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
from Wet Kernel Elevator to kernel silo.
SPECIFICATIONS Quantity Material to be Conveyed Capacity: Type: Size: General Arrangement: Construction Details:
One ( 1 ) unit Wet Kernel Conveyor as follows : Wet Kernels 9,000 kq per hour ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing
Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 56 640 >
rpm rpm Nm (min) 1.5
Motor:Power: Type:
3.75 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 1 of 1
J.20 1
KERNEL SILO
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
KERNEL SILO & FAN
DELIVERY
PREPARED
NW
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To store and dry the kernel to the required moisture level. Hot air is produced by the steam/air heater and blown into the silo by a fan through air ducting system
SPECIFICATIONS Quantity System:
Two ( 2 ) units Kernel Silos with Compartments as follows : Consist of silo, air duct, steam/air heater, fan, shaking grate
Silo Capacity each: Basic Dimensions:
m3 (nett)
70 Width Length Body Height
3,300 mm 3,300 mm 7,100 mm
Construction Details:-
As per drawing
Construction Material:
Mild steel
Air Duct Construction Details: Construction Material:
As per drawing Mild steel
Steam/Air Heater Type: Quantity: Air inlet Condition:
Finless plain tube 1 set for each duct brunch o 30 C Dry bulb 27,000 m3/h flow
Air outlet Condition: Steam condition:
70 3
o
C Dry bulb kg/cm2 @ 95% dryness
Construction: Fin Tube: Fin spacing Temperature control:
Aluminium Copper 2 mm (minimum) by thermostatic control valve with stainlees steel capillary wire
Fan Type: Capacity: Static pressure: Maximum fan speed Motor:
Centrifugal 27,000 m3/h 150 mm wg 1500 rpm Powerapprox. 11kw Vendor to advice Type TEFC, SC, 4-Pole, 415V/3Ph/50Hz, IP 55, Class F Ins. Page 1 of 2
J. 21 2
DRY KERNEL CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
DRY KERNEL CONVEYOR No.1 DELIVERY
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee
Function:
To convey dry kernel from Kernel Silo to kernel Transport
SPECIFICATIONS Quantity Material to be Conveyed Capacity: Type: Size: General Arrangement: Construction Details:
One ( 1 ) unit Dry Kernel as follows : Dry Kernel 9,000 kg per hour ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing
Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 56 375 >
rpm rpm Nm (min) 1.5
Motor:Power: Type:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer:
Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower
Coupling: Bearing:
Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 1 of 1
J. 22 1
CRACKED MIXTURE ELEVATOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
13-May-00
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
DRY KERNEL ELEVATOR DELIVERY
REVISION No. LOCATION
DRAWING NO.
KERNEL RECOVERY PLANT
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To convey Dry Kernel
SPECIFICATIONS Quantity Material to be Conveyed Type: Capacity: General Arrangement: Construction Details:
One (1) unit Dry Kernel Elevator Dry Kernel Conveyor chain c/w buckets 9,000 kq per hour ( for 90MT FFB / hr ) As per drawing As per drawing
Construction Material: Casing: Sprocket Bucket: Chain rail: Chain:
Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
Mild steel with 6mm minimum thickness 12T, 101.6 mm pitch, grey iron Mild steel Mild steel angle Steel c/w hardened steel rollers, 101.6 mm pitch, 6800 kg breaking load Geared Motor coupled to elevator shaft by chain & sprocket 30 rpm 1 1450 30 955 >
rpm rpm Nm (min) 1.5
3 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower. Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS 1. Miantenance door shall be provided at the bottom booth 2. Take-up bearing c/w tensioning devices to be provided at the bottom sprockets & shaft 3. Top booth cover to be bolted construction for ease of maintenance 4. Outlet chute to be provided
Page 1 of 1
J. 23 1
PRIMARY WINNOWER SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
KERNEL WINNOWING DELIVERY
REVISION No. LOCATION KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To separate the cracked mixture from light particles using air separation method
SPECIFICATIONS Quantity System consist of:
One ( 1 ) Primary Winnowing System as follows : Adjustable damper, expension column, support, ducting, nut discharge chute, cyclone, airlock and fan
Material to be separated Separation Capacity:
Palm Nuts Cracked Mixture 9,000 kg per hour.
Separation Column General Arrangement: Construction Details: Construction Material: Size:
As per drawing As per drawing Mild steel 600 mm dia.
Ducting General Arrangement: Construction Details: Construction Material: Basic dimensions:
As per drawing As per drawing Mild steel Diamater: Thickness:
Cyclone General Arrangement: Construction Details: Construction Material: Basic dimensions: Airlock Type: Quantity: General Arrangement: Construction Details: Construction Material: Diameter: Drum Speed: Drive System:
400 mm 6 mm
As per drawing As per drawing Mild steel 1,350 mm dia. Rotary vane 2 As per drawing As per drawing Mild steel 300 mm 45 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 45 467 > Page 1 of 2
rpm rpm Nm (min) 1.5 (min)
J. 24 1
PRIMARY WINNOWER SYSTEM
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
KERNEL WINNOWING DELIVERY
REVISION No. LOCATION KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
J. 24 1
Sheet 2. Motor:-
Power: Type:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Fan Type: Flowrate: Static Pressure:
Centrifugal, self-cleaning 3 18,000 m /hr 375 mm wg
Construction Material: Casing: Impeller: Shaft: Pulley:
Mild steel Carbon steel Carbon steel Cast steel
Speed: Drive System: Belt guard: Type of Mounting: Baseframe: Motor:-
Vendor to advice (not more than 1500 rpm) Motor coupled to fan shaft by belt and pulley To be provided Floor Common baseframe to be provided Power: Type:
approx. 22kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor: Fan:
Crompton Parkinson, Brush Novenco, James Hawden, Chicago
Coupling: Gear reducer: Bearing: Transmission Belt:
Renold, Fenner SUMITOMO, HANSEN, Renold, EPG ElectroPower. NTN, SKF, FAG Fenner
Page 2 of 2
DRY KERNEL TRANSPORT
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
DRY KERNEL TRANSPORT DELIVERY
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
To transport dry kernel from KERNEL SILO to the Kernel Bulk Silo
SPECIFICATIONS Quantity System consist of: Material to be conveyed Separation Capacity:
One ( 1 ) Dry Kernel Transporter as follows : Ducting, cyclone, airlock, fan and supporting fixtures Dry Kernel 9,000 kg per hour.
