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ThyssenKrupp Industries India Pvt. Ltd.

Erection, Operation and Maintenance


Instructions

For

MILLING PLANT

CUSTOMER : Dalmia Sugars Ltd.


Unit 1 & Unit 2,
Uttar Pradesh, INDIA
W.O. NO. : 4M0012 and 4M0021

Manufactured by:
ThyssenKrupp Industries India Private Limited,
Post Bag No. 22, Pimpri,
Pune 411 018.
Phone No. (020) 27425461/2/3/4
Fax No. (020) 27425350
E-mail: tkii@thyssenkrupp.com

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

CONTENTS
SR. No. DESCRIPTION SHEET NO.
SECTION I GENERAL

01 Technical Specifications And Data Sheets 4-20

02 Schedule Of Pumps 21

03 Schedule Of Couplings 22

04 Schedule Of Drive 23

05 Schedule Of Lubricants 24-28

06 Schedule of Bearings 29-30

SECTION II ERECTION INSTRUCTIONS

01 Introduction 32

02 Safety Instructions 32

03 Cane Carrier 32

04 Cane Kicker / Chopper / Cane Cutter / Comber 33

05 Rake Elevator 35

06 Rake Inter carriers 36

07 Conveying and Elevating Chains 36

08 Mills 41

09 Mill Assembly 42

10 Cooling water re-circulation for mill bearings. 43

11 Repair of roller journal in case of wear. 43

12 Tightening Torque Values for Bolts 44

SECTION III OPERATING INSTRUCTIONS

01 Lubrication 45

02 Trial Run Of Mills 45

03 Recommended Hydraulic Pressures 46

04 Adjustment Of Rollers 47

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

CONTENTS
SR. No. DESCRIPTION SHEET NO.
05 Adjustment Of Settings 47

06 Routine Maintenance 48

07 Special Instructions 48

08 Off-season Precautions 49

09 Under Feed or Force Feed Rollers 50

10 Further Important Hints For The Foundations 50

11 Recommended Spare Parts 51

SECTION IV REFERENCE DRAWINGS 54-57

SECTION V OTHER MANUALS

01 Cane Unloader & Mill House Crane

02 Cane Shredder

03 Oil Lubrication System For Shredder

04 Rotary screen

05 Oil Lubrication System For Mills

06 Mill Hydraulic System

07 Centrifugal Pumps

08 Fluid Couplings For Inter carrier Drives

09 Belt conveyor system

10 Cross belt magnetic separator

11 Auto Cane Feeding System

12 Electric Motors

13 Helical Gearboxes

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SECTION-I
1. TECHNICAL SPECIFICATIONS AND DATA SHEETS
SR.
PARTICULARS OF PLANT
NO.
Crushing capacity 260 TCH
Fibre % cane 16
A CANE HANDLING AND FEEDING
1 HYDRAULIC TRUCK
TIPPER 1 Nos
1.1 Capacity 50 MT
1.2 Tilting Angle 55o
1.3 Platform suitability 6 Tyre & 10 Tyre truck
1.4 Platform structure Box type
1.5 Back stopper Retractable Hydraulic
1.6 Front hooking Adjustable Hydraulic
1.12 Power pack unit Designed suitably for outdoor duty
1.13 Time of rotation for 0 to 55 degree 30 sec
1.14 GA Drawing no. SHE-50-20053, suppliers drg.
2 CANE UNLOADER CRANE Three motion type conforming to class IV , IS specification 807 &
3177:1977 with heavy duty grab attachment having a capacity
5MT

2.1 Make Rachitech Engineering Pvt. LTD


2.2 S.W.L. 5MT Including with grab
2.3 Lifts per hour 20 (Maximum) nos.

2.4 Cane per lift 2.5 T (Maximum)


2.5 Span of Crane gantry 26 m
2.6 Height of lift 8m
2.7 Crane Drive Hydraulic Drive
2.7.1 Hydraulic Power pack:
Make WALVOIL
HYD. Control valve Load drop on off type.
2.7.1 Hoisting drum drive 6K series- O/P Torque:470Nm ,461RPM
Make: EATON / VIKERS USA
2.7.2 Holding drum drive 6K series- O/P Torque:470Nm ,461RPM
Make: EATON / VIKERS USA
2.7.3 Cross travel drive Tseries- O/P Torque:83Nm,545RPM
Make: EATON / VIKERS USA
2.7.5 Long travel drive Sq. Cage 5.1 Kw, 960 RPM
2.7.6 No. of operations per hour 300, S4 duty AC 3 phase. no

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
2.8 Crane speeds
2.8.1 Hoisting 26/min
2.8.2 Holding 26/min
2.8.3 Cross travel 29m/min
2.8.4 Long travel 24 m/min
2.9 Wire rope Construction with fibre core.
2.10 Crane gear boxes For Hoisting/Holdings : Italy
For C.T. & L.T. : Rachitech
2.10. Type Planetary with built in Hyd. Disc Brake PG 1602/22+ RB /650
1 Ratio 22:1. Cross Travel: RHDR 350 Ratio 31.5:1
Long Travel: RHDR350, Ratio 40.16:1
2.11 Couplings Half Flexible geared
2.12 Brakes Electro-hydraulic thrusters operator type.
2.13 Control cabin Attached to the Crab
2.14 GA Drawing no. A1/2005-58/01,Rev2
B CANE CARRIERS
1 Tipper Carrier
1.1 G.A. drawing no. MP-1024-0/A
1.2 Carrier Geometry 4000wide ,16m horizontal sprocket c/c
1.2.1 Horizontal loading length 16 m
1.2.2 Inclination 15o
1.3 Chain 60000kg breaking load.
1.3.1 Type Steel Roller Type With K2 Attachment At every Link.
1.3.2 No. of Strands 6
1.3.3 Pitch 200 mm
1.4 Slat 8mm thick, fitted to chain attachment by bolt & nylock nut
1.5 Material of construction
1.5.1 Head Shaft
Material 45C8 IS1570
Diameter at center 400mm
Diameter at bearing 300mm
Head shaft bearings Antifriction self aligning double row C.S. housing
1.5.2 Tail Shaft
Material 45C8 IS1570
Diameter at center 300mm
Diameter at bearing 260mm
Tail shaft bearings Antifriction self aligning double row C.S. housing

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
1.5.3 Sprocket wheels 16 teeth,200MM pitch
Teeth Machine Cut teeth
Material Cast steel IS 1030 Gr. 280-520W
1.5.4 Conveyor plates and frame IS 2062 Gr. A
2 Main Cane Carrier
2.1 G.A. drawing no. MP-1021-0/0
2.2 Carrier Geometry 2500mm Wide, 76.5m horizontal sprocket c/c
2.2.1 Horizontal loading length ~45 m
2.2.2 Inclination 15o
2.2.3 At leveller installation 15o
2.2.4 Before Shredder 15o
2.2.5 Length of 8o portion 31.5 m
2.3 Chain 60000kg breaking load.
2.3.1 Type Steel roller type chain with K2 attachment at every link.
2.3.2 No. of Strands 4
2.3.3 Pitch 200 mm
2.4 Slat 8mm thick, fitted to chain attachment by bolt & nylock nut
2.5 Material of construction
2.5.1 Head Shaft
Material 45C8 IS1570-1979
Diameter at center 350mm
Diameter at bearing 300mm
Head shaft bearings Antifriction self aligning double row C.S. housing
2.5.2 Tail Shaft
Material 45C8 IS1570-1979
Diameter at center 280mm
Diameter at bearing 260mm
Tail shaft bearings Antifriction self aligning double row C.S. housing
2.5.3 Idler Shaft
Material IS 2062 Gr. A
Diameter at center 100 mm
Diameter at bearing 75 mm
Idler shaft bearings Bearing with bush,IS210 FG 200
2.5.4 Sprocket wheels 16 teeth,200MM pitch
Teeth Machine Cut teeth

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
Material Cast steel IS 1030 Gr. 280-520W
2.5.5 Conveyor plates and frame IS 2062 Gr. A
3 2400 mm Belt Conveyor Before
Shredder
3.1 G.A. drawing no. MCE / TKII / 2022 / 06-07 / 01, Rev.01 (Suppliers drg.).
3.2 Carrier Geometry 12220mm horizontal & 3350mm vertical pulley c/c
3.2.1 Belt Width 2400 mm
3.2.2 Length 12.67 m along the belt.
3.2.3 Inclination 15.33o with the horizontal
3.3 Belt
3.3.1 Type N/N, 630/4, top/bottom cover 5/2 thick.
3.3.2 No. of ply 4
3.3.3 Take up Screw take up.
3.3.4 Belt strength 630 kN
3.4 Details of construction
3.4.1 Head Pulley Rubber lagged dia. 630mm x 2600 face width.
3.4.2 Tail / Snub pulley 500 mm / 320 mm dia.
3.4.3 Carrying / Return Idlers 140 mm / 114.3 mm dia.
3.4.4 Skirt board 2200mm W x 450mm H Trough provided throughout the length.
3.4.5 Internal scraper Vee type
3.4.6 External scraper Weight actuated type
3.4.7 Deck plate Provided at the feeding point
3.5 Conveyor speed Variable, 8 80m/min.
3.6 Make Material Conveying Engineers, Gaziabad.
Cane & belt conveyor drive Please refer drive and coupling schedule
4 Tramp Iron Separator
4.1 Type Cross belt magnetic separator
4.2 G.A. drawing no. A3 9037 Rev.1 and A3 9038 Rev.1 (Suppliers drg.).
4.3 Make Super Lift Magnets Pvt. Ltd., Faridabad.
4.4 Magnet size 2400 x 1500 x 1050mm, 14000 kg weight.
4.5 Magnetic separator belt width 1600mm
4.6 Magnet belt speed 15m / min.
4.7 Installed motor power 5 HP
4.8 Operating height 500mm
4.9 Lifting capacity Magnetic tramp iron pieces of 25kg, L: D ratio max. 5 under the
burden depth of semi-prepared cane.
5 Rake carrier (After Shredder) As follows:-

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
5.1 G.A. Drawing no. MP-1025-0/B Qty. 1 no.
5.2 Carrier geometry 2150mm Wide, 23650mm horizontal and 13885vertical sprocket
centre distance (400 inclination).
5.3 Chain
5.3.1 Type Block type forged chain with SS pin, SS bush and K2 attachment at
every 3rd link.
5.3.2 No. of Strands 2
5.3.3 Pitch 229 mm
5.3.4 Breaking Strength 80,000 kg
5.3.5 Locking arrangement of chain With nut and split pin
5.4 Matl. of construction
5.4.1 Head Shaft
Material 45 C8 IS 1570.
Diameter at center 300mm
Diameter at bearing 230mm
Head shaft Bearings Antifriction double roller self aligning cast steel housing
5.4.2 Tail Shaft
Material 45 C8 IS 1570.
Diameter at center 200 mm
Diameter at bearing 180 mm
Tail shaft bearings Antifriction double roller self aligning cast steel housing
5.4.3 Sprocket wheel
Driven Sprocket 14 teeth 229 pitch
Driving Sprocket 14 teeth 229 pitch
Idler Sprocket 12 teeth 229 pitch
Teeth Machine Cut teeth
Material Cast steel IS1030 Gr. 280-520W
5.5 Trough and frame IS 2062 Gr. A
5.6 Drive arrangement Please refer drive and coupling schedule
6 Belt Conveyor After Shredded Cane Rake Carrier
6.1 G.A. drawing no. MCE / TKII / 2022 / 06-07 / 02, Rev.01 (Suppliers drg.).
6.2 Carrier Geometry 16600mm horizontal & 4525mm vertical pulley c/c
6.2.1 Belt Width 2400 mm
6.2.2 Length 17.205 m along the belt.
6.2.3 Inclination 15.24o with the horizontal
6.3 Belt
6.3.1 Type N/N, 630/4, top/bottom cover 5/2 thick.

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
6.3.2 No. of ply 4
6.3.3 Take up Screw take up.
6.3.4 Belt strength 630 kN
6.4 Details of construction
6.4.1 Head Pulley Rubber lagged dia. 630mm x 2600 face width.
6.4.2 Tail / Snub pulley 500 mm / 320 mm dia.
6.4.3 Carrying / Return Idlers 140 mm / 114.3 mm dia.
6.4.4 Skirt board 2200mm W x 450mm H Trough provided throughout the length.
6.4.5 Internal scraper Vee type
6.4.6 External scraper Weight actuated type
6.4.7 Deck plate Provided at the feeding point
6.5 Conveyor speed Variable, 8 80m/min.
6.6 Make Material Conveying Engineers, Gaziabad.
Cane & belt conveyor drive Please refer drive and coupling schedule
th
7 Bagasse Belt Conveyor after 4 mill
7.1 G.A. drawing no. MCE / TKII / 2022 / 06-07 / 03, Rev.02 (Suppliers drg.).
7.2 Carrier Geometry 14000mm horizontal & 3750mm vertical pulley c/c
7.2.1 Belt Width 2000 mm
7.2.2 Length 14.494 m along the belt.
7.2.3 Inclination 15o with the horizontal
7.3 Belt
7.3.1 Type N/N, 630/4, top/bottom cover 5/2 thick.
7.3.2 No. of ply 4
7.3.3 Take up Screw take up.
7.3.4 Belt strength 630 kN
7.4 Details of construction
7.4.1 Head Pulley Rubber lagged dia. 500mm x 2200 face width.
7.4.2 Tail / Snub pulley 400 mm / 320 mm dia.
7.4.3 Carrying / Return Idlers 140 mm / 114.3 mm dia.
7.4.4 Skirt board 1700mm W x 550mm H Trough provided for 2500mm length.
7.4.5 Internal scraper Vee type
7.4.6 External scraper Weight actuated type
7.4.7 Deck plate Provided at the feeding point
7.5 Conveyor speed Fixed, 80m/min.
7.6 Make Material Conveying Engineers, Ghaziabad.

