Boiling House

WSSF-USI TECHNICAL SPECIFICATION Section VI-D
Page - 1 / 154
CONTRACT DOCUMENT FOR
BOILING HOUSE
Table of Contents
0500 JUICE TREATMENT AND CLARIFICATION............................................................7

0501 Juice Measurement................................................................................................7
0501-1 Juice Weighing Scale......................................................................................7
0502 Check Weighment System.....................................................................................9
0502-1 Check Weighment Tank..................................................................................9
0502-2 Check Weighing Scale..................................................................................10
0503 Phosphate Dosing System...................................................................................10
0503-1 Phosphate Preparation Tank.........................................................................10
0503-2 Phosphate Dosing Tank................................................................................11
0503-3 Phosphate Dosing Pump...............................................................................12
0504 Raw Juice Buffer Tank.........................................................................................12
0505 Weighed Juice Pump............................................................................................13
0506 Juice Sulphiter......................................................................................................13
0507 Auto pH Control System.......................................................................................14
0508 Sulphured Juice Receiving Tank..........................................................................15
0509 Sulphured Juice Pump.........................................................................................16
0510 Juice Flow Stabilization System...........................................................................17
0600 CLARIFICATION AND FILTRATION......................................................................18
0601 Flash Tank............................................................................................................ 18
0602 Clarifier................................................................................................................. 18
0602-1 SRT Clarifier..................................................................................................18
0602-2 Rapi-Dorr Clarifier (Alternative to SRT Clarifier)............................................19
0603 Flocculant Dosing System....................................................................................20
0603-1 Flocculant Preparation Tank..........................................................................20
0603-2 Flocculant Dosing Tank.................................................................................21
0603-3 Flocculant Dosing Pump................................................................................21
0604 Bagacillo Handling System...................................................................................21
0604-1 Bagacillo Blower............................................................................................22
0604-2 Bagacillo Piping.............................................................................................22
0604-3 Cyclone Separator.........................................................................................23
0605 Feed Mixer........................................................................................................... 23
0606 Rotary Vacuum Filter and Accessories.................................................................24
0606-1 Vacuum Filtrate Receivers............................................................................25
0606-2 Entrainment Separator..................................................................................25
0606-3 Filter Condenser............................................................................................26
0607 Filtrate Collection Tank.........................................................................................26
0608 Filtrate Transfer Pump..........................................................................................26
0609 Vacuum Pump......................................................................................................27
0610 Mud Recirculation Tank........................................................................................28
0611 Mud Recirculation Pumps.....................................................................................28
0612 Cake Wash Water Pump......................................................................................29
0613 Mud Belt Conveyor...............................................................................................30
0614 Mud Bin................................................................................................................ 30
0615 Filtrate Vibro Screen.............................................................................................31
0616 Filtrate Clarification System (Optional).................................................................32
0700 MILK OF LIME AND SO2 GAS PREPARATION.....................................................33
** marked details to be filled in & confirmed during Detailed Engineering

Page - 2 / 154
BOILING HOUSE
0701 Lime Elevator.......................................................................................................33