Ducting General Arrangement: Construction Details: Construction Material: Diameter:
As per drawing As per drawing API 5L seamless Sch 40 pipe 250 mm
Cyclone General Arrangement: Construction Details: Construction Material: Basic dimensions:
As per drawing As per drawing Mild steel As per drawing
Fan Type:
High Pressure Blower 8,000 m3/hr 450 mm wg
Flowrate: Static Pressure: Construction Material: Casing: Impeller: Shaft: Pulley: Speed: Drive System: Belt guard: Type of Mounting:
Mild steel Carbon steel Carbon steel Cast iron Vendor to advice (not more than 2900 rpm) Motor directly coupled to fan To be provided Floor
Baseframe:
Common baseframe to be provided
Motor:Power: Type:
approx. 7.5kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES Motor:
Crompton Parkinson, Brook
Coupling: Bearing: Fan:
Fenner (Fenaflex), Renold NTN, FAG, SKF Novenco, James Howden, Phoenix
Page 1 of 2
J. 25 1
DRY KERNEL CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
DRY KERNEL CONVEYOR No.2
DELIVERY
REVISION No. LOCATION KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee
Function:
To convey dry kernel from Kernel Silo to kernel Transport
SPECIFICATIONS Quantity Material to be Conveyed Capacity: Type: Size: General Arrangement: Construction Details: Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing: Conveyor Speed: Drive System:
One ( 1 ) unit Dry Kernel as follows : Dry Kernel 9,000 kg per hour ( for 90MT FFB / hr ) Full flight screw 300 mm dia. As per drawing As per drawing Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup 56 rpm Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 56 375 >
rpm rpm Nm (min) 1.5
Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Bearing:
NW
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 1 of 1
J.26 1
BULK KERNEL SILO
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
PREPARED
NW
MACHINE NAME PROJECT CODE
OIL PALM MILL
KERNEL BULK SILO
DELIVERY
REVISION No. LOCATION
KERNEL RECOVERY PLANT
DRAWING NO.
ITEM No. QUANTITY / UNITS
J.27 4
GENERAL Scope
Scope of works include the manfacture, erection & installation commissioning, handing over and guarantee.
Function:
Storage of dry kernel for bulk dispatch.
SPECIFICATIONS Quantity Type: Total Capacity: Main Dimensions:
Four ( 4 ) Kernel Bulk Silo as follows : Steel plate and structure fabricated 100 metric tonnes dry Palm Kernel width: length: height of top section: Bottom Hopper Height: Bottom Hopper Angle: Number of Hopper:
General Arrangement:
4 16 6.2 2 45 4
m m m m o
Silo consist of 4 compartments with 4 discharge hoppers. Each compartment having a width of 4 m x 4 m length. The silo is supported by 10 main legs that are sufficiently braced. The side of the silo is braced by mild steel sections to prevent bulging out. The internal partition plates are also stiffened by mild steel. The silo is covered at the top by mild steel plates with sufficient intermediate trusses. The cover plate is sloped to the side at 2.5o to prevent from stagnant water. A vent pipe, manway is to be provided at the cover plate. Internal ladder shall slo be provided. The discharge hopper shall be equipped with discharge chute complete with rack and pinion and chain operated door. A step ladder with handrial, provided from ground level to the silo top.
Construction Material:Outer Casing: Legs: Leg Bracing: Side and Hopper Bracing: Internal Partition: Internal Bracing: Roof Plate: Roof Trusses: Staircase Main Frame: Handrail: Holding down bolt: Staircase Step: Vent Pipe: Internal Ladder: Manway Size: Height of discharge chute: Discharge Opening:
Mild steel with 6 mm minimum thickness 300 mm dia. Sch 40 carbon steel pipe 80 mm dia. Sch 40 carbon steel pipe bolted to gusset plates 100 x 50 x 6 thk mild steel channel Mild steel with 6mm minimum thickness 100 x 50 x 6 thk mild steel channel Mild steel with 4.5 mm minimum thickness 75 x 75 x 6 mm mild steel angles 150 x 75 x 6 mm mild steel channel 40 mm dia. black pipe medium class M40 x 450mm long ms bolts 175 mm wide x 1000 mm long Galvanised steel grating 200 mm dia. pipe with U-Bend and mesh cover 50 x 6 mm mild steel flat for side frame and 20mm solid mild steel bars 450 x 450 mm 4.5 m from ground level 300 x 300 mm
Page 1 of 1
WATER-TUBE BOILER
SCOPE
To design, supply, deliver to site, installation, testing, commissioning and guarantee of one (1) unit bi-drum water-tube boiler.
SPECIFICATIONS The steam boiler shall be 20,000 kg/hr. water tube Bi-Drum type, designed specifically to burn palm fibre and shells. Steam Condition at Mains Superheat Temperature Approx. Feed Water Temp at MCR Boiler MCR
: : : :
Boiler Operating Range
:
Overload Capacity Range
:
Overall Efficiency Electrical Supply
: :
22 kg/cm2 gauge , 30 o C. 60o C 20,000 kg steam /hour @ operating pressure. 50% to 100% MCR 110% of MCR (short period) Not less than 75 % 415 V ± 6 %, 50 Hz, 3 Phase, 4 wire.
The supply of the steam boiler shall include but not be limited to the following: 1. 2. 3. 4. 5. 6. 7.
Supporting structure. Steam water drums with internal fittings. Headers and tubes. Mountings and fittings. Spring loaded safety valves for steam drum. Soot blower system. Automatic feed water regulation using the latest technology available in the market c/w high, high-high and low and low-low water alarm. The alarm shall not be resetable until the level is corrected. Indicating lights shall also be installed on boiler front and control panel to indicate the states of alarm. 8. Integral feed water piping from feed water pumps to boiler drum.. 9. Integral steam piping from boiler drum to main stop valve and any equipment within the scope of works. 10. All boiler drain piping. 11. Integral electrical system from boiler MCC to equipment. 12. Reflex and Bi-colour water level gauge glasses. 13. Manual and automatic blowdown valves. 14. Furnace grate.