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
Cane & belt conveyor drive Please refer drive and coupling schedule
C CANE PREPARATION UNITS
a. Kicker / Chopper

1.0 General
1.1 G. A. Drg. No. MP - 4498 - 1 / 0
1.2 Type FIXED KNIFE
1.3 Quantity 1x
Width of Carrier/Skirt Board (W)
1.4 2500
mm
1.5 Direction of rotation Reverse
1.6 Clearance from slat 1000
2.0 Drive
2.1 Drive-Single side / Double side Single
2.2 Electric Motor Type SPDP, SLIP RING, LT
2.3 Motor HP / RPM 1 x 500 HP x 1500
Helical, S. F. = 2.0
2.4 Reduction Gear Box
Ratio = 7.2
2.5 Coupling (Input / Output) Gear couplings, 'GBM' make RG 06 / RG 09
3.0 Rotor Assembly
3.1 C/C Bearings (mm) 3250
3.2 RPM of Rotor (Nominal) 200
3.3 Max. Peripheral/Tip Speed (m/sec) 18.8
3.4 Swing Dia. (mm) 1800
3.5 Shaft dia at Hub (mm) 300
3.6 Shaft dia at Brg.(mm) 220
3.7 Shaft extension At both ends
C 45 E
3.8 Shaft material
Ultrasonically Tested
3.9 No. of Flywheels 1 No.
3.10 Knife / Spike Type / Wt.(kg) Fixed / 16 kg.
3.11 No. of Knives 60
3.12 Knife material IS: 2062 Gr. ' B '
3.13 No. of Hubs / Knife holders 30
3.14 Hub / Knife holder material IS: 1030, Gr. 280- 520 N
4.0 Bearing Assembly
4.1 Bearing No. 23048 CCK / C3 / W33
4.2 Adaptor Sleeve No. OH 3048 H
4.3 Bearing hsg. (1 Fixed + 1 Loose) SPLIT, SDGS 3048
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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
4.4 Bearing hsg. Material IS: 1030, Gr. 280- 520 N
4.5 Bearing Lubrication type Grease
b. Head on Cutter

1.0 General
1.1 G. A. Drg. No. MP - 4502 - 1 / 0
1.2 Type FIXED KNIFE
1.3 Quantity 1x
Width of Carrier/Skirt Board (W)
1.4 2500
mm
1.5 Direction of rotation Forward
1.6 Clearance from slat 50
2.0 Drive
2.1 Drive-Single side / Double side Single
2.2 Electric Motor Type SPDP, SLIP RING, LT
2.3 Motor HP / RPM 1 x 600 HP x 600 RPM
2.4 Reduction Gear Box -
2.5 Coupling (Input / Output) Gear coupling, 'GBM' make RG 08
3.0 Rotor Assembly
3.1 C/C Bearings (mm) 3250
3.2 RPM of Rotor (Nominal) 585
3.3 Max. Peripheral/Tip Speed (m/sec) 55.1
3.4 Swing Dia. (mm) 1800
3.5 Shaft dia at Hub (mm) 350
3.6 Shaft dia at Brg.(mm) 260
3.7 Shaft extension At both ends
C 45 E
3.8 Shaft material
Ultrasonically Tested
3.9 No. of Flywheels 1 No.
3.10 Knife / Spike Type / Wt.(kg) Fixed / 19.5 kg.
3.11 No. of Knives 60
IS: 2062 Gr. ' B ' with
3.12 Knife material
Domite tip
3.13 No. of Hubs / Knife holders 30
3.14 Hub / Knife holder material IS: 1030, Gr. 280- 520 N
4.0 Bearing Assembly
4.1 Bearing No. 23056 CCK / C3 / W33
4.2 Adaptor Sleeve No. OH 3056 H
4.3 Bearing hsg. (1 Fixed + 1 Loose) SPLIT, SDGS 3056
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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
4.4 Bearing hsg. Material IS: 1030, Gr. 280- 520 N
4.5 Bearing Lubrication type Grease
c. Cutter - II

1.0 General
1.1 G. A. Drg. No. MP - 4503 - 1 / 0
1.2 Type FIXED KNIFE
1.3 Quantity 1x
Width of Carrier/Skirt Board (W)
1.4 2500
mm
1.5 Direction of rotation Forward
1.6 Clearance from slat 25
2.0 Drive
2.1 Drive-Single side / Double side Single
2.2 Electric Motor Type SPDP, SLIP RING, LT
2.3 Motor HP / RPM 1 x 600 HP x 600 RPM
2.4 Reduction Gear Box -
2.5 Coupling (Input / Output) Gear coupling, 'GBM' make RG 08
3.0 Rotor Assembly
3.1 C/C Bearings (mm) 3250
3.2 RPM of Rotor (Nominal) 585
3.3 Max. Peripheral/Tip Speed (m/sec) 55.1
3.4 Swing Dia. (mm) 1800
3.5 Shaft dia at Hub (mm) 350
3.6 Shaft dia at Brg.(mm) 260
3.7 Shaft extension At both ends
C 45 E
3.8 Shaft material
Ultrasonically Tested
3.9 No. of Flywheels 1 No.
3.10 Knife / Spike Type / Wt.(kg) Fixed / 19.5 kg.
3.11 No. of Knives 92
IS: 2062 Gr. ' B ' with
3.12 Knife material
Domite tip
3.13 No. of Hubs / Knife holders 23
3.14 Hub / Knife holder material IS: 1030, Gr. 280- 520 N
4.0 Bearing Assembly
4.1 Bearing No. 23056 CCK / C3 / W33
4.2 Adaptor Sleeve No. OH 3056 H
4.3 Bearing hsg. (1 Fixed + 1 Loose) SPLIT, SDGS 3056
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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
4.4 Bearing hsg. Material IS: 1030, Gr. 280- 520 N
4.5 Bearing Lubrication type Grease
d. Comber I & II

1.0 General
1.1 G. A. Drg. No. MP - 5098 - 2 / 0 & MP - 5099 - 2 / 0
1.2 Type FIXED SPIKES
1.3 Quantity 1x
Width of Carrier/Skirt Board (W)
1.4 2200
mm
1.5 Direction of rotation Reverse
1.6 Clearance from slat NA
2.0 Drive
2.1 Drive-Single side / Double side Single
2.2 Electric Motor Type TEFC, Squirrel cage
2.3 Motor HP / RPM 20 HP x 1500 RPM
Helical, S. F. = 1.7
2.4 Reduction Gear Box
Ratio = 30
Pin Bush Type Couplings 'MACHWELD' make HMW 170 / HMW
2.5 Coupling (Input / Output)
370
3.0 Rotor Assembly
3.1 C/C Bearings (mm) 3200
3.2 RPM of Rotor (Nominal) 48
3.3 Max. Peripheral/Tip Speed (m/sec) 2.5
3.4 Swing Dia. (mm) 1000
3.5 Shaft dia at Hub (mm) 457mm O.D. Pipe
3.6 Shaft dia at Brg.(mm) 125
3.7 Shaft extension At both ends
C 45 E
3.8 Shaft material
Ultrasonically Tested
3.9 No. of Flywheels Not Required
3.10 Knife / Spike Type / Wt.(kg) Welded / 3 Kg
3.11 No. of Knives 72 Spikes
3.12 Knife material Spike, IS : 2062, Gr. 'A'
3.13 No. of Hubs / Knife holders NA
3.14 Hub / Knife holder material NA
4.0 Bearing Assembly
4.1 Bearing No. 23028 CCK / C3 / W33
4.2 Adaptor Sleeve No. H 3028

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
4.3 Bearing hsg. (1 Fixed + 1 Loose) SN 3028
4.4 Bearing hsg. Material IS: 1030, Gr. 280- 520 N
4.5 Bearing Lubrication type Grease
D AUTOMATIC CANE Refer separate manual
FEEDING DEVICES
E MILLING PLANT
1 Mills GRPF
1.1 Type Three roller mill having GRPF and full size grooved under feed
roller Mill nos. 1 and 4,
Three roller mills having full size grooved under feed roller Mill
nos. 2 and 3.
1.2 Quantity 4
1.3 Size 1100mm (OD) x 2134mm 1150mm (OD) x 2134mm
1.4 Journals
1.4.1 Size, Dia. X length 500 mm x 660 mm 400 mm x 570 mm
1.4.2 Journal centre distance 3200 mm
1.5 Mill Rollers
1.5.1 Material of construction Coarse grain cast iron, conforming to IS: 11201.
Roller shell hardness 180 -210 BHN
Composition of the shell Total carbon - 3.20 to 3.6 %
material Manganese -2.2 to 3.2 %
Silicon - 1.2 to 2.2 percent
Phosphorus - 0.5 % Max.
Sulphur -0.15 % Max.
1.5.2 Material of construction of Roller 45 C8 IS:1570
Shaft
Shaft size at drive end 340 mm diameter 340 mm diameter.
Shaft Diameter at centre 545 mm (nominal) 450 mm (nominal)
1.6 Crown pinions
1.6.1 Main Crown pinions
Material IS:2708 Gr.3 with well dressed, properly profile moulded teeth
Face width 400 mm
No. of teeth 16
Working range 1040 ~ 1130 mm
1.6.2 GRPF Crown pinions
Material IS:2708 Gr.3 with well dressed, properly profile moulded teeth
Face width 400 mm
No. of teeth 16
Working range 1130 ~ 1220 mm
1.6.3 UFR Crown pinions

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
Face width 250 mm
No. of teeth, driving pinion 20, material of construction IS 2708 Gr. 3
Working range 1300 to 1400mm
No. of teeth, driven pinion 18, material of construction IS 2708 Gr. 3
Working range 1300 to 1400mm
1.7 Headstocks
1.7.1 Mill Headstocks
Type Pin type
Material IS:1030 Gr.280~529W
Wear plates Renewable gun metal IS: 318 Gr. LTB 2 wearing plates on feed
side as well as discharge side and with lubricating arrangement
between top roller bearings and wearing plates.
The eccentricity between top roller bearing centre and hydraulic
cap centre is 30 mm towards the feed side of the headstock.
Top and side caps IS:1030 Gr. 280~529W
GRPF Headstocks
1.7.2 Type Cast steel
Material IS:1030 Gr.280~529W
Top caps IS:1030 Gr.280~529W
1.8 Top roller bearing assembly
1.8.1 Material Housing of Cast steel IS 1030 Gr. 280 ~520W with Gunmetal IS:
318 Gr. LTB 2 renewable bearing liner with white metal lining as
per IS: 25.
1.8.2 Cooling of Bearings Water cooling arrangement
1.9 Side roller bearing assembly
1.9.1 Material Housing of Cast steel IS 1030 Gr. 280 ~520W with Gunmetal
IS:318 Gr. LTB 2 renewable bearing liner with white metal lining
as per IS: 25.
1.9.2 Cooling of Bearings Water cooling arrangement
Top roller bearings are interchangeable. Similarly feed side and
discharge roller bearings are interchangeable by their respective
bearings
1.10 Trash beam IS:1030 Gr.280~529W
1.11 Trash plates
Material of construction Cast steel IS:1030 Gr. 280-520W for mill nos. 1,2 & 3,
Forged, normalised for mill no. 4. All trash plates are with wear
protective coating of hardness 55 62 HRC.
Trash plate adjustment In Horizontal, swivel and vertical directions.
1.12 Scrapers
Top roller scrapers Floating, renewable cast iron IS: 210 Gr. FG 200
Discharge roller scrapers Renewable cast iron IS: 210 Gr. FG 200.

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
1.13 Messchaert groove scrapers Spring steel strips secured on square shaft and supported on steel
blocks and provided with lever.
1.14 Juice trough 6 mm thick SS 409, bolted to the headstocks with SS 309 bolts and
washers.
1.15 Loading system Hydraulic loading system
Accumulator 50 L capacity Hydro-pneumatic accumulator, one for each of the
journal of the top roller, one extra as spare.
Hydraulic ram for top cap Diameter of 400 mm
Hydraulic system oil pressure 280 bar (Rated pressure) 350 bar (test pressure).
Actual set pressure shall be 160 to 220 bar progressively
increasing from first to last mill based on brix curve, power
and capacity of the tandem. Refer attached chart.
1.16 Lubrication system
Type of system Forced feed oil lubricator, Cenlub make, (100bar max. working
pressure) for each mill having 24 points.
2 Grooved under feed roller
2.1 Size of roller Outside Dia. of 1100 mm x 2134 mm
2.2 UFR Shaft Details
Material 45 C8 IS 1570
Diameter at bearing 280 mm
Diameter at centre 350 mm
2.3 Speed About 10% higher than the mill roller surface speed
2.4 Adjustment of setting + 25 mm in both the directions.
1.17 Donnelly type Chute
For first mill 1 Nos
Height ~4000 mm
Inclination 90o
Location At the discharge ends of Belt Conveyor after shredder.
Material of construction 6mm thick SS AISI409.
Special features Provision of level sensors for auto- cane feeding arrangement
Adjustment of opening by setting the top and bottom plates up to
+100mm than the original opening for accommodating higher
diameter of rollers and higher capacity of the milling tandem.
G.A. drawing no. MP-1049-0/A
For second & third mill 2 Nos
Height ~4300 mm
Inclination 90o
Location At the discharge end of Interrake Carrier
G.A. drawing no. MP-1050-0-A , MP-1051-0/A
For fourth mill 1 Nos