0702 Lime Slaker.......................................................................................................... 33
0703 Grit Elevator......................................................................................................... 34
0704 Milk of Lime (MOL) Vibro Screen..........................................................................35
0705 Milk of Lime Storage Tanks..................................................................................35
0706 Milk Of Lime Pumps.............................................................................................36
0707 Sulphur Burner.....................................................................................................36
0707-1 Sulphur Burner for Juice Sulphitation............................................................36
0707-2 Sulphur Burner for Syrup Sulphitation...........................................................37
0707-3 Sulphur Melter for Burners............................................................................38
0708 Air Dehumidifier....................................................................................................38
0709 Air Blower............................................................................................................. 38
0709-1 Air Blower for Juice Sulphitation....................................................................38
0709-2 Air Blower for Syrup Sulphitation...................................................................39
0800 JUICE HEATING & EVAPORATION.......................................................................39
0801-1 Juice Heater (Tubular Type)..........................................................................40
0801-2 Clear Juice heater (Plate type)......................................................................41
0801-3 Liquid-Liquid Heat Exchanger.......................................................................42
0802 JH Condensate Extraction System.......................................................................42
0802-1 Condensate Receiver No.1...........................................................................42
0802-2 Condensate Pump for Receiver No.1............................................................43
0803 Clear Juice Column..............................................................................................46
0804 Clear Juice Pump.................................................................................................47
0805 Evaporator Station................................................................................................47
0805-1 First Effect.....................................................................................................48
0805-2 Second Effect................................................................................................49
0805-3 Third Effect....................................................................................................50
0805-4 Fourth Effect..................................................................................................52
0805-5 Fifth Effect.....................................................................................................53
0805-6 External Saveall............................................................................................54
0806 Evaporator Condensate System...........................................................................55
0806-1 Condensate Receiver for First Effect.............................................................55
0806-2 Condensate Pump for First Effect..................................................................56
0806-3 Flash Vessel for Second Effect.....................................................................56
0806-4 Flash Vessel for Third Effect.........................................................................57
0806-5 Flash Vessel for Fourth Effect.......................................................................58
0806-6 Flash Vessel for Fifth Effect...........................................................................58
0806-7 Condensate Pump for Fifth Effect..................................................................59
0807 Syrup Receiving Tank..........................................................................................60
0808 Syrup Extraction Pump.........................................................................................61
0809 Unsulphured Syrup Storage Tank........................................................................61
0810 Sulphured Syrup Transfer Pump..........................................................................62
0811 Syrup Sulphiter.....................................................................................................62
0812 Syrup Clarification System (Optional)...................................................................63
0813 Caustic Soda System...........................................................................................64

Page - 3 / 154
BOILING HOUSE
0813-1 Caustic Soda Tank........................................................................................64

0813-2 Caustic Soda Pump.......................................................................................64
0814 Steam Pressure Stabilization system...................................................................65
0814-1 Overflow Surplus Valve (OSV-1)...................................................................65
0814-2 Overflow Surplus Valve (OSV-1A).................................................................66
0814-5 Relief Valve (RV-1)........................................................................................68
0814-6 Pan Vapour Control Valve (PVCV)..................................................................69
0900 GRAINING AND CRYSTALLIZATION PLANT.......................................................69
0901 Syrup & Molasses Storage Tanks........................................................................69
0902 Molasses Conditioners and Holding Tanks...........................................................70
0902-1 AH Molasses Conditioner..............................................................................70
0902-2 AH Molasses Holding Tank...........................................................................70
0902-3 B1H Molasses Conditioner............................................................................71
0902-4 B1H Molasses Holding Tank.........................................................................71
0902-5 B2H Molasses Conditioner............................................................................71
0902-6 B2H Molasses Holding Tank.........................................................................71
0902-7 CL Molasses Conditioner..............................................................................72
0902-8 CL Molasses Holding Tank............................................................................72
0903 Vacuum Pans.......................................................................................................72
0903-1 Batch Pans for ‘A’ Massecuite Seed..............................................................72
0903-2 Batch Pans for ‘A’ Massecuite.......................................................................75
0903-3 Batch Pan ‘B1’ ‘B2’ & ‘C’ Graining.................................................................77
0903-4 Continuous Pan for ‘B1’ Massecuite Boiling..................................................80
0903-5 Batch Pan for ‘B2’ Massecuite Boiling...........................................................84
0903-6 Batch Pan ‘C’ Massecuite Boiling..................................................................87
0904 Massecuite Distribution Pipe................................................................................90
0905 Pan Condensate System......................................................................................91
0905-1 Pan Condensate Receiving Tank..................................................................91
0905-2 Pan Condensate Pump.................................................................................91
0906 Seed Crystalliser..................................................................................................92
0907 Vacuum Crystalliser..............................................................................................93
0907-1 ‘A’ Vacuum Crystalliser (1 No.)......................................................................93
0907-2 ‘B1’ Vacuum Crystalliser (1 No.)....................................................................93
0907-3 ‘B2’ Vacuum Crystalliser (1 No.)....................................................................93
0907-4 ‘C’ Vacuum Crystalliser (1 No.).....................................................................93
0908 'A' Receiving Crystalliser for 100 t Pan.................................................................94
0909 ‘B’ & ‘C’ Receiving Crystallisers............................................................................95
0909-1 ‘B1’ Receiving Crystalliser for Continuous Pan..............................................95
0909-2 ‘B2’ Receiving Crystalliser.............................................................................96
0909-3 ‘C’ Receiving Crystallisers.............................................................................97
0909-4 Liquidation Crystalliser for Continuous Pan...................................................97
0909-5 Sweet Water Tank.........................................................................................98
0909-6 Sweet Water pumps......................................................................................98
0910 Massecuite Pumps.............................................................................................100
0910-1 ‘B1’ Massecuite Seed Pump for Continuous pans.......................................100
0910-2 ‘C’ Massecuite Pumps.................................................................................101
0910-3 ‘B1’ Massecuite Pump.................................................................................102