15. Explosion doors. 16. Forced, Secondary (over fire) and Induced Draught fans, complete with automatic and manual draught control. All fan sizes, capacities static pressures and volumes are to be specified. 17. Fuel feeder fan complete with feeder spouts and adjustment to facilitate efficient fuel spreading across its whole grate surface. 18. Dust collecting system. 19. Chimney and flue gas ducting. 20. Mechanised fuel feeder of pendulum type with anti fire back flash features. 21. All ducts. 22. All refractories and common red bricks. 23. All galleries, ladders and railings. 24. All main, auxiliary and non-return valves. 25. Water sampling and cooling system. 26. All gauge and instrumentation complete with one (1) steam/water flowmeter, steam/water temperature meter, steam pressure meter, draught/temperature meter and smoke density meter for each boiler. 27. Blowdown chamber silencer complete with piping from the boiler. 28. Instrument and control panel complete with mimic diagram indicating state of operation inclusive of necessary field instrument wiring. All indicating lights shall use 24 VAC power supply. 29. Recommended spare parts and tools for maintenance. 30. Insulation complete for all heated surfaces. 31. Steam pressure and water flow recorders/meters of 250 mm circular type. 32. Operating manuals. 33. Chemicals for boiling outs. 34. Cleaning and painting. 35. One (1) electric driven and one (1) steam driven feed pump of proven performance. The pumps shall be sized at least 1.5 times the MCR of the boiler. 36. Computerised DATA LOGGING system for the operation of the boiler with option for future automation. 37. Detailed technical specifications and drawings. 38. Fixed mounted pollution monitoring instruments Boiler Design & Construction The essence of design shall be reliability and efficiency in order to give long continuous service with high economy and low maintenance cost. In complying with the requirement of the specifications, both with respect to arrangements and details, design is to conform to
the best current engineering practices. Each of the several parts of the plant is to be of the maker 's standard design provided that this design is in general accordance with these specifications. Particular attention shall be given to internal and external access in order to facilitate inspection, cleaning and maintenance. The design, dimensions, and materials of all parts are to be such that they will not suffer damage as a result of stress under the most severe service conditions. Material used in the construction of the boiler and ancillaries are to be of the highest quality and selected particularly to meet the duties expected of them. Steam generation tubes shall be of adequate sizes and tube ends shall be expanded onto their seating. All construction shall be to British Standards or equivalent acceptable to the Malaysian authorities, and in accordance with Lloyd 's safety regulations and local authorities regulations). All designs shall be submitted for approval by the local authorities with all necessary drawings and test certificates. All relevant information and documents shall be copied to the Engineer. Design Code : In accordance to BS 1113 and BS 5759 or approved equivalent standards. Manifolds For Side & Rear Water Walls Constructed from solid drawn hot finished seamless pipe to BS 3602 G410 and closed at each end with a flat plate of material to BS 1501 - 151 - Gr 430A. Inspections & Tests These shall be carried out and certified by Lloyd, Bureau Veritas or other approved authorities. Boiler Mountings & Fittings All mountings and fittings necessary for the safe and proper operation of the plant shall be provided. Each item to be complete with ancillary piping and any other required accessories.
Two water level gauges of Reflex and Bi-colour type located to give easy observation from the boiler floor level. Adequate illumination shall be provided. One remote water level indicator located at the instrument and control panel or at the boiler floor level with adequate illumination shall also be provided.
Safety valves of spring loaded type, for the steam drum, of adequate capacity shall be provided, complete with release piping, supports and silencers as necessary. Steam soot blowers shall be supplied in adequate numbers and situated such that proper cleaning of the heating surfaces is effected and the operating efficiency of the boiler is maintained at its maximum without manual cleaning. Automatic Feed Water regulation shall be provided to maintain automatically the working water level at all times and at varying load conditions. Isolating valves shall be provided on the outlet and inlet of the regulator and a by-pass valve is also provided for use when the regulator is out of commission. The regulator shall be individually connected to the steam and electrical Feed Water pumps. One electric and one steam driven Feed Water pumps of turbine type shall be provided. Capacity of each pump shall be at 150% MCR of boiler rating. Pressure gauges and relief valves shall be provided for each Feed Water line. Water level alarms with distinct audible alarm and coloured indicator lights to signal high and low water levels in the drum. The alarm shall be audible within a 38m distance from the boiler during normal factory operations. The furnace and grate shall be designed for the efficient combustion of oil palm fibre and shell which are the normal fuel utilised. Self de-ashing facilities shall be incorporated. Pin-hole grates are not acceptable. There shall be occasions necessary where firewood and dewatered empty oil palm bunches are used. Fuel normally used are of the following characteristics: Shell to fibre Moisture content in fibre
: up to 25% shell : up to 42% by weight
Moisture content in shell
: up to 22% by weight
Induced, forced and secondary draughts shall be provided with draught control arrangements operated automatically and hand controls at the boiler front. Drafts will be sufficient to ensure effective combustion at maximum continuous rating and meet environmental regulations on smoke density and emission levels. Insulation and refractories, of high quality shall be used. Instrumentation Instrumentation shall be provided for : • • • • • • • •
steam drum and superheater drum pressure gauge (150mm installed on drum). steam drum pressure gauge (250mm installed on boiler front). steam temperature gauge (150mm c/w pocket installed on drum) flue gas temperature gauge. furnace draughts steam flow, water flow and pressure recorders/meters and totaliser (installed on panel). steam, feed water and flue gas temperature recorders/meter (installed on panel) smoke density meter, recorder with alarm at Ringleman 2 scale (installed on panel)
All control instrument shall use 4-20mA signal and meant for hooking-up to Central Control Station (by Others). Platform, Ladders, Staircase All necessary operating floors, access galleries and platforms complete with handrails, stairways and ladders required for the safe and convenient operation and maintenance of the plant. Blowdown And Drains Blowdown outlets and water drainage outlets from drums, headers, etc., shall each be provided with two stop valves in series with special handles or keys. Automatic blow down valves with TDS based controllers shall also be provided.
Water Sampling Cooler
Water sampling shall incorporate a stainless steel cooling coil and associated equipment. The scope shall include the installation of cooling water piping from nearby water supply line.
Chimney Chimney height shall be designed for an efflux velocity of 8 m/sec and to comply with the Malaysian environmental regulations but shall not be less than 30m. Chimney shall be of self-standing type. Necessary sampling points shall be provided in compliance with local authority’s regulations. Ladder and landing platform shall be provided at the sampling points. Number plate measuring 450x450mm painted in black shall be provided at the top of the chimney. Copper strips conductor shall be provided throughout the length of the chimney complete with earthing rods and chambers. Calculation on chimney structural design, efflux and height shall be furnished. Multicyclone A multicyclone dust collecting system shall be designed for emission of particles of less than 0.4 gm/Nm3 and to comply with the Malaysian environmental regulations. Dust removal and disposal system shall be incorporated. A dust handling and disposal system shall incorporate to remove the dust. Maintenance Tools Special tools and apparatus shall be provided for the maintenance and repair of the boiler. One set of tube expanders and one set of mechanical tube cleaner shall be included.