16
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
Height ~4000 mm
Inclination 90o
Location At the discharge end of Interrake Carrier
G.A. drawing no. MP-1052-0/A
3 Single scroll screw conveyor below rotary screen
3.1 G.A. drawing no. PE / MH 83 / 084 00 001, Rev.2 (Suppliers drg.).
3.2 Make Powercon Equipments, Pune.
3.3 Conveyor geometry 5000mm inlet to outlet c/c, 400mm screw pitch, 600mm screw
diameter, trough suitable to handle rotary screen outlet screened
juice mixed with bagasse, juice drainage provision.
3.4 Construction Trough 5 mm SS409, screw 6mm SS409, screw pipe 324mm OD
6mm SS409.
3.5 Drive 15HP motor coupled to Helical speed reduction Gear box to attain
a final speed of ~40 RPM
4 Rake type intermediate carriers As follows:-
between 1st , 2nd & 3rd mill
4.1 G.A. Drawing no. MP-1032-0/A qty. 2 nos for 15 m mill center distance
4.2 Carrier geometry 2150 mm ,10.75m horizontal & 9.25m vertical sprocket center
distance (40.70 inclination), suitable for 15m mill center.
4.4 Chain
4.4.1 Type Block type forged chain with SS pin, SS bush and K2 attachment at
every 3rd link.
4.4.3 Pitch 229 mm
4.4.4 Breaking Strength 80,000 kg
4.4.5 Locking arrangement of chain With nut and split pin
4.5 Matl. of construction
4.5.1 Head Shaft
Material 45 C8 IS 1570.
Diameter at center 250 mm
Diameter at bearing 200 mm
Head shaft Bearings Spherical double roller antifriction bearing with CS housing
4.5.2 Tail Shaft
Material 45 C8 IS 1570.
Diameter at center 170 mm
Diameter at bearing 160 mm
Head shaft Bearings Spherical double roller antifriction bearing with CS housing
4.5.3 Sprocket wheel
Driving Sprocket 14 teeth 229 pitch
Driven Sprocket 14 teeth 229 pitch
Chain Tension Sprocket 12 teeth 229 pitch

17
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
Teeth Machine Cut teeth
Material Cast steel IS1030 Gr. 280-520W

4.6 Trough and frame IS 2062 Gr. A


4.7 Drive arrangement Please refer drive and coupling schedule
5 Rake type intermediate carriers As follows:-
between 3rd & 4th mill
5.1 G.A. Drawing no. MP-1022-0/A, qty. 1 nos. for 15m mill centre distance.
5.2 Carrier geometry 2150mm, 9.29m horizontal and 10.5m vertical sprocket centre
distance (48.50 inclination), suitable for 15m mill centers.
5.4 Chain
5.4.1 Type Block type forged chain with SS pin, SS bush and K2 attachment at
every 3rd link.
5.4.2 No. of Strands 2
5.4.3 Pitch 229 mm
5.4.4 Breaking Strength 80,000 kg
5.4.5 Locking arrangement of chain With nut and split pin
5.5 Matl. of construction
5.5.1 Head Shaft
Material 45 C8 IS 1570.
Diameter at center 250 mm
Diameter at bearing 200 mm
Head shaft Bearings Spherical double roller antifriction bearing with CS housing
5.5.2 Tail Shaft
Material 45 C8 IS 1570.
Diameter at center 170 mm
Diameter at bearing 160 mm
Head shaft Bearings Spherical double roller antifriction bearing with CS housing
5.5.3 Sprocket wheel
Driving Sprocket 14 teeth 229 pitch
Driven Sprocket 14 teeth 229 pitch
Chain Tension Sprocket 12 teeth 229 pitch
Teeth Machine Cut teeth
Material Cast steel IS1030 Gr. 280-520W
5.6 Trough and frame IS 2062 Gr. A
5.7 Drive arrangement Please refer drive and coupling schedule
F IMBIBITION EQUIPMENT and MIXED JUICE PUMP
1 Juice, water Tanks & Pumps

18
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
1.1 Imbibition juice
1.1.1 Whirler below mill no 3 & 4 3rd mill: whirler, 1300 x 1200 mm straight height, 5mm thick
AISI409.
4th mill: whirler , 1200 x 1200 mm straight height, 5mm thick
AISI409.
1.1.2 Outlet and overflow gutters 6 thick AISI409, to connect the juice tray and whirler tanks and
interconnection between whirler tanks.
1.1.3 Imbibition juice piping 200 MS ERW heavy.
1.2 Unscreened juice
1.2.1 Whirler below mill no. 1 and 2 1st mill: whirler, 1500 x 1200 mm straight height, 5mm thick
AISI409
2nd mill: Common whirlers, 1500 x 1200 mm straight height,
5mm thick AISI409.
1.2.2 Unscreened juice piping 250 MS ERW heavy.
1.3 Screened juice
1.3.1 Screened juice tank 2500 x 3000 mm height, 5mm thick AISI409, 90 HL capacity.
1.3.2 Screened juice piping 250 MS ERW heavy.
1.4 Imbibition water
1.4.1 Imbibition water flow meter Water flow meter, 150 Cub.M
1.4.2 Imbibitions water piping 125 MS ERW medium.
1.5 For imbibition juice, unscreened Please refer pump schedule
juice, screened juice & imbibition
water pump details:-
G MILL HOUSE CRANE AND GANTRY
1 Crane details Three motions electrically operated overhead travelling crane
conforming to class II IS specification 807 & 3177:1977 having
box type bridge girder.
1.1 Make Rachitech Engineering Pvt. Ltd.
1.2 Duty Indoor
1.2.1 S.W.L. (202=40) Tonnes
1.2.2 Aux. crab 5 Tonnes
1.3 Span of Crane 24 m to suit mill house span of 26m
1.4 Height of lift 14.5m
1.5 Crane Drive Electric drive, S4 duty AC 3 phase, make CG / BBL
1.5.1 Hoisting drum drive TEFC Slipring-30 HP,960 RPM
1.5.2 Long travel TEFC Slipring 12.5HP,960 RPM
1.5.3 Cross travel drive TEFC Slipring 10 HP,960 RPM
1.6 Crane gearboxes Helical, crane duty, dust free
1.6.1 Make Crane manufacturers own make.
1.6.2 Details Hoist:RHDR400,31.5:1& 1 open Zg=103,Zp=19,M=8
Long travel:RVTR400,72:1, Cross travel:RHDR350,31.5:1&1open
Zg=6,Zp=14,M=8
19
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR.
PARTICULARS OF PLANT
NO.
1.7 Wire rope Fibre core construction IS2266
1.8 Crane control From floor by means of pendant suspended from trolley.
1.9 Crane speeds
1.9.1 Hoisting 2 M/min
1.9.2 Long travel 10 M/min
1.9.3 Cross travel 10 M/min
1.10 Brake Electro hydraulic thruster type.
1.11 Long travel & DSL length 84 m
1.12 G.A. Drawing no. A1/2006-06/01 Manufacturers dwg.

2 Crane gantry and rail


2.1 Gantry WPB 700300149.9 supported on mill house building columns.
2.2 Long travel rail CR 80 rail
Cross travel rail 50 mm sq bar
2.3 Gantry Span 24 m rail c/c
2.4 Gantry length 84m

20
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

2. PUMP SCHEDULE
PUMP DETAILS QTY., MOTOR DETAILS
SR. SIZE &
DESCRIPTION CAPACITY (WORKING + MAKE
NO. HEAD-M MODEL HP RPM
M3/Hr. STAND-BY)
HOT WATER IMBIBITION Sintech Precision
1 150.00 60 2,( 1 + 1 ) CPS 150 320 60.00 1440
PUMP Products Ltd.
Sintech Precision
2 IMBIBITION JUICE PUMP 200.00 16 2,( 2 + 0 ) STF 150 32M 30.00 960
Products Ltd
Sintech Precision
3 SCREENED JUICE PUMP 400.00 24 2,( 1 + 1 ) CPS 150 320 50.00 1440
Products Ltd
UNSCREENED JUICE Sintech Precision
4 250.00 16 2,( 1 + 1 ) CPS 150 32H 40.00 960
PUMP Products Ltd

21
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

3. COUPLING SCHEDULE
SIZE OF THE COUPLING BETWEEN
SR.
EQUIPMENT
NO.
MOTOR & GEARBOX GEARBOX & EQUIPMENT

1 AUXILLARY CANE CARRIER PINBUSH TYPE SIZE 2.625" N.A.

2 CANE CARRIER PINBUSH TYPE SIZE 3.25" N.A.

3 RAKE ELEVATOR PINBUSH TYPE SIZE 3.25" N.A.

RAKE INTERCARRIER 3 IN FLUID COUPLING


4 N.A.
NOS. MODEL SM-6
BELT CONVEYOR AFTER FULL FLEXIBLE GEAR COUPLING
5 PINBUSH TYPE SIZE 2.125"HD
FOURTH MILL GC-106 NU
BELT CONVEYOR BEFORE FULL FLEXIBLE GEAR COUPLING
6 PINBUSH TYPE SIZE 2.375"HD
MILLS 2 IN NOS GC-108 NU

22
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

4. DRIVE SCHEDULE
GEAR BOX INSTALLED V.SPEED GEARBOX REQUIRED
SR. GEARBOX OPEN GEAR & FINAL
FOR QTY. MOTOR OUTPUT OUTPUT NOMINAL GEARBOX SIZE
NO. INPUT RPM PINION SPEED, RPM
EQUIPMENT HP/RPM RPM RPM RATIO

AUXILLARY 442.5- 120/25T,16M HELICAL,


1 1X 45/1475 442.5-1475 4.92-16.39 90 3.41
CANE CARRIER 1475 250FW PD31 R11 V41 90:1

MAIN CANE 108/25T,25M HELICAL,


2 1X 75/1480 444-1480 444-1480 4.44-14.8 100 3.43
CARRIER 250FW PD40 R11 V12 100:1

RAKE 80/34T,16M HELICAL,


3 1X 55/1480 444-1480 444-1480 5.55-18.5 80 7.87
ELEVATOR 230FW PD31 R11 V12 80:1

RAKE INTER 80/30T,16M HELICAL


4 3X 37/1470 --- 1470 21 71 7.75
CARRIER 160FW. PD28 R11 V12 71:1
BELT
CONVEYOR HELICAL
5 1X 22/1460 --- 1460 52 28 N.A. 52
AFTER 4TH PD18 R11 V12 28:1
MILL
BELT
CONVEYORS
BEFORE HELICAL
6 2X 37.28/1480 --- 1480 41.7 35.5 N. A. 41.7
SHREDDER & PD22 R11 V00 35.5:1.
AFTER
SHREDDER

23
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

5.SCHEDULE OF LUBRICANTS
SR. ITEM DESCRIPTION METHOD OF QTY OF TRADENAME OF TRADENAME OF TRADENAME OF TRADENAME OF
NO. APPLICATION LUBRICANT. HPCL BPCL GULF IOCL
3 NOS. HYDRAULIC CANE UNLOADERS
I) MOTORS GREASE GUN 25 Kg LITHON 2 SHELL MP Grease 2 MP Grease 2 SERVOGEM-2
II)HYDRAULIC MEDIUM FOR GRAB OIL FILLING 200 L 68 CCU ENKLO 68 Harmony AW 68 SERVOSYSTEM 68
MECHANISM
III) TRACK WHEELS BY HAND 25 L BHARAT HYDRO SERVOCYL C 530
220
IV) PLAIN SLEEVE BEARINGS FOR TRACK GREASE GUN 10 Kg LITHON 2 SHELL MP Grease 2 MP Grease 2 SERVOGEM-2
WHEELS
V) ANTIFRICTION BEARINGS FOR TRACK GREASE GUN 10 Kg CAMEX SERVOGEM-2
WHEELS COMPOUND D
VI) SHEAVE AND HOOK BLOCK PLAIN GREASE GUN 5 Kg CAMEX SERVOLEX L1
SLEEVE BRGS. COMPOUND D
VII) SHEAVE AND HOOK BLOCK GREASE GUN 5 Kg CAMEX SERVOLEX L1
ANTIFRICTION BRGS. COMPOUND D
VIII) WIRE ROPE BY HAND 10 Kg CADMIUM CADMIUM
COMPOUND COMPOUND
IX) OPEN SPUR GEARING BY HAND 80 L HYTAK 1 SHELL SG II SEVOCOAT 120
X) VARIOUS GEAR BOXES OIL FILLING 100 L BHARAT SERVOCYL C 530
COMPOUND O
XI) HOOK SWIVEL BY HAND 1 Kg LITHON 2 SHELL MP Grease 2 MP Grease 2 SERVOGEM-2
XII) ELECTRICAL PARTS BY HAND 100 Kg SILICONE SPRAY SILICONE SPRAY SILICONE SPRAY SILICONE SPRAY
ONE NO. - HYDRAULIC TRUCK TIPPER
Hydraulic Power Pack Oil Filling 100 L Servo System 68 Servo System 68 Servo System 68 Servo System 68
Pins At Various Locations GREASE GUN 10 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO. - TIPPER (AUXILIARY)
CARRIER WITH DRIVE
I)CHAINS GREASE GUN 50 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) BEARINGS OF DRIVING AND DRIVEN GREASE CUP 8 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
SHAFTS
III)OPEN GEARS SUMP LUBRICATION 30 L HYTAK 1 SHELL SG II SEVOCOAT 120
IV) ENCLOSED REDUCTION GEAR BOX OIL FILLING 64 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
(PD31)
V)MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO. - MAIN CANE CARRIER WITH
24
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR. ITEM DESCRIPTION METHOD OF QTY OF TRADENAME OF TRADENAME OF TRADENAME OF TRADENAME OF