Page - 4 / 154
BOILING HOUSE
0910-4 ‘B1’ & ‘C’ Liquidation Pumps.......................................................................103

0911 Vertical Crystalliser.............................................................................................104
0911-1 ‘B1’ Vertical Crystalliser...............................................................................104
0911-2 ‘C’ Vertical Crystalliser.................................................................................105
0912 Cooling System for Vertical Crystallisers............................................................107
0912-1 Hot Water Surge Tank.................................................................................107
0912-2 Hot Water Circulation Pump for Vertical Crystallisers..................................107
0912-3 Cold Water Surge Tank...............................................................................108
0912-4 Cold Water Circulation Pump for Vertical Crystallisers................................109
0912-5 Cooling Tower for Vertical crystalliser cooling system...................................109
0913 Overhead Tanks.................................................................................................110
0913-1 Hot Water Overhead Tank (2 Nos.).............................................................110
0913-2 Cold Water Overhead Tank (2 Nos.)...........................................................110
0913-3 Drinking Water Overhead Tank (1 No.).......................................................110
0914 Cooling Tower for Condensate cooling...............................................................111
0915 Service Water Pump...........................................................................................111
1000 CENTRIFUGAL STATION.....................................................................................112
1001 'A' Massecuite Centrifugals.................................................................................112
1002 Super Heated Wash Water System....................................................................120
1002-1 Surge Tank..................................................................................................120
1002-2 Superheated Wash Water Heater................................................................120
1002-3 Superheated Wash Water Pump.................................................................121
1003 Instrument Air System Assembly........................................................................121
1003-1 Air Compressor...........................................................................................122
1003-2 Air Receiver.................................................................................................122
1003-3 Air Drier.......................................................................................................122
1004 AH Molasses Receiving Tank.............................................................................123
1005 AH Molasses Pump............................................................................................123
1006 AL Molasses Receiving Tank.............................................................................124
1007 AL Molasses Pump.............................................................................................125
1008 ‘B’ & ‘CA’ Continuous Centrifugal Machines.......................................................126
1008-1 ‘B1’ Continuous Centrifugal Machine...........................................................126
1008-2 ‘B2’ Continuous Centrifugal Machines.........................................................129
1008-3 ‘CA’ Continuous Centrifugal Machines........................................................129
1009 B Magma Mixers................................................................................................130
1009-2 ‘B1’ Magma Mixer........................................................................................130
1009-2 ‘B2’ Magma Mixer........................................................................................131
1010 ‘B’ Magma Pump................................................................................................131
1010-1 ‘B1’ Magma Pump.......................................................................................131
1010-2 ‘B2’ Magma Pump.......................................................................................132
1011 B Molasses Receiving Tanks..............................................................................132
1011-1 ‘B1’ Molasses Tank.....................................................................................132
1011-2 ‘B2’ Molasses Tank.....................................................................................132
1012 B Molasses Pumps.............................................................................................132
1012-1 ‘B1’ Molasses Pump....................................................................................132
1012-2 ‘B2’ Molasses Pump....................................................................................132
1013 C- After Magma Mixer........................................................................................133
1014 C-After Magma Pump.........................................................................................133
1015 CL Molasses tank...............................................................................................133

Page - 5 / 154
BOILING HOUSE
1016 CL Molasses Pump............................................................................................133