Fuel Feeding System One complete set of automatic fuel feeding system shall be offered with the supply. The feeding system shall be pendulum type with anti fire flash features incorporated with it. The gearbox/geared motor used for the drive system shall have at least 1.5 factor of safety. The fuel feeding system supplied must be ensured of effective distribution of the palm fibre and shell over the fire grate. Detail design shall be furnished together with the tender. Cleaning & Painting After fabrication and before delivery to the Site, the boilers and ancillaries are to be well wire-brushed and cleaned, before given one coat of primer. After erection the whole plant including bare pipe surfaces and handrailings are to be wire-brushed and cleaned, after which all parts except surfaces intended to be lagged are to be given two coats of white colour and quality paint. All paintwork is to be finished in colour according to specifications. All hot surfaces shall be painted with one coat of primer and two coats of finishes of silicon-based heat resistant paint in accordance with manufacturer’s recommendation. Drawing & Specifications Sufficient drawings technical data and specifications shall be furnished together with the tender. Schedules of electrical loading, fan sizes, etc. shall also be provided. Submission of NDT done on welds and joints are necessary. Electrical Motor Control Center (MCC) of IP44 complete with MCCB, ammeter, voltmeter, starters, ventilation fan and internal light shall be provided. Cables to motors shall be of PVC/SWA/PVA copper type and run on G.I cable trays. All electrical works shall be in accordance with rule and regulation of local authorities, BS and IEC Standard. Fans All fans shall be tested and witnessed by the Engineer in workshop or at the site for capacity, pressure and mechanical balancing to ensure that these comply with the requirements specified. The test procedures shall conform to BS or equivalent
standards. Induced draught fan blades shall be of heat resistance material and the fan speed shall not be more than 750 rpm. ID fan shall be coupled with fluid coupling to motor. Fan Damper Controller. Induced draught fan damper shall be controlled by PID Controller through hydraulic type actuator. Forced draught fan damper shall be controlled by the same type of controller either through electrical or hydraulic actuator and the damper shall be located at the fan inlet. Tests on Completion The manufacturer shall carry out capacity and rating tests to ensure the specifications are complied, before taking over by the Owner. The boiler unit shall be steamed continuously to its maximum continuous rating for a minimum period of three (3) hours operating in conjunction with the turbo alternators. The capacity test on each boiler unit shall be carried out to achieve a 110% output rating during this period. Technical data, specifications and relevant literatures shall also be provided for technical evaluation. Approved Makes Motor Gearboxes Pump Fan
: : :
: Elektrim, Crompton, TEFC, 4-pole, Class F, IP 55 HANSEN, Renold, Benzlar-Sala SIHI, Worthington Airvenco, ABB-Flakt, Phoenix
Flanges DIN PN 40 for for pressure above 3 kg/cm2 DIN PN 16 for for pressure below 3 kg/cm2
FUEL CONVEYOR - Horizontal
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
FUEL CONVEYOR
DELIVERY
PREPARED
NW
REVISION No. LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No. QUANTITY / UNITS
K. 1 1
GENERAL Scope
Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee.
Function:
To convey Oli Palm Solid waste fuel to the boilers.
SPECIFICATIONS Quantity Type: Capacity: Dimension
One ( 1 ) unit Fuel Screw Conveyor. Full flight screw - 750 mm dia. 30,000 kg / hr of mixed fuel ( for 90 tons FFB per hour ) as per drawing
Construction Material: Housing Screw Frame: Wear Plate:
6 mm thick m.s. plate Mild steel Mild steel sections Mild steel of minimum 6mm thk
Conveying Section: Inclination: Conveyor Shaft Speed: Dimension: Drive System:
Bottom section of the conveyor Contractor to advise 35 rpm As per drawing Geared motor coupled conveyor shaft by transmission chain & spocket
Transmission Sprocket Ratio:
1.43
Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 50 >
rpm rpm 1,433 Nm (min) 1.5
Motor:Power: Type:
7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins.,415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent.
Motor: Gear reducer: Coupling: Transmission Chain:
Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki
Bearing:
NTN, SKF, FAG
OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Top of the conveyor shall be covered with ms plate. 5. Provision for maintenance platform and ladder to be provided. Page 1 of 2
FUEL CONVEYOR - Inclined
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
FUEL CONVEYOR No. 2
DELIVERY
PREPARED
NW
REVISION No. LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No.
K. 2
QUANTITY / UNITS
GENERAL Scope
1
Scope of works include the design, fabrication, delivery, erection installation, testing, commissioning and guarantee.
Function:
To convey shell and fibre from Fuel ( Screw ) Conveyor to the boiler fuel feeder.
SPECIFICATIONS Quantity Type: Capacity:
One ( 1 ) unit Inclined Fuel ( Scrapper ) Conveyor. 750mm width Tray - scrapper plate on twin roller chain & sprocket 30,000 kg of mixed fuel of Fibre & Shell. for 90 MT FFB per hour Operation
Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate: Conveying Section: Inclination: Conveyor Shaft Speed: Dimension: Drive: Transmission Sprocket Ratio: Variable Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor:
Steel c/w hardened steel flanged rollers, 150 mm pitch, 15000 kg breaking load Mild steel Mild steel sections 493.2mm PCD, grey cast iron Mild steel of minimum 6mm thk 750 mm width - Top section of the conveyor 6 deg 35 rpm As per drawing Motor directly coupled to Cyclo speed reducer by HJ Adaptor 1.43 1450 50 >
rpm rpm 3,534 Nm (min) 1.5
Motor:Power: Type:
7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V / 3-Ph / 50 Hz
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
Crompton Parkinson SUMITOMO, Hansen, Renold, EPG ElectroPower Fenner (Fenaflex) Renold, Tsubaki Renold, Tsubaki, PC, ACE NTN
OTHER REQUIREMENTS:1. Vendor to furnish technical specifications, drawings and catalogues 2. Wear plate of 6mm minimum thickness to be provided for chain rails 3. Mild steel outlet chute to be provided at the end of the conveyor 4. Drive end shaft fitted with flange bearings
Page 1 of 2
FUEL CONVEYOR - Inclined
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
FUEL CONVEYOR No. 2
DELIVERY
PREPARED
NW
REVISION No. LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No. QUANTITY / UNITS
5. Non-drive end shaft to be fitted with chain tensioning devises c/w take-up bearings 6. Contractor to provide drawing and detail specifications.