NO. APPLICATION LUBRICANT. HPCL BPCL GULF IOCL
DRIVE
I)CHAINS GREASE GUN 50 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) BEARINGS OF DRIVING AND DRIVEN GREASE CUP 8 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
SHAFTS
III)OPEN GEARS SUMP LUBRICATION 30 L HYTAK 1 SHELL SG II SEVOCOAT 120
IV) ENCLOSED REDUCTION GEAR BOX OIL FILLING 80 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
(PD40)
V) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO. - BELT CONVEYOR BEFORE
SHREDDER
I)VARIOUS PULLEYS AND GUIDES GREASE GUN 18 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) ENCLOSED REDUCTION GEAR BOX OIL FILLING 27 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
(PD22)
III) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO. - TRAMP IRON MAGNETIC
SEPARATOR
I)VARIOUS PULLEYS AND GUIDES GREASE GUN 20 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) ENCLOSED REDUCTION GEAR BOX OIL FILLING 20 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
III) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO - RAKE CARRIER
I) BEARINGS OF DRIVING,DRIVEN & GREASE CUP 16 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
IDLER SHAFTS
II)DRIVING CHAINS BY BRUSH 30 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
III)OPEN GEARS SUMP LUBRICATION 30 L HYTAK 1 SHELL SG II SERVOCOAT 120
IV) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
V) ENCLOSED REDUCTION GEAR BOX OIL FILLING 64 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
(PD31)
ONE NO. - BELT CONVEYOR AFTER SHREDDED CANE RAKE
CARRIER
I)VARIOUS PULLEYS AND GUIDES GREASE GUN 18 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) ENCLOSED REDUCTION GEAR BOX OIL FILLING 27 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
(PD22)
III) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO. - BAGASSE BELT CONVEYOR
AFTER 4TH MILL
I)VARIOUS PULLEYS AND GUIDES GREASE GUN 18 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
25
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR. ITEM DESCRIPTION METHOD OF QTY OF TRADENAME OF TRADENAME OF TRADENAME OF TRADENAME OF


NO. APPLICATION LUBRICANT. HPCL BPCL GULF IOCL
II) ENCLOSED REDUCTION GEAR BOX OIL FILLING 14 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
(PD18)
III) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO. - CANE KICKER WITH DRIVE
I)BEARINGS FILLING BY NIPPLE 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) KICKER DRIVE GEARED COUPLING GREASE FILLING 4 Kg LITHON 2/3 LANTHAX 2 GULF CROWN EP2 SERVOGEM-EP2
III) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) ENCLOSED REDUCTION GEAR BOX OIL FILLING 63 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
FOR KICKER (PIV.PC-31)
ONE NO. - CANE CUTTER - 1 WITH
DRIVE
I)BEARINGS FILLING BY NIPPLE 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) CUTTER DRIVE GEARED COUPLING GREASE FILLING 4 Kg LITHON 2/3 LANTHAX 2 GULF CROWN EP2 SERVOGEM-EP2
III) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO. - CANE CUTTER - 2 WITH
DRIVE
I)BEARINGS FILLING BY NIPPLE 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) CUTTER DRIVE GEARED COUPLING GREASE FILLING 4 Kg LITHON 2/3 LANTHAX 2 GULF CROWN EP2 SERVOGEM-EP2
III) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO. - CANE COMBER - 1 WITH
DRIVE
I)BEARINGS FILLING BY NIPPLE 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) ENCLOSED REDUCTION GEAR BOX OIL FILLING 9 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
FOR COMBER (PD16)
III) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
ONE NO. - CANE COMBER - 2 WITH
DRIVE
I)BEARINGS FILLING BY NIPPLE 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) ENCLOSED REDUCTION GEAR BOX OIL FILLING 9 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
FOR COMBER (PD16)
III) MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
JUICE & WATER PUMPS, MOTORS. FILLING BY NIPPLE 30 L LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
FOUR NOS. CANE MILLS
I)MILL BEARINGS AND TOP ROLLER OIL FILLING IN 120 L CRUSHWELL 2 SHELL SMG 75 SERVOSM-175 / 85*
GUIDES LUBRICATOR

26
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR. ITEM DESCRIPTION METHOD OF QTY OF TRADENAME OF TRADENAME OF TRADENAME OF TRADENAME OF


NO. APPLICATION LUBRICANT. HPCL BPCL GULF IOCL
II)CROWN WHEELS SUMP LUBRICATION 450 L HYTAK 2 SEVOCOAT 140
3 NOS-INTERMEDIATE CARRIERS
I) BEARINGS OF DRIVING,DRIVEN & GREASE CUP 36 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
IDLER SHAFTS
II)DRIVING CHAINS BY BRUSH 60 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
III)OPEN GEARS SUMP LUBRICATION 60 L HYTAK 1 SHELL SG II SERVOCOAT 120
IV)FLUID COUPLING OIL FILLING 18 L ENKLO 32 SHELL SHO 32 SERVOSYSTEM-32
V) MOTOR GREASE FILLING 10 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
VI) ENCLOSED REDUCTION GEAR BOX OIL FILLING 14 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
(PD28)
ONE NO. - SCREW CONVEYOR WITH
DRIVE
I)BEARINGS FILLING BY NIPPLE 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
II) ENCLOSED REDUCTION GEAR BOX OIL FILLING 10 L PARTHAN EP 320 AMOCAM 320 EP Lubricant HD 320 SERVOMESH SP 320
(PD16)
III)DRIVING MOTOR GREASE FILLING 3 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
HYDRO PNEUMATIC ACCUMLATORS
I)HYDRAULIC MEDIUM CIRCULATION PUMP 500 L ENKLO 68 Harmony AW 68 SERVOSYSTEM -68
TWO NOS. - SHREDDER DRIVE GREASE APPLICATION 20 Kg LITHON 3 SHELL MP Grease 3 MP Grease 3 SERVOGEM-3
SLIPRING MOTOR
ONE NO - MILL HOUSE CRANE
I) MOTORS GREASE GUN 25 Kg LITHON 2 SHELL MP Grease 2 MP Grease 2 SERVOGEM-2
II) TRACK WHEELS BY HAND 25 Kg BHARAT HYDRO SERVOCYL C 530
220
III) PLAIN SLEEVE BEARINGS FOR TRACK GREASE GUN Kg LITHON 2 SHELL MP Grease 2 MP Grease 2 SERVOGEM-2
WHEELS
IV) ANTIFRICTION BEARINGS FOR TRACK GREASE GUN Kg CAMEX SERVOGEM-2
WHEELS COMPOUND D
V) SHEAVE AND HOOK BLOCK PLAIN GREASE GUN Kg CAMEX SERVOLEX L1
SLEEVE BRGS. COMPOUND D
VI) SHEAVE AND HOOK BLOCK GREASE GUN Kg CAMEX SERVOLEX L1
ANTIFRICTION BRGS. COMPOUND D
VII) WIRE ROPE BY HAND Kg CADMIUM CADMIUM
COMPOUND COMPOUND
VIII) OPEN SPUR GEARING BY HAND L HYTAK 1 SHELL SG II SEVOCOAT 120
IX) VARIOUS GEAR BOXES OIL FILLING 96 L BHARAT SERVOCYL C 530

27
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SR. ITEM DESCRIPTION METHOD OF QTY OF TRADENAME OF TRADENAME OF TRADENAME OF TRADENAME OF


NO. APPLICATION LUBRICANT. HPCL BPCL GULF IOCL
COMPOUND O
X) HOOK SWIVEL BY HAND Kg LITHON 2 SHELL MP Grease 2 MP Grease 2 SERVOGEM-2
XI) ELECTRICAL PARTS BY HAND 96 Kg SILICONE SPRAY SILICONE SPRAY SILICONE SPRAY SILICONE SPRAY

28
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

6. BEARING SCHEDULE

SR. BEARING DETAILS BEARING HOUSING DETAILS


EQUIPMENT
NO. TYPE SIZE LOCATION QTY. SIZE QTY.
Sph. Roller Bearing with adapter sleeve
Head Shaft 2 C.S. Antifriction Bearing housing with liner dia 300 1+1
AUXILLARY CANE 23064 CCK/W33
1
CARRIER Sph. Roller Bearing with adapter sleeve
Tail Shaft 2 C.S. Antifriction Bearing housing with liner dia 260 1+1
23056CCK/W33
Sph. Roller Bearing with adapter sleeve
Head Shaft 2 C.S. Antifriction Bearing housing with liner dia 300 1+1
CANE CARRIER 23064 CCK/W33
2
MAIN Sph. Roller Bearing with adapter sleeve
Tail Shaft 2 C.S. Antifriction Bearing housing with liner dia 260 1+1
23056 CCK/W33-
Sph. Roller Bearing with adapter sleeve
Head Shaft 2 C.S. Antifriction Bearing housing with liner dia 240 1+1
23052CCK/W33
Sph. Roller Bearing with adapter sleeve
Tail Shaft 2 C.S. Antifriction Bearing housing with liner dia 180 1+1
RAKE CANE 23040CCK/W33
3
CARRIER Sph. Roller Bearing with adapter sleeve
Chain tension 4 C.S. Antifriction Bearing housing with liner dia 180 2+2
23040CCK/W33
Sph. Roller Bearing with adapter sleeve
Idler 2 C.S. Antifriction Bearing housing with liner dia 180 1+1
23040CCK/W33
Sph. Roller Bearing with adapter sleeve
Head Shaft 6 C.S. Antifriction Bearing housing with liner dia 200 3+3
23044CCK/W33
Sph. Roller Bearing with adapter sleeve
4 RAKE INTER CARRIER Tail Shaft/ Idler 6 C.S. Antifriction Bearing housing with liner dia 150 3+3
23034CCK/W33
Sph. Roller Bearing with adapter sleeve
Chain tension 6 C.S. Antifriction Bearing housing with liner dia 180 3+3
23034CCK/W33
6 MILLS Assembly as per drawing no. MP-4390-2/0 Top Half
As per drawing no. MP-5032-2/0 Top roller 32 Assembly as per drawing no. MP-4360-2/0 Bottom 8
Half
As per drawing no. MP-3516-3/A U. F. R. 16 As per drawing no. MP-3479-3/0 8
29
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

6. BEARING SCHEDULE

SR. BEARING DETAILS BEARING HOUSING DETAILS


EQUIPMENT
NO. TYPE SIZE LOCATION QTY. SIZE QTY.
As per drawing no. MP-4392-1/0 Side roller As per drawing no. MP-1020-0/0 8 LH+8 RH

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SECTION II
ERECTION INSTRUCTIONS:
1. INTRODUCTION:
This manual contains all the information and instructions necessary for erection, operation and maintenance of
the Sugar Cane Milling Plant.
During assembly, repair and maintenance, it is essential to observe the local rules for safety and the prevention
of accidents. The operators or any other personnel in charge of the repair and maintenance work shall be made
conversant with the mechanical and electrical functioning mode of the plant to such an extent that they can
take immediate action in case of disturbance or emergency (e.g. accidents). It is advisable that the respective
personnel be given access to one copy of this instruction manual.
Care is to be taken when working on the rotating machine parts, whether for maintenance, repairs or
replacing spare parts, which the machine cannot be switched on. Appropriate safety measures must ensure
that nobody has an opportunity to switch on the machine during this working time.
When repairs are carried out on the rotating parts, it must be safeguarded to prevent it from rotating before
the work starts.

2. SAFETY INSTRUCTIONS:
- The plant is intended solely for the application agreed with the manufacturer. The manufacturer is not liable
for damage resulting from non-compliance. Unauthorised modifications and changes to the plant machines
carried out by the operator and which could impair the operation and safety of the machines are not
permitted and relieve ThyssenKrupp Industries India Pvt. Ltd. from all liabilities.
- It must be clear which members of the staff are responsible for assembly, commissioning, operation and
maintenance so that safety is not impaired when handling the plant.
- It is forbidden to stand under suspended loads.
- Electrical connections must be sufficiently protected. Damaged electrical wires must be replaced
immediately. Only skilled authorised person should carry out the work on the plants electrical equipment.
- Protective earthings must be carried out and checked with special care.
- Before starting any machine checks that the machines and their safety devices are in a safe condition and the
machine is complete with all accessories.
- Only original spares from ThyssenKrupp Industries India Pvt. Ltd may be used.

3. CANE CARRIER:
A thorough foundation survey is a pre-requisite before beginning with Erection of the Cane carrier. Check
foundations with respect to fore and aft centre lines and elevations at all column footings with respect to cane
carrier GA and foundation drawings. Prepare and place supporting packing plates for column base plates on
the foundations, which are then to be levelled by taper wedges.
Supporting structure at drive end should now be erected in position with foundation bolts in pockets. Level
and verticality should be adjusted. Distance from centreline of 1st Mill and Fibrizer Centre to the 1st set of
columns should be maintained correctly. Half grout all foundations pockets leaving adequate threaded portion
of the foundation bolt for adjustment.

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

After four days curing time for the grout, tighten foundation bolts and adjust levels correctly. All members of
the structure and sidewalls should now be fully tightened. Distance between sidewalls should be correctly
adjusted to the dimension shown in drawings to allow adequate clearance for the apron.
Mark required level for the driving shaft pedestal supporting brackets on both the main columns. Holding the
brackets in perfect level, check the level and alignment by straight edge. And weld the brackets to columns.
Driving shaft assembly with pedestal bearings is now to be placed in position. Scrape the bearings in position.
Driving shaft and tail shaft assemblies with sprockets and bearings to be placed in position and aligned at right
angles to the cane carrier centreline and parallel to each other. Teeth of two sprockets on each shaft shall be
aligned (in one line). Sprocket centres with respect to cane carrier centreline shall be checked at both Head
and Tail shaft. Fit wedge border and wedges. Tighten holding down bolts fully.
Complete all columns with side walls and idler pulleys or guide angles as provided including the take-up
structure with take-up shaft assembly. Complete alignment of runners and sidewalls maintaining required
distance between them so as to leave required clearance for the apron to run free without binding on sides. At
the driving end, the runners should be so adjusted that a line projected from the runner remains about 10 mm
below the carrier chain roller in the driving sprocket, at top position.
Complete installation of open gearing, gearbox and variable speed drive with motor. Open gearing shall be
checked by blue matching and measuring backlash at least in four places. After alignment secure drive
components on the base frame by stoppers to prevent shifting.
Assemble chain and apron slats in about 6 feet long lengths ensuring that direction of overlap of slats is as
shown in the drawings. Place these assembled lengths in position and complete assembly. Complete erection
of apron leaving sag between pair of idler pulley sets. This sag can be adjusted by take up screws as required.
Alternatively slats slide on angle runner supports provided inside the skirt boards on the return side.
For assembly of apron a suitable winch should be used. Assembly work can also be done with the help of
drive itself however one has to be very careful while doing so.

