Capacity Curing Management

8/9/2019 Capacity Curing Management

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Capacity CuringManagement of ContinuousCentrifugal Machines

By:

Engr. Abdul Aziz TahirTechnical Director, Ranipur Sugar Mills Priate !i"ited, Ranipur


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Over View The Ra# Massecuite $uring Station o% Boiling &ouse is the

"ost cost e'ectie Station in the point o% ie# o% Electrical,(peration and Maintenance cost heads. By controlling theseheads, "eaning %ull saing can be "ade #hich #ill ulti"ately

share the pro)tability o% the pro*ect. The Paper is the reie#o% actiities per%or"ed at continuous centri%ugal station. +t%ocused the criteria %or selection o% conti "achine, its erection, selection o% the belts and pulleys design %or po#ertrans"ission, selection o% "achine rp" and nic-el #or-ingscreens, start up and operation precautions, necessary steps%or capacity gaining, scheduled and preentie "aintenance,bas-et -eeping, sa%ety deices, preentie "easures to aoid"a*or brea- do#n o% the "achine, technical details o% di'erent"a-e bas-ets, co"paratie capacity test %or di'erent "a-e"achines, pay bac- period calculations %or high capacity ne#"achine and case study %or /// T$D plant #or-ing #ith highcapacity conti "achines.


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The presentation details:01 (er ie# o% a $onti Machine21 Selection o% the type o% $onti Machine31 E'ect o% rp" and Bas-et Angle41 Space and Mechanical Structure Re5uire"ent61 +nstallation7Erection precautions1 Selection o% 8ic-el #or-ing Screens

91 Selection o% Belts type and Pulley design %or Po#erTrans"ission

1 Start up Precautions;1 (perational Para"eters0/1 Massecuite


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The presentation details:041 Machine Maintenance

061 $auses o% Ma*or Machine Accidents01 Precautions to Stop the Machine %or oer non crop

Period091 $o"paratie Technical Details o% di'erent Ma-eBas-ets

01 $o"paratie $apacity Run Data %or Di'erentMa-es Machines

0;1 Paybac- Period o% &igh $apacity local "ade $onti.

Machine2/1 $ase Study %or Replacing ?00// $onti Machines

#ith S?026/201 Machines %or /// T$D Plant

221 Reco""endations


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Over View of a ContinuousCentrifugal Machine


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2- Selection of the type of Conti Machine

+t includes:

A- Curing Capacity Tons/hr with given condition of

a Massecuite type and its !

i. Bri= ii. Purity iii. Te"perature

" Sugar #ualityi. Purity

$ $as%et &'M

C $as%et (iameter and Angle

i. Bas-et dia"eter at top

ii. Bas-et angle #ith respect to the tangential at the centre o%bas-et @ see at Sr. no. 09


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)- *+ect of rpm and $as%et Angle

A- &pm are selected with the massecuite type, normal recommendedrpm and "as%et angle with eperience are follow!

a. 0//7 3/ at A Massecuite

b. 0// 1 0//7 3/ at B Massecuite

c. 0// 1 2///7 34 at $ Massecuite

$- high rpm "eyond the recommended limit may cause!

a. $rystal da"ageb. Reduce capacity curing

c. Decrease the belts li%e

d. Decrease the bearing li%e

e1 lti"ately ris- operation o% the Machine

C- low rpm against recommended limits may cause

a. !o# 5uality sugar production

b. More "olasses circulation in the syste"


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)- *+ect of rpm and $as%et Angle

(- lesser degree "as%et against the recommendedangle "ay cause7re5uire :

a. Resistance to trael the "assecuite7 sugar

oer the bas-et screen.

b. More po#er de"and %or capacity run.

*- higher degree "as%et "eyond the recommendedangle may cause!

a. !o# 5uality sugar production

b. More "olasses circulation in the syste"


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.- Space and Mechanical Structure &euirement

A- Ma%e steel structure according to ornearest to the Manufacturer (esign

$- 0ea% Structure or over loaded structuremay result in!

a. ibration trans"ission %ro" one "achine toother

b. reduction in bearing li%ec. reduction in through put o% the battery

d. Bas-et da"age or "a*or "achine accidents

e. $onstant li%e ris- threat %or the operators


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1- nstallation/ *rection 'recautions

$hec- :a. That Machine is dyna"ically pre1balanced at designed rp".

b. The co"plete #elding point o% the structure

c. &orizontal le%t right C// balance o% the structure

d. C// balance o% the drie unit7 housing o% the "achine

e. C// balance o% bas-et top ring a%ter )tting

%. ery +"portant to note that: Feeding Pug Mill center,Feeding Pipe of pug mill, distributor of machine isvertically in line.

g. Pug mill feeding pipe diameter should not less than 8 inches for K1100Machine and 10 inch for K1200K12!0 or e"uivalent ma#e machines.

h. $he length of feeding pipe from main control valve to feed control valve%&gar type' e"ual to bas#et length ( 1 ft. as sho)n in

under given s#etch.