Page 2 of 2
K. 2 1
FUEL FEED CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
FUEL CONVEYOR No. 3 DELIVERY
REVISION No. LOCATION BOILER HOUSE
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the design, fabrication, delivery testing, installation, commissioning and guarantee.
Function:
To convey Oil Palm solid waste fuel to the Boiler.
SPECIFICATIONS Quantity Type: Capacity:
One ( 1 ) unit Fuel Feed Conveyor as follows : Drag chain c/w scrapper plate 30,000 kg/hr of mixed fuel
Construction Material: Chain:
Steel c/w hardened steel rollers, 100 mm pitch, 6800 kg breaking load
Drag Plate: Frame: Sprocket: Wear Plate: Conveying Section: Inclination: Conveyor Shaft Speed: Dimension: Drive System:
Mild steel Mild steel sections 250 mm PCD, grey cast iron Mild steel of minimum 6mm thk Bottom section of the conveyor Horizontal S-Type 35 rpm As per drawing Geared motor coupled conveyor shaft by tarnsmission chain & sprocket
Transmission Sprocket Ratio: Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1.43
Motor
11 KW TEFC 4-pole, S.C, IP 55, Class F Ins.,415V/3-Ph/50 Hz
Power: Type:
1450 50 >
rpm rpm 2,101 Nm (min) 1.5
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devices c/w take-up bearings 5. Top of the conveyor shall be covered with suitable size wire mesh
Page 1 of 1
K. 3 1
FUEL PLATFORM
SPECIFICATION SHEETS PROJECT NAME PROJECT CODE
DATE: OIL PALM MILL
DELIVERY
MACHINE NAME
FUEL AND BOILER OPERATING PLATFORM
PREPARED REVISION No.
13-May-00 NW 1
LOCATION DRAWING No.
BOILER STATION
Item No.
K3
Quantity
Lot
GENERAL Scope
Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee.
Function:
To be used as boiler operating platform, fuel storage
SPECIFICATIONS General Arrangment: Construction Details: Construction Material: Structures: Plaform Handrail:
One lot Fuel and Boiler Operating Platform. As per drawing As per drawing Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe
OTHER REQUIREMENTS 1. Handrail shall be 900mm high with intermediete poles at 2000 c/c or otherwise shown in the drawings 2. 100mm high kick plate to be provided around the platform
Page 1 of 1
FUEL FEED CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
FUEL CONVEYOR No. 4 DELIVERY
REVISION No. LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee.
Function:
To convey shell and fibre from the inclined fuel conveyor to Boilers fuel feeder
SPECIFICATIONS Quantity Type: Capacity:
One ( 1 ) unit Fuel Feed Conveyor as follows : Scrapper plate on twin roller chain & sprocket. 30,000 kg / hr of mixed fuel of fibre & shell for 90 MT FFB per hour operation.
Construction Material: Chain: Drag Plate: Frame: Sprocket: Wear Plate: Conveying Section: Conveyor Shaft Speed: Dimension: Drive System: Transmission Sprocket Ratio: Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type: APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
Steel c/w hardened steel rollers, 100 mm pitch, 15000 kg breaking load Mild steel Mild steel sections 250mm PCD, grey cast iron Mild steel of minimum 6mm thk Bottom section of the conveyor 35 As per drawing
rpm
Geared motor coupled conveyor shaft by tarnsmission chain & sprocket 1.43 1450 rpm 50 rpm 1,433 Nm (min) > 1.5 7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins.,415V/3-Ph/50 Hz Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devices c/w take-up bearings 5. Top of the conveyor shall be covered with suitable size wire mesh 6. Contractor shall provide drawing and detail specification. Page 1 of 2
K. 4 1
FUEL STORAGE PLATFORM
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
FUEL PLATFORM
DELIVERY
PREPARED
NW
REVISION No. LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee.
Function:
To be used as boiler fuel storage platform
SPECIFICATIONS Quantity General Arrangment:
One lot Fuel Storage Platform as follows : As per drawing
Construction Details: Construction Material: Structures: Plaform Handrail:
As per drawing Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe
OTHER REQUIREMENTS 1. Handrail shall be 40 mm black pipe 900mm high with intermediete poles at 2000 c/c or otherwise shown in the drawings 2. 100mm high kick plate to be provided around the platform 3. Provision for stairways, walkways and ladder to be provided. 4. Tenderer shall provide details and drawing in the offer.
Page 1 of 1
K. 5 1
EXCESS FUEL DISPOSAL CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
EXCESS FUEL CONVEYOR DELIVERY
REVISION No. LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee.
Function:
To convey excess fuel from the boiler fuel feeder conveyor for disposal
SPECIFICATIONS Quantity
One ( 1 ) unit Excess Fuel Disposal Conveyor complete with top cover as follows :
Type: Capacity:
Full flight Screw - 750 mm dia. 30,000 kg Solid waste fuel per hour. for 90 MT FFB per hour operation.
Construction Material: Housing Screw Frame: Wear Plate: Top cover
6 mm thick ms plate Mild steel Mild steel sections Mild steel of minimum 6mm thk 6 mm thick ms plate
Conveying Section:
Bottom section of the conveyor
Conveyor Shaft Speed: Dimension: Drive System:
35 rpm As per drawing Geared motor coupled conveyor shaft by tarnsmission chain & sprocket 1.43
Transmission Sprocket Ratio: Gear box: Input speed: Output speed: Output torque: Design Service Factor:
1450 50 >
rpm rpm 1,003 Nm (min) 1.5
Motor:Power: Type:
5.25 KW TEFC 4-pole, S.C, IP 55, Class F Ins.,415V/3-Ph/50 Hz
APPROVED MAKES Motor: Gear reducer:
Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower
Coupling: Transmission Chain: Conveyor Chain: Bearing:
Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
OTHER REQUIREMENTS:1. Wear plate of 6mm minimum thickness to be provided for chain rails 2. Mild steel outlet chute to be provided at the end of the conveyor 3. Drive end shaft fitted with flange bearings 4. Non-drive end shaft to be fitted with chain tensioning devices c/w take-up bearings 5. Top of the conveyor shall be covered with suitable size wire mesh 6. Contractor shall provide drawing and detail specification. Page 1 of 1
K. 6 1
SUPPORTING STRUCTURE
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
STRUCTURE FOR K 6.
DELIVERY
NW
REVISION No. LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No.