TRIAL RUN:
Before starting the carrier, ensure that correct grade of lubricating oil in filled in the enclosed reduction
gearbox and gear compound is added to hood of open gear. Also check and ensure that greasing arrangement
is provided for Drive and tail shaft bearings.
Check the carrier along its complete length for any possibility of fouling. Inch the drive, carefully observing
for any rubbing, fouling, and noise along the length of carrier.
After successful inching trial, carrier should be run for about four hours to check temperature, gearbox, motor
dynodrive operation etc.
Readjust the chain tension if necessary during and after trial operation before operating the carrier on load.

4.CANE KICKER / CHOPPER / CANE CUTTER / COMBER:


The foundation surface should be level and free from loose concrete. Check top face of foundation surface
for correct elevation. Tally the same with elevation required as per drawings in order to get the correct
clearance from knife top to apron top and also sufficient margin for grouting.
Mark centreline of preparatory device at right angles to Cane Carrier centreline correctly. Place the base
plates for bearing housings on top of foundation with required packing plates, ensuring that adequate
clearance margin for grouting is available. Check level on the top machined surface of the base plates with
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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

a straight edge resting on both the base plates. Level both base plates correctly, at the same time maintain
levels of both the plates by the straight edge also, adjusting shims where required. Grout the base plates
for the bearing housings. Insert & position the foundation bolts through the base plates & the anchor
plates.
After a lapse of 2 to 3 days, place the complete rotor assembly with bearing housings on the base plates.
Tighten the foundation bolts. Take out outer side covers of the pedestals to check clearance between
bearing rollers and outer race. Adjust, if required, as per recommended value in the drawings. Also
ensure that locknut is secured by bending locking tab on lock washer after adjusting clearance.
Ensure locating rings are fitted on the drive side and also ensure free float for shaft expansion on non-
drive side. Slide labyrinth bush back in position and lock with grub screw and bolt up end covers. See that
correct quality of grease is filled in 30% volume of the bearing housings.
Check clearance between labyrinth and side covers all over. Adjust by shims if required, Also ensure that
the labyrinth is locked leaving equal clearance on both sides between the grooves in cover plate.
Tighten all the bolts fully.
Install rotor-side coupling half on the rotor shaft and gear box / motor side coupling half on the gear-box
/ motor shaft.
Place foundation bolts for gear-box / motor in foundation pockets. Install gear-box /motor on the base
plates keeping at least 5-mm (total) shims between gear-box / motor base and base plates. Align couplings
correctly with the help of dial gauge, leaving a gap between coupling faces as per drawing. Foundation
bolts to be grouted after satisfactory alignment is obtained.
After adequate curing, say for four days, final adjustment of the coupling to be carried out by adjusting
shims, if required. Assemble pins and bushes in case of Pin-bush type coupling and sleeve halves in case
of Geared coupling only after no load trial of the motor.
Knives can now be fitted on the rotor. Torque tighten High tensile bolts of knives to specified torque as
per the chart enclosed.
COMBERS:
The comber assembly with bearings are to be directly placed on the mounting beams provided on the
support structure. Install rotor-side coupling half on the rotor shaft and gear-box / motor side coupling half
on the gear-box / motor shaft.
Install gear-box /motor on the base frame keeping at least 5-mm (total) shims between gear-box / motor
base and base plates. Align couplings correctly with the help of dial gauge, leaving a gap between
coupling faces as per drawing. mounting bolts to be tightened to the base frame after satisfactory
alignment is obtained.
TRIAL RUN
Initially, run the Kicker / Chopper / Cutters / Combers without load for at least 4 hours and watch
behaviour of the bearings. If bearings run hot, look for rubbing between labyrinth rings. Sometimes
bearings may overheat due to excess grease, which will melt and come out from bottom. This grease
should not be replaced. After stabilizing the bearings, Leveller / Chopper / Cutter / Kicker can be taken on
load.

IMPORTANT NOTE:
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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

BEFORE USING ARC-WELDING, FOR ANY REASON, ON THE ROTOR, FOLLOWING


PRECAUTION MUST BE TAKEN, OTHERWISE THE BEARINGS MIGHT BE PERMANENTLY
DAMAGED.
The precaution is to avoid the welding currents passing from the bearing inner race to the bearing outer
race by way of the rollers of the bearings. These currents might cause pitting at the bearing surfaces,
thereby, causing irreparable damages.
The idea, therefore, is to provide a better and alternate path for the welding currents. This is achieved
preferably by connecting the ground (or earth) connection of the welding set to any one of the rotor
hammers / rotor discs.
Alternatively, the ground connection of the welding set and rotor may both be connected to the nearest
available structural steel.
While lifting, moving or transporting the rotor for the purpose of erection or maintenance, care must
be taken to ensure that the rotor is never lifted or supported at bearings. This otherwise may damage
the bearings permanently. It is always advisable to lift the rotor winding a rope around the hub/ knife
holders, sufficiently away from the bearing housings.

5. RAKE ELEVATOR:
Supporting structure should be erected in position with foundation bolts in pockets and suitable packing
provided under column base plates. Level, verticality and spacing inside columns should be adjusted. Distance
from cross centreline of 1st Mill to the 1st set of columns should be maintained correctly as per drawing. Half
grout all foundations pockets leaving adequate threaded portion of the foundation bolt for adjustment.
After allowing sufficient time for grout to set in, bolts to be tightened and columns to be checked and minor
adjustment, if required, to be attended. Trough with supporting brackets to be placed in position and aligned
perfectly parallel to the centreline of tandem. It should be ensured that runners are correctly aligned, their
levels maintained as per drawings and welded joints in runners are ground smooth to ensure smooth operation.
Head shaft and tail shaft assemblies with sprockets and bearings to be placed in position and aligned at right
angles to the trough and parallel to each other. Teeth of two sprockets on each shaft shall be aligned (in one
line). Sprocket centres with respect to rake elevator centreline shall be checked at both Head and Tail shaft.
Head shaft centre distance from centreline of 1st mill to be maintained correctly as shown in drawing and
drive shaft bearings to be checked and scraped in position if necessary. Fit wedge border and wedges. Tighten
holding down bolts fully.
Complete installation of open gearing, gearbox and variable speed drive with motor. Open gearing shall be
checked by blue matching and measuring backlash at least in four places. Secure drive components on base
frame by stoppers to prevent shifting
Chain to be placed in position and then rakes are to be bolted on. When using block-type forged chain with
welded locking plates, care is to be taken to ensure that locking plates are welded using suitable special
welding electrodes only since lock plates welded using ordinary M.S. Electrodes will not withstand load and
will drop out. Chain to be only lightly tightened at the time of erection and is to be tensioned suitably during
and after no-load trials.

TRIAL RUN:

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

Before starting the elevator, ensure that correct grade of lubricating oil in filled in the enclosed reduction
gearbox and gear compound is added to hood of open gear. Also check and ensure that greasing arrangement
is provided for Drive and tail shaft bearings.
Check the elevator along its complete length for any possibility of fouling. Inch the drive, carefully observing
for any rubbing, fouling, and noise along the length of carrier.
After successful inching trial, carrier should be run for about four hours to check temperature, gearbox, motor
operation etc.
Readjust the chain tension if necessary during and after trial operation before operating the elevator on load.

6. RAKE TYPE INTER CARRIERS:


This equipment is similar to Rake Elevator and is to be installed between two successive mills with
feeding to the mills being done in most cases through a Donnelly chute. The erection procedure is same as
Rake Elevator. The drive for this is generally of a fixed speed type, consisting of Motor, Gearbox, Pinion
and a Gear. Trial runs to be carried out in the similar way as that for the Rake Elevator.

7. CONVEYING AND ELEVATING CHAINS:


INSTALLATION
General Requirements:

1. Shaft Alignment Shafts must be rigidly supported in properly designed bearings. Shaft
displacement will destroy the initial alignment and shorten chain and sprocket life. Align
the shaft horizontally with a levelling device. Head and tail shafts must be parallel and at
90o to the direction of travel of the chain or conveyor. Take-ups provide a means for shaft
alignment and chain tension adjustment.

2. Sprocket Alignment Sprockets must be in a line and not offset on the shafts. Abnormal
sprocket and chain sidebar wear will result if alignment is not maintained.

When two or more strands of chain must operate as a unit, as in a double strand conveyor, the
sprocket teeth on the head shaft must be timed to pick up the load on each chain
simultaneously. Aligning the keyways in the shaft and then aligning the keyways of the
sprockets, on tooth centerline, will assure the proper match. Sprockets should be ordered
keywayed-in-line and matched in pairs. Since the tail shaft is an idling shaft it is usually
keyed to only one sprocket. The other sprocket(s) is held in alignment by set collars and is
allowed to turn freely. This permits the sprocket to position itself if uneven wear takes place
in the chain strands.

3. Chain Place the chain around the sprockets with the free ends meeting on one sprocket.
When assembling straight sidebar chains, insert the connecting link and then the closing bar
over the pins. Drive the closing bar onto both pins at the same time taking care not to bend
the link. Most chains are designed with a press-fit between the pins and bars. Do not grind
away a pin end so that it fits loosely in the chain sidebar.

If a multiple strand installation, where the chains must operate as a unit, be sure the chains
are reasonably matched for equal length. Uneven loading may result if they are not matched.

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

Proper chain tension is essential. A chain that is too tight will cause an overload condition.
A chain that is too loose may cause pulsation or interference, which result in abnormal chain
and sprocket wear.

4. Freedom from Interference Contact between the moving parts of the conveyor and adjacent
objects must not occur. Clearance should be provided to allow for normal chain sag and take-up
movement. Guides and tracks should be smooth and free of foreign objects. Exit and entry points of
guides and tracks must permit the chain to pass with a minimum amount of impact or interference.

Start-up:

1. Adjust chain tension. On high temperature applications chains must be adjusted while cold.

2. Check conveyor and surrounding area for tools, loose parts, etc. which might obstruct conveyor
operation or create a safety hazard.

3. Jog conveyor through one complete cycle.

4. Start conveyor and run with no load. Make certain that all chain joints flex freely.

5. If the application permits the use of oil, lubricate each chain joint with a good grade of non-detergent
petroleum base oil. The oil should be applied between the sidebars at each joint and be of a viscosity
such that it will flow freely into the pin-bushing area. Grease may be used if it can be applied
(forced) directly to the pin-bushing area. However, heavy grease applied to the outside will not flow
into the joint and may even act as a barrier to subsequent lubrication or trap contained materials inside
the joint.

6. A break-in-running period of 8 to 12 hours, under no load, will normally allow the chain joints to seat
properly. It is normal for the chain to elongate slightly during this period. A final adjustment of the
take-ups may be required.

OPERATION

Loading:

1. Loading any conveyor should be accomplished as gently as possible to reduce impact. The load
should, if possible, be placed or slid on to the conveyor to reduce surging caused by rough and
irregular loading.

2. Unload the conveyor before shutting it down. Starting a loaded conveyor placs extra strain on all the
equipment.

3. A conveyor should be run occasionally during extended shut down period to keep the working parts
of the system free from corrosion and in operating condition. Overloads and shortened life will result
if the system is allowed to bind up from corrosion.

MAINTENANCE

A chain conveyor, like any other operating equipment, requires good maintenance to obtain long life and
satisfactory performance.
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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

In the following paragraphs, it is assumed that: (1) the components of the system have been properly selected
for the application; (2) the shafts, sprockets and conveyor have been installed correctly; and (3) adequate
lubrication has been provided.

INSPECTION SCHEDULE

The major requirement is to establish a practical schedule and to follow it faithfully. Experience will indicate
any need for changes in the schedule.

As with all new equipment, some readjustment may be required during the initial break-in period.
Therefore, the initial schedule should provide for frequent inspections. After the system has been run-in, the
time between inspections may be extended. Such changes should be made gradually as experience indicates.

Inspection Items:

1. Lubrication It has been shown that a separating wedge of fluid lubricant is formed in operating
chain joints much like that formed in journal bearings. Therefore fluid lubrication must be applied to
assure an ample oil supply to minimize metal to metal contact.

Manual Make sure the lubrication schedule is being followed, and that the oil is being properly
applied.

Drip Inspect the filling of oiler cups and the rate of feed. Check that the feed pipes are not
clogged and are properly positioned over the chain.

Bath Inspect the oil level and check that there is no sludge. Drain, flush and refill the system,
as the application requires.

If the chains have not been lubricated properly, the joints may have brownish (rusty) color and the
pins of the connecting link of the chain, when removed, may be discolored (light or dark brown).
Also, the pins may be roughened, grooved or galled.

Properly lubricated chains will not show the brownish colour at the joints but will be brightly polished
with a very high luster.

2. Wear on link plates and sides of sprocket teeth Such wear indicates misalignment.

3. Shaft and sprocket alignment Check shaft and sprocket alignment directly. This check may
reveal misalignment before wear on chains and sprockets become apparent.

4. Wear on working faces of sprocket teeth Check for wear on the working faces of the sprocket
teeth. As the system runs in, these faces should develop a bright polished appearance. Scratches,
galls, grooves or visible changes in tooth form are signs of trouble, probably caused by lubrication
failure or overloading.