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nstallation/ *rection

'recautions


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3- Selection of 4ic%el 0or%ing

Screens

Standard Screens &igh (pen area

screensMass

!

Type

Slot Si5e

60 7 89mm

Openarea6:9

Thic%ness

6mm9

SlotSi5e

60 7 89mm

Openarea6:9

Thic%ness

6mm9

A /./; 2.9/ 00F /.36 /./; 0.6

22.3/ F /.363

B /./ 2.9 .// F /.36 /./ 0.2

04.9/ F /.33

$ /./4 2.4

/./ 2.9

.6/ F

.// F

/.36

/.36

/./4 0./

/./ 0.2

;.9/ F

04.9/ F

/.33

/.33


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3- Selection of 4ic%el 0or%ing Screens ;igh open area screens are cost e+ective "ut 2C ?1= 6(p dp9 6(p @ dp9

/ .C

8p>2

?1BB?1=622)??96)??-229/

6. ?119

!p:H e'ectie pitch length !P H 36./ ""

$H centre distance @chosen @8earest standard length %ro" )gure 8o.6

2 @ Calculate the eact centre distance ofpulleys

after "elt length is determined

$ H bI@b1 2 = @Dp dp7 4 $ H 2;2.2/ I @2;2.21 2 = @300 22;74


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=- Selection of V $elts type and 'ulley design for'ower Transmission

Step 'rocedures &esults

9. ? - (etermine the power per $elt Pr H 0.;3 I /.36 H 09.2

See table 8o.00 basic horse po#errating %or $ type belts

2 @ (etermine the arc of contact Arc $ontact H 0/ J / @Dp J dp 7 $

correction factor, Drom Ta"le 4o1 Arc $ontact H 0/ J / = @300 J 22;l40.0/ H 09.

) @ (etermine the length Do > contact correction factor

Correction Ta"le 4o3 D8 > length correction factor > ?B?

$alculate the 8o. o% belts re5uired

8u"ber o% belts H Pd @Pr I

31 $entre distance H 040 ""4 1 Belts to be used : $06/, pcs


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B1 belts Di"ensions @""TA$8* 4o)


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$1 Mini"u" 1BeltsPulleyDia"eters @in ""

Ta"le 4o.


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D1 belts PulleyDesign

nder "entioned is belts pulley design guide lines #ith di"ensions in "".

6Digure 2 and Ta"le 4o19


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E1 Accurate and Grong designPullies

6Ta"le 4o39


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F- Start up 're-cautions


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F- Start up 're-cautions

+. Stea" up the %eeding pipe o% Pug "ill at both side o% the "assecuite controlale to reduce the iscosity o% the %eeding "assecuite at the start up andpreent the "assecuite %ro" entering the "achine, during "assecuitere"oing %ro" Pug"ill %eeding pipe , te"porarily blind the %eeding pipe o% the"achine .

L. Stop the stea" heating #hen %eeding "assecuite and "achine gained goodoperation te"perature and "achine ca"e in nor"al operation.

?. $lose the %eed control ale and open the Main "assecuite $ontrol ale.

!. Start the "achine, a%ter Delta run, start %eeding "assecuite and notice the oerall behaior o% the "achine at operating conditions, a%ter satis%action, regulatethe "assecuite %eed control ale.

M. Al#ays use hot #ater o% /1 6 $ i""ediate a%ter the agar control ale along#ith "assecuite %eed to lubricate the "assecuite %or ease o% e5ual distribution#ith in the distributor.

8. ery +"portant to regulate operation o% the "achine %or good 5uality sugarproduction at designed capacity at recommended Ampere of the Machine.If there is problem with operation at full load, check and rectify it but

do not leave it pending for next crop or compromise at reducedcapacity operation.


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;- Operational 'arameters 6other than tolisted a"ove9

A. se nozzle #ater spray at bas-et to "aintain Sugar 5uality #ith %ollo#ing conditions:

at distance not less than 6/ "" #ater te"perature / 1 6/ $ #ater pressure 2 -g7c"2 good spray is obsered #ith )sh tail type nozzles spraying at t#o points at 0/ degree to each other.

B. Aoid oer #ashing the sugar crystals, better chec- is to "aintain "olasses bri=, +% at reco""ended"olasses bri= sugar 5uality is not achieed then chec- other para"eters li-e:

"achine rp" nu"ber o% belts and tightening condition "assecuite 5uality n7# screen condition internal cleaning o% the "achine casing distributor

$. $hec- and "aintain:

cleaning the "achine casing at de)ned interals inspection o% the sugar 5uality hourly record the data %orN

%eeding "assecuite te"perature #ater spray te"perature running A"pere o% the "achine bearing te"perature

sugar and "olasses 5uality


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?B- Massecuite Deeding Arrangements

A- (rive less 'ressure Deeding $ottle


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??- MassecuiteConditioning!