1017 'C Fore' Continuous Centrifugal Machine...........................................................133
1018 C- Fore Magma Mixer.........................................................................................134
1019 C-Fore Magma Pump.........................................................................................134
1020 Final Molasses Receiving Tank..........................................................................134
1021 FM Pump Below Machines.................................................................................134
1022 Final Molasses Weighing Scale..........................................................................134
1023 Weighed Final Molasses Receiving Tank...........................................................136
1024 FM Pump Below Weighing Scale.......................................................................136
1025 Sugar Melter.......................................................................................................136
1026 Melt Pump.......................................................................................................... 137
1027 Centrifugal House overhead crane.....................................................................138
1028 Final Molasses Handling....................................................................................139
1028-1 Final Molasses Storage Tank......................................................................139
1028-2 Final Molasses Loading Tank........................................................................140
1028-3 Final Molasses Transfer Pump......................................................................140
1100 SUGAR HANDLING, DRYING & BAGGING.........................................................140
1101 Sugar Hoppers...................................................................................................140
1101-1 Sugar Receiving Hopper.............................................................................140
1101-2 Plain Tray Hopper.......................................................................................141
1101-3 Belt Conveyor (BC-1) between Hopper & Drier...........................................141
1101-4 Belt conveyor between FBD and hopper before elevator (BC-2) - Deleted..141
1102 Fluidised Bed Sugar Dryer/ Rotary Sugar Dryer.................................................142
1103 Sugar Elevator....................................................................................................142
1104 Sugar Grader......................................................................................................143
1105 Sugar Distribution Belt Conveyors......................................................................144
1106 Sugar Bins.......................................................................................................... 144
1107 Sugar Weighing and Bag Filling System.............................................................144
1107-1 Sugar Bag Check Weighment Scale...........................................................145
1108 Slat Conveyor.....................................................................................................145
1109 Bag Stitching Machines......................................................................................145
1110 Dry Seed Belt Conveyor.....................................................................................145
1111 Rori Sugar Melter...............................................................................................146
1112 Rori Melt Pump...................................................................................................146
1113 Dust Collection System......................................................................................147
1114 Sugar Bag Handling System...............................................................................148
1115 Stacker & Portable belt conveyors......................................................................148
1115-1 Stacker set 16’.............................................................................................148
1115-2 Stacker set 32’............................................................................................149
1115-3 Portable conveyors 3.5 m............................................................................149
1200 CONDENSING PLANT..........................................................................................151
1201 Evaporator Condenser.......................................................................................151
1202 Pan Condensers.................................................................................................152
1202-1 Condensers for ‘A’ Massecuite seed Pan (80 t – 1 No.)..............................152
1202-2 Condensers for ‘A’ Massecuite Pan (100 t).................................................152
1202-3 Condensers for ‘B’ & ‘C’ Graining Pan (80 t – 1 No.)...................................152

Page - 6 / 154
BOILING HOUSE
1202-4 Condensers for ‘B1’ Massecuite Continuous Pan (40 t/h – 1 No.)...............152
1202-5 Condensers for ‘B2’ Massecuite Pan (80 t - 1 No.)......................................153
1202-6 Condensers for ‘C’ Massecuite Pan............................................................153
1203 Air Ejector........................................................................................................... 153
1204 Injection Water Pump.........................................................................................154
1205 Hot and Cold Water Channel..............................................................................154

Page - 7 / 154
BOILING HOUSE
TECHNICAL SPECIFICATION
0500 JUICE TREATMENT AND CLARIFICATION
0501 Juice Measurement
0501-1 Juice Weighing Scale
Quantity : 1 No.
Automatic electronic weighing system for weighment of screened juice from mill
house is a load cell based system, having maximum capacity of 6.5 t/tip. The
capacity can be adjusted at site, depending upon the crushing rate.
Capacity : 6.5 t/tip

No. of tips : 60 tips/h (minimum)
Accuracy : ± 0.25% of full scale reading
Load Cell :
Type : Strain Gauge
Quantity : 4 (2 Active + 2 Dummy)
Properties of fluid to be handled
Liquid : Screened Juice

Specific gravity : 1.04
Temperature : 40 – 45 C
The system shall be complete with suitable feed tank, weigh tank, load cell system,
batching controller, control valves.
The Load Cell System shall consist of following:
Load Cells
Active load cell:
Quantity : 2 Nos.
Type : * Strain Gauge
Overloading : 200 % min
Withstanding temperature: 55 C
Vibration : 3 microns
Housing :
Material : AISI 304, S25 tin plated, filled with inert Gas
Protection : IP 68
Dummy load cell :

Quantity : 2 nos.
Type : * Strain Gauge
Batching Controller
Quantity : 1 No.