5. Chain tension should be checked and adjusted.

Chain elongation An elongation of as much as six percent indicates that the chain is riding near its
limit of allowable height on the sprocket teeth.

A gradual increase in chain length is the result of normal wear. A sudden increase in slack indicates
one or more of the following:

a) Lubrication failure;
b) Excessive overloading or shock;
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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

c) Displacement of shaft bearings;


d) Displacement or failure of take-ups.

6. Inspect the chain periodically to be sure it is free from dirt, grit or other abrasive material. Clean our
extraneous material from the chain, especially the kind that sets up or hardens. Even under the best
operating conditions periodic cleaning of the chain is good economy. Gummed lubricant and the
products of normal wear can cause rapid pin and bushing wear.

7. Guides, tracks and the area below the conveyor should be inspected frequently for build up of
material or dirt, which will cause interference or binding of the chain. Exit and entry points of guides
and tracks must permit the chain to pass with a minimum amount of impact or interference. If
lubricated, check for proper lubrication. Roller chain tracks can be over-lubricated reducing the
friction to the point where the rollers will slide rather than roll.

8. Exceptionally low chain conveyor speed coupled with high drag friction will occasionally cause
surging. A slight increase in speed will correct this problem if the friction cannot be reduced.

9. Apron and pan bead openings should be inspected. If the beads have been wedged apart or otherwise
distorted fine material may leak into moving parts and cause excessive wear.

Objectionable Procedures:

1. New link in an old chain Never insert a new link in a chain that has been appreciably
elongated by wear. The pitch of the new link will be shorter that of the other links, and the
resulting shock, each time the link engages the sprocket, will reduce the life of the chain.

2. New chain on worn sprockets Do not install a new chain on badly worn sprockets. A few
hours operations under such conditions can do more damage to the chain than months of
normal use.

Storage of idle chains and sprockets:

Unless properly protected, the components of a conveyor system deteriorate during long periods of
idleness. If a chain is to be stored, remove it from the sprockets, clean and reoil it and cover it with heavy
grease. Store the chain where it will be protected from moisture and mechanical injury.

The sprockets may be left in place on the shafts. Cover each with heavy grease and protect them from
mechanical injury.

Before placing the conveyor in service again, thoroughly clean the chain and sprockets or remove the
protective grease; then relubricate the chain.

Operation of elevators:

Adjust take-ups or check out functioning of gravity take-ups before putting elevator into operation. Then
start the new elevator chain or replacement chain by jogging the system through the complete cycle. If no
problems arise, run the chain in for about four hours without a load. After this break-in period normal
operation may begin.

39
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

Material should not be allowed to build up in the boot by overloading. Properly regulated flow, within the
capacity of the buckets, will extend service life and prevent surging caused by the buckets digging out the
boot.

During normal operation start the elevator empty. This prevents overload of chain and ensures that
elevator is not stooped loaded with a danger of back run.

IMPORTANT NOTE:
BEFORE USING ARC-WELDING, FOR ANY REASON, ON ANY ROTATING PART, FOLLOWING
PRECAUTION MUST BE TAKEN, OTHERWISE THE BEARINGS MIGHT BE PERMANENTLY
DAMAGED.

40
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

The precaution is to avoid the welding currents passing from the bearing inner race to the bearing outer race
by way of the rollers of the bearings. These currents might cause pitting at the bearing surfaces, thereby,
causing irreparable damages.
The idea, therefore, is to provide a better and alternate path for the welding currents. This is achieved
preferably by connecting the ground (or earth) connection of the welding set to any one of the rotor
hammers / rotor discs.
Alternatively, the ground connection of the welding set and rotor may both be connected to the nearest
available structural steel.
While lifting, moving or transporting the rotor for the purpose of erection or maintenance, care must be
taken to ensure that the rotor is never lifted or supported at bearings. This otherwise may damage the
bearings permanently. It is always advisable to lift the rotor winding a rope around the hub or the rotor
discs, sufficiently away from the bearing housings.

8. MILLS
As a first step, the foundation is to be checked. For this, proper centre lines are to be fixed at right angles to
each other, one along the line of cane travel and the other along centre line of top roller for each mill. Angle
iron frames and piano wires are to be used for this purpose. The piano wire is stretched tightly along these
centre lines. Care is to be taken to see that these two centre lines are exactly at right angles to each other.
The foundation is then checked for accuracy with reference to these centre lines. The elevation of foundation
also to be checked considering min. 60 mm grouting allowance. Particular attention is to be paid to anchor
plate fitting area at the bottom. This should be plain and in proper level. Top face of foundation should be
fairly in good level. Chip off loose material.
Place supporting plate 100 x 100 x 25 thk on both sides of the foundation bolt pocket. Place Mill base frames
on these supporting plates with foundation bolts, wedge borders & anchor plates in position. Level frames to
required elevation with the help of taper wedges between supporting plates & base frame. Level one pair of
base frames with the help of straight edge & master level keeping centre lines in correct alignment.
Tighten foundation bolt fully without disturbing level. After this additional supporting plates should be
provided in intermediate spaces. This procedure is to be repeated for all mills.
Alternatively when headstocks are installed directly on the foundation without base frame, please follow
separate instructions as per technical specification no.: 1607-B-00686.
Now, the headstocks are to be placed on base frames, taking care to identify R.H, L.H headstocks. The wedges
are to be installed between wedge border and headstock. This facilitates longitudinal shifting of headstock for
alignment. The headstocks are to be properly aligned and levelled with respect to centre lines as well as to
each other. The straight edge is again used for this purpose. Ensure verticality of the headstock.
The top roller bearing liners are to be lapped with top roller journals and installed in the headstocks. After blue
matching of mill bearing liners with the roller journal, assemble the elbow and fully tighten the same using
Teflon sealing tape (or similar) in suitable orientation, to suit ease of laying and terminating of lubrication
pipeline at the bearing. Elbow should be fitted on both the faces of the bearing liner, before SRBH and TRBH
are assembled on the roller journal.

9. MILL ASSEMBLY.

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

The top roller assembled on headstocks is now to be removed. The trash beam supporting brackets, lever
assemblies, tie bolts etc. are to be installed. The trash beam is then erected in position. Both bottom rollers,
duly assembled with bearings and crown wheels, juice guards are to be erected. Side caps (with keys or pins)
are to be fitted.
Before assembly of bearings on rollers, lap the bearings with journals for proper seating.
The roller setting device is to be put on headstock and the rollers and trash plate are to be set as per the setting
chart given. If the stationary flanges for top roller have been provided the same have to be fitted before fitting
of top roller.
After fitting top roller, top caps and top & bottom scrapers are to be erected. Messchaert knives assembly is to
be installed carefully with the knives lightly touching the messchaert grooves on feed roller. The scrapers and
trash plates are also lightly tightened initially.
All cooling water pipes for the roller bearings are ready fabricated and marked for erection. Piping is to be
connected in position along with main inlet and return lines.
Lubricator (either motorised or chain driven) is to be installed and piping to each lubrication point is to be
completed. Before fitting of the pipes at site, pipes should be blown through to take off the possible adherent
impurities.
Service gangway can now be installed.
The Mill Hydraulic system consisting of Accumulators, Panel board, Oil reservoir with pump and switchboard
are to be installed on a frame by the side of the Service gangway and required piping is connected to the Top
caps of all the Mills. All these accessories are supplied loose, pipelines are supplied in full length and all are
to be erected and connected as per drawings and instruction manuals of the manufacturers of the system.
All Juice gutters are connected to juice trays and Juice whirler tanks are to be erected on foundations
alongwith pumps. The DSM screens are to be installed on staging provided for the same.
Piping for Juice and water is sent loose and is to be fabricated and erected at site. Hot water imbibition system
is to be installed as shown in the drawing. All pipelines for Juice, water, lubrication and hydraulic system are
to be thoroughly tested for any leakages before trials.
All crown pinion guards are to be fitted and recommended lubricants are to be filled in all turbine oil tanks,
enclosed gearboxes, open gearing guards, crown pinion guards, pedestal bearings and lubricators. Fill only
recommended lubricants in each unit and up to the level marked.
The headstocks and pedestal bearings are to be drilled and reamed for fitting Dowel Pins. Doweling of
headstocks, last motion gear shaft pedestals and 1st motion pinion shaft pedestals should be done before trial
run. Remaining pedestals should be secured in position by wedges and doweled after no further adjustment are
required after no load run.

10. COOLING WATER RECIRCULATION FOR MILL ROLLER BEARINGS.

It is a normal practice to send the mill roller bearings cooling water to a pit / tank where it is cooled to ambient
temperature, and pumped back to the service water tank. Cooling water flows from the service tank to the
mills. This ensures that the cooling water flow to the mill bearings is always by gravity, at low pressure (2 to
42
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

2.5 Kg/cm2 gauge). Flow of cooling water to each bearing is adjusted, independently, by valve on the mill
floor, and flow quantity can be visually checked as well as temperature can be sensed manually or by
thermometer at the funnel provided on mill service gangway.
If cooling water temperature from a particular bearing is high then increase the water flow quantity (check any
blockages in the pipe line) and once again check temperature after one/two minutes. The flow of lubricant to
this bearing from dose feeder of lubrication system is increased by adjusting the setting screw. If this does not
help, and temperature continues to be high, then excess lubricant is pumped to this bearing, by an external
manual pump, till the temperature stabilises. This is particularly necessary when liners are new or during
starting of the season. Excessive hydraulic pressure could also be a reason for high bearing temperature.
Please check that the hydraulic pressure is adjusted in the recommended limits.
It is not recommended to apply external cooling water to the bearings, as this does not help. In fact this
external water finds its way to the crown pinion guard oil reservoir, and displaces the lubrication oil, out of the
sump. This seriously affects the lubrication of crown pinions leading to excessive wear of the teeth.

11. PROCEDURE FOR REPAIR OF ROLLER JOURNAL IN CASE OF WEAR


It is not uncommon that some scratch marks can develop on the shaft journal and liner mating surface after a
seasons operation. These are normally due to foreign particles trapped in journal area. If marks are shallow
they are polished smooth with fine emery paper.
If the marks are deep due to scoring and abrading of shaft journal, which is a rare occurrence, due to complete
failure of lubrication etc., or when journal looses its geometry (taper/ eccentricity / out of roundness ) due to
several seasons of working, than the standard practice of rectification of any damage to Roller Shaft Journal is
as follows:
a) Shaft Journal is machined by taking a light cut of about 0.2 to 0.5 mm and in some cases even
up to 1mm depth, and journal is ground smooth and polished.
b) The packing (total about 10mm thick, 2nos. 2mm thk and 1 no. 6 mm thk) provided between
the TRBH and the headstock or the Top and bottom half of the TRBH / SRBH are reduced to
adjust the journal clearance, and blue matching with journal is done by scraping the liner. If
the journal dia reduction is too large than decision is made to install a new liner, which is
machined to suit new reduced diameter of the shaft. (In your case two TRBH halves are
bolted together with new liner for finish machining the bore.)
c) Do not weld and rebuild the shaft. This never becomes necessary.

43
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

12. TIGHTENING TORQUE VALUES FOR BOLTS


TORQUE VALUES IN Nm FOR VARIOUS GRADES

BOLT SIZE 4.6 5.6 6.9 8.8 10.9 12.9


M2 0.123 0.162 0.314 0.373 0.520 0.628

M3 0.441 0.588 1.128 1.344 1.883 2.256

M4 1.000 1.344 2.599 3.040 4.315 5.148

M5 1.961 2.648 5.099 6.031 8.483 10.200

M6 3.432 4.511 8.728 10.300 14.710 17.652

M7 5.590 7.453 14.220 17.162 24.517 28.439

M8 8.238 10.787 21.575 25.497 35.304 42.168

M10 16.670 21.575 42.168 50.014 70.608 85.317

M12 28.440 38.246 73.550 87.279 122.600 147.100

M14 45.110 60.801 116.700 138.300 194.200 235.400

M16 69.63 93.163 178.500 210.800 299.100 357.900

M18 95.12 127.500 245.200 289.300 411.900 490.300

M20 135.300 180.450 384.100 411.900 578.600 696.300

M22 182.400 245.160 470.700 559.000 748.500 941.400

M24 230.5 308.910 598.200 711.000 1000.000 1196.000

M27 343.200 460.900 887.500 1049.000 1481.000 1775.000

M30 465.800 622.720 1206.000 1422.000 2010.000 2403.000

M33 632.500 848.300 1628.000 1932.000 2716.000 3266.000

M36 814.000 1089.000 2099.000 2481.000 3491.000 4197.000

M39 1059.000 1412.000 2716.000 3226.000 4531.000 5443.000

M42 1304.000 1746.000 3364.000 3991.000 5609.000 6727.000

M45 1638.000 2177.000 4207.000 4992.000 7012.000 8414.000

M48 1981.000 2638.000 5080.000 6021.000 8473.000 10150.000

M52 2540.000 3393.000 6541.000 7747.000 10885.000 13092.000

M56 3168.000 4227.000 8149.000 9650.000 13582.000 16279.000

M60 3932.000 5247.000 10101.000 11964.000 16867.000 20202.000

M64 4737.000 6306.000 12160.000 14416.000 20300.000 24320.000

This torques is guide values for Metric standard thread and head size, without grease or any lubricant. Reduce
the tightening torque by 20% if the lubricant is used. Resultant utilisation of yeild strength is 90%.