K. 7
QUANTITY / UNITS
1
GENERAL Scope
Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee.
Function:
Steel Structure to support the excess fuel conveyor
SPECIFICATIONS Quantity General Arrangment:
One lot Supporting structure as follows: As per drawing
Construction Details: Construction Material: Structures: Walkway Plaform Handrail:
As per drawing Mild steel sections Mild steel chequered plate of 6mm thick 40mm dia.black pipe
OTHER REQUIREMENTS 1. Walkway of 800mm width and Handrail shall be 900mm high with intermediete poles at 2000 c/c or otherwise shown in the drawing 2. 100mm high kick plate to be provided around the platform
Page 1 of 1
FUEL RETURN ELEVATOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
FUEL RETURN ELEVATOR
DELIVERY
PREPARED
NW
REVISION No. LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No. QUANTITY / UNITS
K. 8 1
GENERAL Scope
Scope of works include the Design, manufacture, delivery & installation commissioning, handing over and guarantee 12 months.
Function:
To convey solid waste fuel from the storage area back to the fuel feed conveyor
SPECIFICATIONS Quantity Type: Capacity: General Arrangement: Construction Details: Construction Material: Casing: Sprocket Bucket: Chain rail: Wear plate: Chain:
One (1) unit Fuel Return Conveyor Double conveyor chain c/w buckets 30,000 kg Solid waste fuel per hour. As per drawing As per drawing
Mild steel with 6mm minimum thickness 12T, 150mm pitch, grey iron Mild steel Mild steel angle Mild steel with 10mm minimum thickness Steel c/w hardened steel flanged rollers, 150mm pitch, 13600 kg breaking load
Drive: Shaft Speed: Transmission Sprocket Ratio: Speed Reducer: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
Geared Motor coupled to elevator shaft by chain & sprocket 25 rpm 1
APPROVED MAKES Motor: Gear reducer: Coupling: Transmission Chain: Conveyor Chain: Bearing:
Specified or Equivalent Crompton Parkinson, Brush SUMITOMO, HANSEN, Renold, EPG ElectroPower. Fenner (Fenaflex), Renold Renold, Tsubaki Renold, Tsubaki, PC NTN, SKF, FAG
1450 25 2865 >
rpm rpm Nm (min) 1.5
7.5 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
OTHER REQUIREMENTS 1. Miantenance door shall be provided at the elevator booth 2. Top cover shall be bolted for ease of maintenance 3. Take-up bearing with adjustable bolt and screw shall be provided at the bottom booth for chain tightening 4. Mild steel outlet chute shall be provided 5. Plumber block bearing shall be fixed at the top booth
Page 1 of 1
WATER TUBE BOILER
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
WATER TUBE BOILER
DELIVERY
PREPARED
NW
REVISION No. LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No. QUANTITY / UNITS
GENERAL Scope
SPECIFICATIONS Quantity
Steam Condition at Mains Superheat Temperature Approx. Feed Water Temp at MCR Boiler MCR Boiler Operating Range Overload Capacity Range Overall Efficiency Electrical Supply
K. 9 1
Scope of works include the assistance in the unloading, safe keeping, close co-operation between the contractors, outside the battery limits of the Boiler contract, such as connections of water & electricity supply, assisting in the HP testing and during commissioning.
One ( 1 ) unit Water Tube Boiler as follows : The steam boiler shall be 35,000 kg/hr. water tube type, designed specifically to burn palm oil solid waste of fibre, shell and empty bunches. 21 kg/cm2 gauge , 30 o C. 60o C 35,000 kg steam /hour @ operating pressure. 50% to 100% MCR 110% of MCR(short period) 74 % AT Max. 414 V ± 6 %, 50 Hz, 3 Phase, 4 wire. The supply of the steam boiler shall include but not be limited to the following: 1. Supporting structure. 2. Steam water drums with internal fittings. 3. Headers and tubes. 4. Mountings and fittings. 5. Spring loaded safety valves for steam drum. 6. Soot blower system. 7. Automatic feed water regulation using the latest technology available in the market c/w high, high-high and low and low-low water alarm. The alarm shall not be resetable until the level is corrected. Indicating lights shall also be installed on boiler front and control panel to indicate the states of alarm. 8. Integral feed water piping from feed water pumps to boiler drum.. 9. Integral steam piping from boiler drum to main stop valve and any equipment within the scope of works. 10. All boiler drain piping. 11. Integral electrical system from boiler MCC to equipment. 12. Reflex and Bi-colour water level gauge glasses. 13. Manual and automatic blowdown valves. 14. Furnace grate. 15. Explosion doors. 16. Forced, Secondary (over fire) and Induced Draught fans, complete with automatic and manual draught control. All fan sizes, capacities static pressures and volumes are to be specified. 17. Fuel feeder fan complete with feeder spouts and adjustment to facilitate efficient fuel spreading across its whole grate surface. 18. Dust collecting system. 19. Chimney and flue gas ducting. 20. Mechanised fuel feeder of pendulum type with anti fire back flash features. 21. All ducts. 22. All refractories and common red bricks. 23. All galleries, ladders and railings. 24. All main, auxiliary and non-return valves. 25. Water sampling and cooling system. 26. All gauge and instrumentation complete with one (1) steam/water flowmeter, steam/water temperature meter, steam pressure meter, draught/temperature meter and smoke density meter for each boiler.
Page 1 of 3
WATER TUBE BOILER
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
WATER TUBE BOILER
DELIVERY
PREPARED
NW
REVISION No. LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No.
K. 9
QUANTITY / UNITS
1
Sheet 2. 27. Blowdown chamber silencer complete with piping from the boiler. 28. Instrument and control panel complete with mimic diagram indicating state of operation inclusive of necessary field instrument wiring. All indicating lights shall use 24 VAC power supply. 29. Recommended spare parts and tools for maintenance. 30. Insulation complete for all heated surfaces. 31. Steam pressure and water flow recorders/meters of 250 mm circular type. 32. Operating manuals. 33. Chemicals for boiling outs. 34. Cleaning and painting. 35. One (1) electric driven and one (1) steam driven feed pump of proven performance. The pumps shall be sized at least 1.5 times the MCR of the boiler. 36. Computerised DATA LOGGING system for the operation of the boiler with option for future automation. 37. Detailed technical specifications and drawings. 38. Fixed mounted pollution monitoring instruments Fuel Material
There shall be occasions necessary where firewood and dewatered empty oil palm bunches are used. Fuel normally used are of the following characteristics: Shell to fibre : up to 25% shell Moisture content : up to in 42% fibre by weight Moisture content : up to in 22% shell by weight
Fans.