Page - 8 / 154
BOILING HOUSE
Type/Make : * Digital/Scholar
The batching controller houses a batch control system comprising of MCB’s, relays,
switches, 24 VDC power supply etc. The batch control system would control the
batching sequence thereby controlling the charging and discharging of the cane
juice.
A brief description of the batching controller is given below supplier should provide
description of his system separately.
The Cane Juice is charged in the weigh tank from the top tank by the charging valve
with the help of Coarse/Fine mode. The weight of the Cane Juice is seen on the
weighment display. The Cane Juice is charged in coarse mode for approximately
90% of the set point. The balance juice is charged in fine mode. As soon as the set
point is reached, the Charge Fine Valve is turned OFF. At this stage the Discharge
Valve is turned ON. After the juice is discharged the discharge valve is turned OFF.
After the juice is discharged and before the starting of next cycle the amount of juice
tipped in this cycle is communicated to the MIS Software in the PC.
The above cycle keeps on repeating till it is stopped by putting Cycle Start/Stop
switch to Stop position.
Followings are provided on the batching controller panel:
a) Switches/Push Buttons:
Auto / Manual
Cycle Start / Stop
Charge – Coarse / Fine
Discharge – On /Off
Print Report
Emergency
b) Lamps:
Auto selected
Manual selected
Cycle on
230 VAC on
24 VDC on
Emergency on
c) Digital indication:
No. of batching cycles
Net instantaneous weight
Preset batching weight
d) Keyboard:
For entering the values
Facility for calibration of tare weight shall also be provided
MIS Software

Page - 9 / 154
BOILING HOUSE
The batching controller shall be connected to the DCS. An MIS software would log
the weight of the juice discharged in each tipping. It would also generate reports for
various queries. Facility for setting/changing of weight per tip for the scale shall be
provided in the software which shall be incorporated in the DCS.
Following reports shall be available from the MIS software:
Hourly tipping report

Shift wise Tipping Report (Shift Timings to be entered in the software)
Daily Tipping Report.
Query Based Report.
All the above reports shall have following fields :
Sr. No.
Date
Time
Net Weight of the molasses batched
Cumulative Weight of the molasses batched
Status of each batch.
Control Valves
Quantity :
Charging valve : 1 No. (fitted in top tank)
Discharging valve : 1 No. (fitted in weigh tank)
Size : * 400 mm
Type : Butterfly, eccentric disc, with site replaceable seat.
Material of construction:
Body : Cast Iron
Wetted parts : SS, AISI 304
Gland housing : SG Iron
Gland packing : Multi layer Teflon impregnated Asbestos + rubber
Seat ring : Glass filled Teflon
A GA drawing shall be submitted indicating the major dimensions suitable for

installation, Terminal points, foundation drawings if any, location of all flanges (with 3-
dimensions) within the terminal point suitable for providing piping connection.
0502 Check Weighment System
To counter check the juice weighment or calibrate the mass flow meter readings at
periodical intervals.
0502-1 Check Weighment Tank
Quantity : 1 No.

Page - 10 / 154
BOILING HOUSE
Capacity : 12 m3
Type : Circular, open top
Material : Mild steel
Outlet nipple size : 150 mm
Diameter : * 2200 mm
Height : * 3200 mm
Plate Thickness : 8 mm
0502-2 Check Weighing Scale
Quantity : 1 No.
Type : Platform Scale, Load cell type

Weighing capacity : 10 t
Minimum graduation : 2.5 kg
Accuracy :  0.15 kg
Platform Size L x W : * mm
0503 Phosphate Dosing System
0503-1 Phosphate Preparation Tank
Quantity : 1 No.
For preparation of phosphoric acid. The tank shall be of stainless steel (SS)
construction, vertical and cylindrical shape with open top.
Capacity : 1.5 m3
Supplier should specify the following parameters
Height : * 1400 mm
Material : SS
Thickness : 5 mm
The tank shall be provided with electrically operated paddle type stirrer for the
preparation of phosphoric acid, one outlet connection and a drain connection.
Stirrer type : * Arm

Speed : * 24 rpm
Motor:
Rating : * 0.75 kW
Speed : * 1450
The tank shall be positioned above the phosphate dosing tank for gravity flow of
phosphoric acid. Suitable approach staircase and platform shall be provided for
preparing solution.