44
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SECTION III
OPERATING INSTRUCTIONS:
1. LUBRICATION:
Appropriate lubrication of the milling plant and its related equipment is of utmost importance. Excessive
lubrication will cause an increased consumption of lubricants, and on the other hand poor lubricating will be
detrimental to the bearings.
The enclosed schedule shows the lubricating points and lubricants recommended for the respective points. In
order to ensure filling of correct lubricant quantity and grade, our clients are advised to have this information
painted in red letters on white background distinctly captioned in black border through their own sources at
most locations. Use glossy enamel paint on primer surface.
During assembly, all bearings, chains, and other movable parts must be installed properly oiled and greased.
Special care should be taken to ensure that the roller and ball bearings must be filled 40 %, with the grease
being thoroughly pressed into the spaces in between the rollers, Care should be taken not to lubricate fast
running bearings excessively and as otherwise due to an inevitable churning effect, the temperature of the
bearing increases. The temperature of the bearings should normally not to exceed 20 to 30 degrees C above
the ambient temperature.
The roller bearings for the cane chopper are initially filled with grease. Chains of bagasse & cane carrier are to
be well greased until the old grease is forced out.

2. TRIAL RUN OF MILLS:


Prior to any trial run, all crown pinion and gear guards are to be fitted and recommended grade of lubricants
are to be filled in all turbine oil tanks, enclosed gearboxes, open gearing guards, crown pinion guards, pedestal
bearings and Mill bearing lubricators. Fill each unit only up to the level marked.
Mill bearing lubricators are to be thoroughly tested to ensure proper supply of oil to Mill bearings. These
lubricators are initially to be set for maximum delivery and oil flow is thereafter regulated after sufficient
running in of bearings to a minimum value sufficient to maintain good lubrication.
All pipelines are to be thoroughly tested for proper flow and leakages.
Initial trials begin with only the gearing side being run by means of Auxiliary drive unit without coupling the
turbine and the system is observed for any abnormality, which is attended if noticed.
Thereafter, the tail bar with two square couplings is connected between top roller and gear shaft. The Mill
rollers are then run by the Auxiliary drive unit. At this time, grinding of scrapers, trash plates etc. can be done
by putting water on rollers or by sand grinding to some extent.
The mill drive is to be independently run without coupling the enclosed gearbox. Manufacturers operation
manuals may please be referred for more details. Before this, in case of steam turbine drive, all inlet steam
lines are to be thoroughly cleaned by steam blowing. After satisfactory no load trial, coupling halves are to be
connected and mill can be run on no load.

45
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

In case of GRPF or TRPF systems provided with independent drive, trials for the D.C. motor are conducted
separately in an uncoupled condition. The system is then coupled and run at low speed for sufficient time. The
speed is to be increased to normal speed after satisfactory slow speed trial.
The trash & scraper plates require bedding in respective roller grooves. For this reason sand grinding must be
done during trial run. For grinding of trash & scraper plates, the rollers are sprinkled with water, sand & oil.
Grinding of scrapers etc. can be carried out properly during turbine trials.
All pedestal bearings, roller bearings etc. are to be continuously observed for a run of 8 hours. Should
individual bearings run hot, mill speed should be reduced.
After the first trial run of the mill, all keys & bolts, particularly bearing holding down and cap bolts &
foundation bolts will have to be re-tightened. In the same way all bolts of the auxiliary equipment including
piping are to be re-tightened.
When a satisfactory no load trial run is over, the complete mill plant is ready for operation. First of all the
trash plates to be tightened reasonably so that the same are just in contact with the rollers. Scraper plates will
also be tightened frequently for proper cleaning of rollers during initial milling operations.
It is most advisable to start the auxiliary equipment of the Milling plant viz. Cane carriers, Rake Elevator and
Inter carriers, Cane cutter, Cane leveller, Pumps, Bagasse carriers etc. after completion of the erection if elec-
tricity is available. However it should be ensured that enclosed reduction gearboxes, protective casing of the
open gears and Fluid couplings of Inter carrier drives (where provided) are filled with correct quality and
quantity of lubricants. Particular care is to be taken in lubricating the Bibby or Geared couplings.
On starting the Cane carrier, the interlocking of motors for Cane cutters & Levellers to be taken into
consideration & should be provided. Further interlocking arrangement should also be provided beginning from
Bagasse elevator & conveyor up to the first cane-receiving carrier in the plant.
It is most important to set correct hydraulic pressure for all the Mills before start of crushing operation. This
could be kept about 180 Kg/cm2 initially at the first Mill with increasing pressure down the tandem to the last
mill. This is to be increased after satisfactory initial operation.

3. RECOMMENDED HYDRAULIC PRESSURE (bar).


MILL NO. 1 2 3 4
OFF SIDE 160 160 170 170
CROWN SIDE 180 180 190 190

FOLLOWING POINTS TO BE NOTED WHILE DECIDING THE MILL HYDRAULIC PRESSURE.


1. Crown side pressure shall be 10% higher than the off side pressure.
2. Precharge pressure of the hydraulic accumulators shall be 130~150 bar.
3. Hydraulic pressure and Index of Prepared cane are interdependent.
4. To control the Top roller lift within limits, the hydraulic pressure shall be adjusted.
5. The RME and the last mill bagasse moisture shall govern the hydraulic pressure.

4. ADJUSTMENT OF MILL ROLLERS


46
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

Performance of the Milling tandem during the first run is to be continuously observed and mill openings
adjusted for optimum capacity and extraction. (Please refer to the mill setting sheet attached al the end of the
instructions manual.)
Correct setting of the mill is a must in order to achieve desired capacity, extraction & smooth uninterrupted
running of mills. We have provided excellent adjust abilities for the mill setting as follows: -
1. For horizontal adjustment of bottom rollers, pressure bolts & draw bolts have been provided to close or
open the setting respectively.
2. For vertical adjustment of trash plate assembly-packing plates can be added or taken out from below the
trash beam supporting brackets. Large size jack bolts are provided for lifting or lowering the trash beam
assembly.
3. For horizontal adjustment of trash plate assembly jack bolts are provided on both sides of trash beam
supporting brackets for forward & backward shifting.
4. For swinging the trash plate assembly, Levers with Tie bolts are provided on both sides for forward &
backward swinging.
5. Bottom face of trash beam is machined at right angles to vertical line of the beam. If spirit level shows this
face in perfect level, the trash plate curve will be correct as per drawing. This is an important check when
the mill is closed and after every setting this position should be verified for correctness.
6. After adjustment of mill openings the pressure bolts in the side caps should be secured by means of
locking bolts to prevent same getting loose.

5. ADJUSTMENT OF MILL SETTINGS:


Mill settings indicated on the setting chart are only for reference and to provide a general idea of the setting
required from the point of view of initial start and are not to be considered firm and final. Mills openings are
generally required to be adjusted depending on actual operating conditions for achieving optimum capacity
and extraction from the tandem.
Mill openings can be readily adjusted after detailed analysis of results from the tandem and based on
experience. Perfect adjustment of the trash beam is however not possibly after placing the top roller in position
and following precautions therefore need to be taken when changing roller settings:
1. In case of opening the Feed opening, the Trash beam assembly should be shifted towards the Feed roller
by tightening pressure screws on the Feed side of the supporting bracket by an amount equal to the
increase in Feed opening.
2. In case of reduction of Feed opening, the Trash beam assembly to be similarly drawn back.
3. While adjusting Trash beam assembly, the jack bolts for vertical adjustment as well as draw bolts of the
Lever arm should be loosened.
4. Excessive tightening of the Trash plate on the Feed roller through draw bolts of the Lever arms may
disturb slope of the Trash plate and will cause choking of the Mill and should be avoided.
5. The mill setting for achieving the guaranteed performance parameters is as detailed in the mill setting
drawing no. MP-4335-1, Rev.0, along with the sample procedure for calculating the same.

6. ROUTINE MAINTENANCE:

47
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

Routine maintenance of various equipment of the tandem generally consisting of but not limited to the
following points is to be regularly attended.
1. Lubricate all points as per attached schedule.
2. Refill lubricating pump of the mills during each working shift of 8 hours after cleaning the strainer at the
time of each refill.
3. Observing cooling water temperature of the mill roller bearings, oil cooler outlet water.
4. Observe temperature of all open gearing bearings.
5. Check the oil in open gearing and pedestal bearing.
6. Mill rollers should be watched for clean running and if required scraper plates for top and discharge roller
should be tightened. Scrapers are to be checked and tightened every week as part of routine operation.
7. Hydraulic buckets in the Top cap should be replaced every off-season without fail for dependable service.
During operation, failure of buckets is not uncommon and watch should be kept on the Hydraulic system
for proper operation. Buckets should be replaced in case pressure is not sustained by the system and oil is
found leaking out from bottom of cap.
8. Holding down bolts and other bolts for all bearing pedestals, headstocks etc. should be checked and
retorqued if required at the time of cleaning.
9. Chains of all carriers should be watched and take-up screws should be tightened to reduce slack as
required. Excessive slack is liable to damage Slats and Rakes and is to be avoided.
10. Fixing bolts for Rakes and slats should be checked and tightened every week as time permits.
11. Structural bolts should be tightened every cleaning.

7. SPECIAL MAINTENANCE INSTRUCTIONS


1. In order to avoid tilting of top roller bearing & thereby increasing the side thrust on the wearing slide
plates, the clearance between the wearing slide plates & mating surface of top roller bearing should
strictly be kept 0.1 to 0.2 mm maximum by adding brass packing plates behind the wearing slide plates, if
required.
2. The trash plate should not be tightened too much on feed roller.
3. The flap of juice imbibitions tray for the 1st mill should be fixed keeping proper gap between flap & pipe
so that splashing of juice will be avoided.
4. The mating surface of the pressure plate & the top roller bearing should be greased while assembling.
5. A limit to the diameters for the old rollers is set up by the minimum operating centre distance of the crown
wheel. The rollers are required to be reshelled when the sum of the P.C.D. of top & bottom rollers &
minimum setting becomes less than the minimum operating centre distance of crown wheels as specified
in drawings.
6. First fitting of juice trays should be done by M.S. bolts. Then each bolt should be replaced by Stainless
Steel bolts so as to avoid damage to bolts in case of minor mismatch of holes.
7. Trash beam after any readjustment should be checked to ensure that it is vertical by applying precision
spirit level below the machined face of the trash beam. Please keep discharge side lever stud nut covered
and locked and keys with Chief Engineer so that trash beam position will be undisturbed.

48
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

8. Every season, the Crown wheels should be reversed on the roller shafts to bring the new tooth face to
come in contact. Afterwards if teeth are sufficiently worn-out, welding layer should be put on to get the
original profile. The surfaces then should be made smooth by grinding.
9. The parts which come in contact with juice i.e. inside of Headstocks, Mixed juice receiving tank etc. are
to be painted properly. We recommend the use of Epoxy-based acid and alkali resisting enamel for this
purpose.
The above instructions for erection and operation of the milling plant and its components are meant only for
general guidance.
It is impossible to include in this document necessary instructions for all breakdowns that may occur during
operation.
The above instructions are ofcourse no substitute for the guidance of our staff.
The supplier shall not be held responsible for any breakdowns whatsoever in the plant, which in the opinion of
the owners of the plant could have been avoided by providing appropriate explanations in this document.

8. INSTRUCTIONS FOR OFF-SEASON MAINTENANCE.


As soon as the season is over, there are certain precautions necessary so that mill house machinery is not
damaged during the prolonged stoppage period of four to six months. Off-season maintenance also helps in
identifying the any impending problem areas.
1. Mills should be opened, to remove the rollers. This prevents fretting corrosion on the roller journal, due to
prolonged resting of the roller weight on same journal area. Corrosion is also caused due to ingress of
water during cleaning of mills.
2. Mill rollers journals should be inspected and any scratch marks etc. should be polished smooth with fine
emery paper. Journal surface shall be applied with grease and protected by covering with plastic. Mill
roller should be placed on the wooden planks, with load resting on the shell area, and not on the bearing
journal.
3. Any damage to the mill bearing liners should be inspected and repaired/replaced. Liners should be scraped
and blue matching with the mill journal as well as seat of the liner in TRBH / SRBH should be checked.
See procedure for repair of shaft journal for more details.
4. Any damage to the grooving of the mill roller should be repaired. Grooves should be renewed by
machining if necessary. The reduced diameter of the roller after machining should be used for determining
the new mill setting for the next season. If the roller diameter reduces below the wear allowance of the
roller, than roller should be taken up for re-shelling.
5. Condition of wear components such as trash plates and scrapers should be checked and same should be
built up and hard-faced for reuse in the next season. In case these items are damaged beyond repair than
decision should be taken for replacement. Trash plate profile in this case can be determined to suit new
diameters of the rollers and the mill settings.
6. Crown pinions, square couplings of mill drive are also subject to wear. Attention should be given to
regular lubrication of these items to limit the wear. During the first off season it is required to rebuild by
hard-facing the working face of the teeth of the crown pinion and sometimes the square coupling. Ensure
the profile of the teeth after build up, by using a template.
7. Heavy rotors such as shredder, cutter bearing housings should be completely filled with grease. The rotors
should be manually rotated at regular intervals through one or two revolutions so that the rollers are not
49
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

contacting at the same points. The grease should be drained during the start of the new season using
flushing oil and rotating the rotor with drive for about one to two minutes till the grease is dissolved and
than it is flushed out. New lubricant of recommended grade is filled before taking machine on load.
8. The condition of wear components such as cutter knives, shredder hammers, runners of the carriers, pins /
bushes and rollers of the carrier chains, rakes, slats should be inspected and necessary repair / replacement
actions should be taken.
9. The sprocket teeth of chain carriers, specially block type chain, are subject to wear. Same should be
inspected and local worn out area should be weld built up and final layer should be with hard-facing
electrode. If this is done during initial one to two months (i.e. during first cleaning shutdown) of running
of the carriers than further wear is arrested and the life of the sprocket teeth is extended substantially, with
only limited repair required in the later operating life.
10. For maintenance of the cranes / drive components / lubrication system please refer separate O&M
instructions from vendors enclosed.