Induced, forced and secondary draughts shall be provided with draught control arrangements operated automatically and hand controls at the boiler front. Drafts will be sufficient to ensure effective combustion at maximum continuous rating and meet environmental regulations on smoke density and emission levels.
Insulation & Refractory
Insulation and refractories, of high quality shall be used.
Instrumentation
Instrumentation shall be provided for : steam drum and superheater drum pressure gauge (150mm installed on drum). steam drum pressure gauge (250mm installed on boiler front). steam temperature gauge (150mm c/w pocket installed on drum) flue gas temperature gauge. furnace draughts steam flow, water flow and pressure recorders/meters and totaliser (installed on panel). steam, feed water and flue gas temperature recorders/meter (installed on panel) smoke density meter, recorder with alarm at Ringleman 2 scale (installed on panel) All control instrument shall use 4-20mA signal and meant for hooking-up to Central Control Station (by Others).
Platform, Ladders, Staircase
All necessary operating floors, access galleries and platforms complete with handrails, stairways and ladders required for the safe and convenient operation and maintenance of the plant.
Blowdown And Drains
Blowdown outlets and water drainage outlets from drums, headers, etc., shall each be provided with two stop valves in series with special handles or keys. Automatic blow down valves with TDS based controllers shall also be provided.
Water Sampling Cooler
Water sampling shall incorporate a stainless steel cooling coil and associated equipment. The scope shall include the installation of cooling water piping from nearby water supply line.
Page 2 of 3
WATER TUBE BOILER
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
WATER TUBE BOILER
DELIVERY
PREPARED
NW
REVISION No. LOCATION
DRAWING NO.
BOILER HOUSE
ITEM No.
K. 9
QUANTITY / UNITS
1
Sheet 3. Chimney
Chimney height shall be designed for an efflux velocity of 8 m/sec and to comply with the Malaysian environmental regulations but shall not be less than 30m. Chimney shall be of self-standing type. Necessary sampling points shall be provided in compliance with local authority’s regulations. Ladder and landing platform shall be provided at the sampling points. Copper strips conductor shall be provided throughout the length of the chimney complete with earthing rods and chambers. Calculation on chimney structural design, efflux and height shall be furnished.
Multicyclone
A multicyclone dust collecting system shall be designed for emission of particles of less than 0.4 gm/Nm3 and to comply with the Malaysian environmental regulations. Dust removal and disposal system shall be incorporated. A dust handling and disposal system shall incorporate to remove the dust.
Fuel Feeding System
One complete set of automatic fuel feeding system shall be offered with the supply. The feeding system shall be pendulum type with anti fire flash features incorporated with it. The gearbox/geared motor used for the drive system shall have at least 1.5 factor of safety. The fuel feeding system supplied must be ensured of effective distribution of the palm fibre and shell over the fire grate. Detail design shall be furnished together with the tender.
Drawing & Specifications
Sufficient drawings technical data and specifications shall be furnished together with the tender. Schedules of electrical loading, fan sizes, etc. shall also be provided. Submission of NDT done on welds and joints are necessary.
Electrical
Motor Control Center (MCC) of IP44 complete with MCCB, ammeter, voltmeter, starters, ventilation fan and internal light shall be provided. Cables to motors shall be of PVC/SWA/PVA copper type and run on G.I cable trays. All electrical works shall be in accordance with rule and regulation of local authorities, BS and IEC Standard.
Fans
All fans shall be tested and witnessed by the Engineer in workshop or at the site for capacity, pressure and mechanical balancing to ensure that these comply with the requirements specified. The test procedures shall conform to BS or equivalent standards. Induced draught fan blades shall be of heat resistance material and the fan speed shall not be more than 750 rpm. ID fan shall be coupled with fluid coupling to motor.
Fan Damper Controller.
Induced draught fan damper shall be controlled by PID Controller through hydraulic type actuator. Forced draught fan damper shall be controlled by the same type of controller either through electrical or hydraulic actuator and the damper shall be located at the fan inlet.
Page 3 of 3
ASH REMOVAL CONVEYOR
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
NW
ASH REMOVAL CONVEYOR DELIVERY
REVISION No. LOCATION
BOILER HOUSE
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the design, fabrication, installation testing, commissioning, handing over and guarantee
Function:
The removal of Ash from the Boiler for disposal
SPECIFICATIONS Quantity Material to convey Capacity: Type: Size: General Arrangement: Construction Details:
One ( 1 ) unit Ash Removal Conveyor as follows: Boiler Ash 3,000 kg per hour Full flight screw 300 mm dia. As per drawing As per drawing
Construction Material: Casing: Wear plate:
Screw Shaft: Shaft joint: Hanger bearing:
Mild steel of 6mm minimum thickness Mild steel with 6mm minimum thickness fitted thoughout the conveyor extended at least 100mm above the center line of the conveyor Mild steel of 6mm minimum thickness Seamless API 5L Gr B Sch 80 pipe Solid carbon steel Bronze bushing c/w C.I housing, grease nipple and cup
Conveyor Speed: Drive System:
56
rpm
Geared motor directly coupled to conveyor shaft by flexible coupling
Gear box: Input speed: Output speed: Output torque: Design Service Factor: Motor:Power: Type:
2.2 KW TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz
APPROVED MAKES
Specified or Equivalent
Motor: Gear reducer: Coupling: Bearing:
Crompton Parkinson, Brush SUMITOMO, Renold, HANSEN, EPG ElectroPower Fenner (Fenaflex), Renold FAG, SKF, NTN
1450 56 375 >
rpm rpm Nm (min) 1.5
OTHER REQUIREMENTS:1. Mild steel outlet chute to be provided at the end of the conveyor c/w sliding door 2. Hanger bearing shall be fitted at 3m c/c maximum spacing or as indicated 3. Flange bearings to be fitted at both end of the conveyor and one of them shall be roller thrust 4. Top of the conveyor shall be covered with 3mm thk m.s plate
Page 1 of 1
K. 11 1
GROUND FEED TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME PROJECT CODE
OIL PALM MILL
PREPARED
GROUND FEED TANK
DELIVERY
NW
REVISION No.
LOCATION BOILER WATER FEED
DRAWING NO.
ITEM No. QUANTITY
L 1. 1
GENERAL Scope
Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee.