Ta"le 4o FType of

Massecuite

DeedingTemperatur

e

Cooling &e-heating Media andTemperature &ange

A /$ i. open air crystallizer cooling

B 66$ i. open air $rystallizer cooling to /$.

ii. one step ertical crystallizer orGer-spoor #ater cooling to 66$

$ 6$ i. open air $rystallizer cooling to/$

ii. .$ #ater cooling to 4/$

iii. #ater re1heating to 6$


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?2- Maimum Capacity Gain

Most o% the para"eters are listed aboe, others are to:A1 $ontrol "assecuite te"perature at not belo# than 66$B1 Run "achine at "a=i"u" reco""ended A"pere$. +nstall A"pere "eter in %ront o% the (perator at each "achineD. +nstall easy operatie "assecuite %eed control ale

E. -eep clean:

a. +nside o% the "achine casing b. 87G screen o% the Machine c. "assecuite distributor

d. hot #ater spray nozzles


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?)- *ssential safety (evices ofthe Machine

A. ibration trip deice

B. Bearing Te"perature +ndicator

$. A"pere Meter and oerload running

electrical trip deice


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?.- Machine Maintenance

A Scheduled MaintenanceEach "achine should be stop #ee-ly oer a period %or chec- upand "aintenance o%:i. Bas-et !1?ey bolts and Top ring boltsii. cleaning o% distributor, bac- linner and 87G screensiii. greasing the bearingsi. inspection o% the . belts condition

$- 'reventive Maintenance$hec- and "aintain record o% ibration li"its o% each "achinerunning at %ull rp" #ith no load. +% ibration o% the "achineincreases the li"its, i""ediately stop the "achine and gothrough chec- up and "aintenance to get bac- the"achine in the sa"e li"its o% ibration. Reco""endedsa%e li"it o% ibration %or "achine bas-et is less than 0./ ""per sec.


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?1- Causes of MaEor MachineAccidents

A- 8oosen/ thread slipping of the 8-Hey "olts

a. Al#ays use !1?ey Bolts o% &igh tensile "aterial and do notco"pro"ise on MS bolts.

b. Replace the bolts i% thread loosen and once at the start o% theseason.

$- 8oosen the top ring "olts

a. Al#ays chec- and tighten these bolts during schedule"aintenance.

C- 8oosen the 4/0 screen from Screen holder ring

(- (amaging the 4/0 screen*- Cho%ing of the Deed distri"utor of the $as%etD- Cold start of the Machine with cold massecuite in the feed

distri"utorG- nitial high vi"ration reading of the $as%et during start up;- Cold feeding of the massecuite during start run- Stuc% o+ "earings due to no greasing etc


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?3 'recautions to stopMachine!

A- for interval, during operation!a. co"plete e"pty and stea" #ash the "assecuite%eeding pipe o% Pug "ill.

b. close tightly the "assecuite "ain control ale, no

lea-age should obsere a%ter its closure.c. blind the %eeding pipe o% the "achine

d. stea" #ash the "achine to clean any "assecuiteand sugar crystals adhering the internal parts o% the"achine.

e. +nsure the distributor is %ree o% "assecuite or %oreign"aterial

%. shut o' the "achine and "ade it po#er o' %ro" the "aincontrol panel.

$-'ermanent for over non crop perioda. Properly grease the bearings

b. close7blind all openings o% the "achine casing

c. "ade %e# "anual turns o% the bas-et t#ice a #ee-.


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?=- $as%etHeeping

A1 Mar- the releant position o% !1-ey bolts o% drie unit#ith bas-et a%ter co"pletion o% rotary balancing o% thebas-et.

B1 (pen the bas-et a%ter the co"pletion o% the ca"paignand -eep it body %ree at balanced position.

$1 Re1)t the sa"e bas-et in sa"e "achine #ith sa"e drieunit at the sa"e releant "ar-ed position. This ise=perienced e=ercise #hich cut o' "ore than 6/ F

rebalancing e=penses o% the bas-et %or ne=t crop run.


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091 Comparative Technical (etails ofdi+erent ma%e $as%ets@nstalled at &anipur Sugar Mills Ta"le

4o


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091 Comparative Technical (etails ofdi+erent ma%e $as%ets@nstalled at &anipur Sugar Mills Ta"le

4o


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S.8o Particulars SB?1026/73/


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Table No.10-B


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$ontinued Table 8o.02, $ase Study o% Replacing ?00//Machines #ith S-026/ Machines %or /// T$D Plant

A- Total *lectric operational cost saving for the Season

6&s9 F,..1,3BBB

Maintenance Saving Cost!

?- Maintenance Cost for ?B 4os H-??BB machines I

&s2?1,BBJ per season 6&s9 2,?1,BBBB

2- Maintenance Cost for 1 4os SH-?21B machines I&s231,31BJ per season 6&s9 ?,)2F,21BB

$- Total Maintenance Cost Saving for 1 4os S%?21BMachines &s F)B,=1BB

C- Total Saving Cost per Season 6&s9 ,2=3,)1BB

$ost per Machine, Re% Table 8o. 00


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Capacity Curing Management

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