9. UNDERFEED OR FORCE FEED ROLLERS:


Mills are incorporated with Force Feed Rollers when installing Rake Inter carriers and Donnelly Chutes. This
arrangement consists of an IVth roller fitted on the feed side and supported on Gunmetal or roller bearings.
These bearings are then bolted onto the Headstock itself at a suitable height. The Donnelly chute feeds the cut
cane between top roller and this IVth roller. This roller could be of the same diameter as the main rollers. In
case of underfeed roller the diameter is less than the main roller.

10. FURTHER IMPORTANT HINTS FOR THE FOUNDATIONS:


The gangways provided in the foundations are meant for better accessibility to the foundations bolts and water
logging should be prevented. The whole foundation is easily accessible by means of stairs. Multiple Drains are
to be provided to avoid accumulation of dirty water and subsequently all these drains are to be connected with
each other and then to main sewer.
The foundation holes are to be covered with small wooden boards or paper while grouting the base frames so
that mortar may not fail into the opening. After allowing sufficient time for setting of the grouting, the milling
plant may be erected completely.

50
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

11. RECOMMENDED STOCK OF SPARE PARTS:


To ensure continuity of operation, we recommend the following minimum essential operating spares to be
procured and maintained by our clients:
1. Cane Carrier chain 20 m.
2. Knives for Cane Kicker / Chopper / Cutter 8 nos.
3. Knife holder for Cane Kicker / Chopper / Cutter 4 nos. Slats for cane
carrier 50 nos.
4. Carbon brushes for motors of Cane Chopper 6 nos.
5. Synthetic Hydraulic Bucket 10 nos.
6. Ungrooved Top roller suitable for all mills. 2 nos.
7. Ungrooved bottom roller suitable for all mills 2 nos.
8. Bearing liner 8 nos.
9. Top scraper plate - Ungrooved 2 nos.
10. Bottom scraper plate - Ungrooved 2 nos.
11. Trash plate 1 nos. for each mill.
12. Block type chain for intermediate carrier. 200 links
13. Rakes for intermediate carrier 100 nos.
14. Fusible plug for intermediate carrier drive 1 no.
15. Spares for Hydraulic System 1 set
16. Forced feed oil lubricator 1 no.
The above instructions for erection & operation of the Milling plant & components are meant only for general
guidance.
It is impossible to include in the operation manual the instructions for every event, which may occur during
operation.

51
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

MILL SETTINGS - Ramnagar Chinni Mills Ltd., Unit 1 & 2. (REF.


SEC. III, POINTS 4 & 5)
4.25 RPM (i. e. @ RATED SPEED), 16% F
TCH = 260
F = 16

D1 = 1.067 D2 = 1.067 D3=1.067 D4 = 1.067


L1 = 2.134 L2 = 2.134 L3 = 2.134 L4 = 2.134
N1 = 4.2 5 N2 = 4.25 N3 = 4.25 N4 = 4.25

K1 = 3.142 * D1* N1* L1* 60 * 1.2


K2 = 3.142 * D2* N2* L2* 60 * 1.2
K3 = 3.142 * D3* N3* L3* 60 * 1.2
K4 = 3.142 * D4* N4* L4* 60 * 1.2

B1 = TCH * F * 1000 / 32
B1 = 13 * 10 4
B2 = TCH * F * 1000 / 40 D01 = B1 * 1000 / (K1 * 1217 * 1.3)
B2 = 10.4 * 10 4 D01 = 38
B3 = TCH * F * 1000 / 49 D02 = B2 * 1000 / (K2 * 1252 * 1.3) F01 = 1.9 * D01
B3 = 8.49 * 10 4 D02 = 30 F01 = 68
B4 = TCH * F * 1000 / 50 D03 = B3 * 1000 / (K3 * 1277 * 1.3) F02 = 1.8 * D02
B4 = 8.32 * 10 4 D03 = 24 F02 = 53
D04 = B4 * 1000 / (K4 * 1292 * 1.3) F03 = 1.8 * D03
D04 = 23 F03 = 43
F04 = 1.8 * D04
F04 = 41

D01R = D01 10 F01R = F01 10 T1 = 1.8 * F01 13


D01R = 12.887 F01R = 58 T1 = 110

D02R = D02 8 F02R = F02 8 T2 = 1.7 * F02 10


D02R = 9.797 F02R = 45 T2 = 86

D03R = D03 6 F03R = F03 6 T3 = 1.7 * F03 8


D03R = 8.244 F03R = 37 T3 = 69

D04R = D04 6 F04R = F04 6 T4 = 1.7 * F04 8


D04R = 7.797 F04R = 35 T4 = 66

D01R = 28 F01R = 58 T1 = 110


D02R = 22 F02R = 45 T2 = 86
D03R = 18 F03R = 37 T3 = 69
D04R = 17 F04R = 35 T4 = 66

RECOMMENDED SETTINGS:-

FEED DISCHARGE TRASH PLATE


1ST MILL 58 28 110
2ND MILL 45 22 86
3RD MILL 37 18 69
4TH MILL 35 17 66

52
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

WHERE
TCH = TON CAPACITY PER HOUR.
F = FIBRE % CANE.
D? = MILL ROLLER DIA.(NOMONAL) IN MTR.
L? = SHELL LENGTH IN MTR.
N? = RPM OF MILL
? = MILL NO.
K? = MILL CONSTANT
UPRATING 'K?' INVIEW OF ROLLER SURFACE TREATMENT MULTIPLIED BY 1.2
FIBRE % BAGASSE AFTER EACH MILL
I MILL = 32
II MILL = 40
III MILL = 49
IV MILL = 50
V MILL =
VI MILL =
BAGASSE DENSITY AFTER EACH MILL
I MILL = 1217 KG/M3
II MILL = 1252 KG/M3
III MILL = 1277 KG/M3
IV MILL = 1292 KG/M3
V MILL =
VI MILL =
DO? = DISCHARGE OPENING IN OPERATION IN mm
FO? = FEED OPENING IN OPERATION IN mm
B? = WEIGHT OF BAGASSE AFTER EACH MILL IN KG.
ROLLER RISE FOR FEED AND DISCHARGE ROLLER IN mm
I MILL = 10
II MILL = 8
III MILL = 6
IV MILL = 6
V MILL =
VI MILL =
ROLLER RISE FOR TRASH PLATE IN mm
I MILL = 13
II MILL = 10
III MILL = 8
IV MILL = 8
V MILL =
VI MILL =
DO?R = DISCHARGE SETTING AT REST IN mm.
FO?R = FEED SETTING AT REST IN mm.
T? = TRASH PLATE SETTING IN mm.

53
MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

SECTION-IV
LIST OF REFERENCE DRAWING

SR NO. DESCRIPTION DRAWING NO.

1 ARRANGEMENT OF CANE UNLODER GANTRY MP-1036-0/0

2 G.A. OF TIPPER CARRIER MP-1024-0/A

3 FOUNDATION FOR TIPPER CARRIER MP-0881-00/0

4 G.A.FOR CANE CARRIER MP-1021-0/0

5 FOUNDATION PLAN FOR CANE CARRIER MP-0880-00/0

6 MCE/TKII/2022/06-
GA OF 2400mm W BELT CONVEYOR BEFORE SHREDDER
07/01 REV.01

7 MCE/TKII/2022/06-
GA OF 2400mm W BELT CONVEYOR AFTER SHREDDER
07/02 REV.01

8 MCE/TKII/2022/06-
GA OF 2000mm W BELT CONVEYOR AFTER 4TH MILL
07/03 REV.02

9 G.A RAKE CARRIER( AFTER SHREDDER) MP-1025-0/B

10 FOUNDATION PLAN FOR RAKE CARRIER MP-1033-0/B

11 FOUNDATION PLAN FOR MILL MP-0877-00/J

12 G.A.FOR RAKE INTER CARRIER ( MILL NOS. 1,2 & 3) MP-1032-0/A

13 G.A.FOR RAKE INTER CARRIER (MILL NO. 4) MP-1022-0/B

14 DONNELLY CHUTE FOR 1st MILL MP-1049-0/A

15 DONNELLY CHUTE FOR 2nd MILL MP-1050-0/A

16 DONNELLY CHUTE FOR 3rd MILL MP-1051-0/A

17 DONNELLY CHUTE FOR 4th MILL MP-1052-0/A

18 SIDE CAP ASSEMBLY MP-0828-1/0

19 JUICE TRAY MP-4364-1/B

20 TOP ROLLER-60 P MP-4368-1/0

21 FEED ROLLER-60 P, 1ST MILL MP-4369-1/A

22 DISCHARGE ROLLER-60 P MP-4370-1/A

23 UNDER FEED ROLLER-60 P MP-4371-1/0

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

24 TOP ROLLER-GRPF-60 P MP-4372-1/0

25 BOTTOM ROLLER-GRPF-60 P MP-4373-1/0

26 TOP ROLLER-40 P MP-4374-1/0

27 FEED ROLLER-40 P MP-4375-1/0

28 DISCHARGE ROLLER-40 P MP-4376-1/0

29 UNDER FEED ROLLER-40 P MP-4377-1/0

30 TOP ROLLER-GRPF-40 P MP-4378-1/0

31 BOTTOM ROLLER-GRPF-40 P MP-4379-1/0

32 TOP CAP ASSEMBLY MP-4380-1/0

33 SIDE CAP ASSEMBLY MP-0828-1/0

34 JUICE OUTLET& OVER FLOW GUTTER MP-4381-1/B

35 TRASH BEAM ASSLY. MP-4386-1/A

36 FEED ROLLER-60 P, 2ND MILL MP-4388-1/0

37 ASSEMBLY OF TOP ROLLER BEARING HOUSING MP-5032-2/0

38 ASSLY OF SIDE ROLLER BEARING HOUSING MP-4392-1/0

39 TOP& BOTTOM SCRAPER ASSLY. MP-4425-1/0

40 JUICE IMBIBITION TRAY MP-4305-2/0

41 ASSLY OF MILL BASE FRAME MP-5013-2/A

42 PIN TYPE HEAD STOCK ASSLY MP-5025-2/A

43 TRASH PLATE FOR 1st MILL MP-1026-0/A

44 TRASH PLATE FOR 2nd MILL MP-1027-0/A

45 TRASH PLATE FOR 3rd MILL MP-1028-0/A

46 TRASH PLATE FOR 4th MILL MP-1029-0/A

47 DISCHARGE CHUTE FOR 4th MILL MP-1047-0/0

48 STATIC COLLAR MP-4461-1/0

49 MESSCHAERT KNIVES ASSEMBLY 60 MM PITCH MP-5064-2/0

50 MESSCHAERT KNIVES ASSEMBLY 40 MM PITCH MP-5065-2/0

51 DISCHARGE SIDE PLATE FOR 1st,2nd,3rd MILL MP-1044-0/0

52 DISCHARGE SIDE PLATE FOR 4TH MILL MP-1047-0/0

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

53 ASSEMBLY OF MILL BASE FRAME MP-5013-2/A

54 BRACKET FOR TOP SCRAPER L.H & R.H. MP-5031-2/0

55 TOP & BOTTOM SCRAPER ASSEMBLY MP-4425-1/0

56 LOCKING ARM 2nd,3rd MILL MP-3338-1/0

57 UFR BEARING ASSBMBLY 2nd,3rd MILL MP-3516-3/A

58 PINION GUARD FOR GRPF ROLLER MP-5093-2/0

59 PINION GUARD FOR UF ROLLER MP-5096-2/0

60 ASSEMBLY OF WATER IMBIBITION DEVICE MP-4104-2/0

61 CROWN PINION GUARD FOR MILL MP-4482-1/0

62 GANTRY GRIDER FOR MILL HOUSE MP-1030-0/0

63 COOLING WATER PIPING FOR MILL MP-4487-1/0

64 LAYOUT OF THE MILLING PLANT MP-1014-0/E

65 SERVICE GANGWAY MP-0884-00/0

66 SCRAP HOLDING FOR HYD. SYSTEM. MP-4496-1/0

67 HYDRAULIC DRIVE FOR MILL & GRPF ROLLER MP-5016-2/D

68 SCHEME FOR JUICE & WATER IMBIBITION PIPING MP-4506-1/0

69 DRIVE BASEFRAME FOR TIPPER CARRIER MP-4467-1/0

70 DRIVE BASEFRAME FOR CANE CARRIER MP-4468-1/0

71 DRIVE BASEFRAME FOR RAKE CARRIER MP-4469-1/0

72 DRIVE BASEFRAME FOR RAKE INTER CARRIER MP-4470-1/0

73 DRIVE BASEFRAME FOR BELT CONV. BEFORE SHREDDER MP-4507-1/0

74 DRIVE BASEFRAME FOR BELT CONV. AFTER SHREDDER MP-4507-1/0

75 DRIVE BASEFRAME FOR BELT CONV. AFTER 4TH MILL MP-4508-1/0

76 PRESSURE CHUTE ASSEMBLY FOR 1ST MILL GRPF MP-1059-0/0

77 PRESSURE CHUTE ASSEMBLY FOR 4TH MILL GRPF MP-1060-0/0

78 STATIC COLLAR FOR GRPF MP-4456-1/-0

79 FEED SIDE PLATE FOR GRPF MP-5095-2/0

80 BEARING ASSEMBLY FOR GRPF MP-5070-2/0

81 UFR BEARING ASSEMBLY FOR GRPF MP-4624-3/0

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.
ThyssenKrupp Industries India Pvt. Ltd.

82 MILL SETTING MP-4512-1/0

83 STAGING FOR ROTARY SCREEN MP-1057-0

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MILLING PLANT MANUAL FOR DALMIA SUGARS UNITS 1 & 2.