Function:
To store and pre-heat soft water before feeding to DEAERATOR FEED TANK
SPECIFICATIONS Quantity Capacity: Construction Details:Construction Material:Tank Shell Tank Bottom Tank Roof Open Steam Coil: Insulation:
Nozzles to be provided:Uses water inlet overflow drain vent steam inlet temp. gauge temp.probe Flanges:
One ( 1 ) Ground Feed Tank as follows : m3 120 As per drawing and in accordance with BS 2654 Mild steel Mild steel Mild steel 50mm dia. seamless API 5L Gr B Sch 40 80mm thk Rockwool insulation c/w 0.7mm thk.aluminium sheet
Size (mm)
Qty
100 100 100 150 50 3/4 " BSP 3/4 " BSP
1 1 1 1 1 1 1
Protusion (mm) 150 150 150 150 150 80 80
Flange Material PN 10 PN 10 PN 10 PN 10 PN 16
Raised face slip-on to DIN 2526
Other Accessories:Mild steel monkey ladder c/w cage 2.3m from ground to the top Mechanical stainless steel float level indicator Bottom manhole of 600mm diameter Top manhole of 600mm diameter Internal monkey ladder
Page 1 of 1
GI 'C' BS 1387 GI 'C' BS 1387 GI 'C' BS 1387 GI 'C' BS 1387 seamless API 5L Gr B Sch 40
SOFTENER BOOSTER PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE OIL PALM MILL
PREPARED
NW
SOFTENER BOOSTER PUMP DELIVERY
REVISION No. LOCATION
DRAWING NO.
BOILER WATER FEED
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the design, manufacture, delivery installation, testing, commissioning and guarantee
Function:
To pump clarified water to the Softeners
SPECIFICATION Type Connection
Two ( 2 ) Softener Booster Pumps as follows : Centrifugal, End-suction Raised face flange to BS 4504 PN 10
OPERATING DATA Capacity Medium Temperature Specific Gravity Deleivery Head Speed NPSH available
60 water ambient 1 60 2900 3
m3/hr
m liquid RPM (Max) m liquid
CONSTRUCTION Casing Impeller Shaft Sealing Wetted Parts Coupling Drive: Motor:-
Cast Iron GG25 Cast Iron GG25 S.S AISI 304 Gland packing S.S AISI 304 Flexible Motor directly coupled with flexible coupling to the pump
Power: Type: APPROVED MAKES
5.5 kw Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent.
Pump: Motor: Coupling: Bearing:
Robuschi, SIHI, Grundfos Crompton Parkinson, Brush Fenner (Fenaflex), Renold NTN, SKF, FAG
OTHER REQUIREMENTS 1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 1
L 2. 2
DEAERATOR FEED TANK
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
DEAERATOR FEED TANK
DELIVERY
PREPARED
NW
REVISION No. LOCATION
DRAWING NO.
BOILER WATER FEED
ITEM No. QUANTITY / UNITS
L 3. 1
GENERAL Scope
Scope of works include the design, fabrication, delivery installation, testing, commissioning and guarantee
Function:
To store and heat soft water before feeding to Deaerator
SPECIFICATIONS Quantity Capacity: Construction Details:Construction Material:Tank Shell Tank Bottom Tank Roof Open Steam Coil: Supporting structure: Insulation:
One ( 1 ) Deaerator Feed Tank as follows : 45 m3 As per drawing Mild steel Mild steel Mild steel 50mm dia. seamless API 5L Gr B Sch 40 Mild steel 80mm thk Rockwool insulation c/w gauge 0.7mm aluminium sheet cladding
Nozzles to be provided:Users water inlet overflow drain vent steam inlet temperature gauge temperature probe Flanges:
Size (mm) Protrusion (mm) 100 150 100 150 100 150 150 150 50 150 3/4 " BSP Socket 3/4 " BSP Socket Slip-on raised face To BS 4504
Other Accessories:Mild steel monkey ladder Mechanical float level indicator Top manhole of 600mm diameter
Page 1 of 1
Flange PN 10 PN 10 PN 10 PN 10 PN 16
Material GI 'C' BS 1387 GI 'C' BS 1387 GI 'C' BS 1387 GI 'C' BS 1387 seamless API 5L
DEAERATOR FEED PUMP
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DEAERATOR FEED PUMP DELIVERY
REVISION No. LOCATION
BOILER WATER TREATMENT
DRAWING NO.
ITEM No. QUANTITY / UNITS
GENERAL Scope
Scope of works include the design, manufacture, delivery installation, testing, commissioning and guarantee.
SPECIFICATION Quantity Type Connection
Two ( 2 ) Deaerator Pump as follows : Centrifugal, End-suction Raised face BS 4504 PN 16
OPERATING DATA Capacity Medium Temperature Specific Gravity Viscousity Delivery Head Speed NPSH available
60 Water 90 1 0.00114 128 1450 3
CONSTRUCTION Casing Impeller Shaft Sealing Coupling Drive: Motor:-
m3/hr o
C
Ns/m2 KPa RPM (Max) m liquid
Cast Iron GG-C25 Cast Iron GG-C25 or bronze carbon steel Gland Packing Flexible Motor directly coupled with flexible coupling to the pump Power: Type:
APPROVED MAKES Pump: Motor: Coupling: Bearing:
18 kw - Vendor to advice TEFC 4-pole, S.C, IP 55, Class F Ins., 415V/3-Ph/50 Hz Specified or Equivalent Robuschi, Warman, MTP Crompton Parkinson, Brook Fenner (Fenaflex), Renold NTN, SKF, FAG
OTHER REQUIREMENTS 1. Vendor to provide technical details, cataloques, performance curve and etc.
Page 1 of 1
L 4. 2
DUPLEX WATER SOFTENER
SPECIFICATION SHEETS PROJECT NAME
DATE:
7-Aug-99
MACHINE NAME
PROJECT CODE
OIL PALM MILL
PREPARED
NW
DUPLEX WATER SOFTENER DELIVERY
REVISION No. LOCATION
DRAWING NO.
BOILER WATER TREATMENT
ITEM No. QUANTITY
L 5. 1
GENERAL Scope
Scope of works include the Design, manufacture, delivery, installation testing, commissioning and guarantee.
Function
To condition the water before deaeration and feed to water tube boiler
SPECIFICATION
The water softener shall have the following specifications:-
Quantity Type
One (1) unit Duplex Water softener DUPLEX
Capacity
45 m3/hr of water flow.
Type of resin
Food grade
Piping System
Integral piping system shall be provided.
Inlet Water Quality
Colour
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