Page - 11 / 154
BOILING HOUSE
0503-2 Phosphate Dosing Tank
Quantity : 1 No.
For preparation and addition of phosphoric acid in the screened juice receiving tank.
The tank shall be of stainless steel (SS) construction, vertical and cylindrical shape
with open top.
Capacity : 4.0 m3
Supplier should specify the following parameters
Height : * 2300 mm
Material : SS
Thickness : 5 mm
The tank shall be provided with electrically operated paddle type stirrer for the
preparation of phosphoric acid, one outlet connection and a drain connection.
Stirrer type : * Arm

Speed : * 24 rpm
Motor:
Rating : * 1.5 kW
Speed : * 1450
Poly vinyl chloride (PVC) piping shall be provided for phosphoric acid from the dosing
tank to the screened juice receiving tank.
The tank shall be positioned above the screened juice receiving tank for gravity flow
of phosphoric acid. Suitable approach staircase and platform shall be provided for
preparing solution.

Page - 12 / 154
BOILING HOUSE
0503-3 Phosphate Dosing Pump
Quantity : 2 Nos. (1 No. working & 1 No. standby)
For pumping of phosphoric acid to the screened juice receiving tank. The pump shall
be of variable speed, metering type.
Type : Metering Type

Make : * Variable speed, metering type
Capacity, variable : 0 – 100 l/m
Head : 20 m
Casing : SS 316/410
Piston : SS 316/410
Shaft : SS 410
Motor : AC VFD
Rating : * 2.2 kW
Speed : * 1000

0504 Raw Juice Buffer Tank
Quantity : 1 No.
The weighed juice from weighing scale or through mass flow meter is received in a
carbon steel, vertical cylindrical, tank provided with top cover and vent. This tank
shall be provided with local and remote level indicators.
Capacity : 50 m3
Height : * 4000 mm
Material : Carbon steel

Thickness : * 12 mm
The tank shall be provided with outlet connection to suction of screened juice pump
and a drain connection.
Outlet connection : 300 mm NB

Drain connection : 80 mm NB

Page - 13 / 154
BOILING HOUSE
0505 Weighed Juice Pump
Quantity : 2 Nos. (1 working & 1 standby)
To pump weighed juice from weighed juice buffer tank to the juice sulphiter through
juice heaters.
Horizontal centrifugal pump directly driven by electric motor, mounted on carbon

steel fabricated common base frame.
Capacity : 350 m3/h

Head : 70 m
Juice to be pumped
Specific gravity : 1.05 – 1.06
Viscosity : 5 cP
PH : 5.5 ± 0.5
Temperature : 25 - 45 C
Material of construction
Casing : Cast Iron
Impeller : Stainless steel
Shaft : Stainless steel
Sleeve : Stainless steel
Seal : Gland
Coupling type : Tyre type

Drive:
Motor : TEFC, Squirrel cage suitable for 400 V, 3 phase, 50 Hz
With VFD and speed locking mechanism.
Power : * 110 kW
Speed : 1450 rpm
Frame size : * As per vendor specs.
The pump shall be complete with coupling, motor, starter, common base frame,
coupling guard, motor guard and foundation bolts.

0506 Juice Sulphiter
Quantity : 1 No.
Juice sulphitation vessel shall be provided with pre-liming, shock liming and main
reaction tank built in one vessel. The sulphitation unit shall consist of one pre-liming
tank having minimum one minute juice retention time and one main reaction tank
having 7 minutes juice retention time with provision of 20 seconds juice retention time
for shock liming.

Page - 14 / 154
BOILING HOUSE
Pre-liming Tank:
Diameter : 4200 mm
Height : * 2500 mm
Main Reaction Tank:
Working volume : 44 m3
Diameter : 4200 mm
Working height : * 3500 mm
Plate thickness:
Shell : 16 mm
Bottom plate : 18 mm
Top plate : 12 mm
The juice sulphiter shall be of carbon steel construction and sulphur di-oxide shall be
used as motive force for effective juice circulation in the reaction tank.
Stirrer is to be provided for proper mixing of mixed juice and milk of lime in the pre-
liming tank. The stirrer shall be driven by electric motor and gearbox of following
specification:
Stirrer speed : 72 rpm
Drive motor
Type : TEFC, Squirrel cage motor suitable for 400 V, 3 phase
and 50 Hz.
Motor power : * 3.7 kW
Speed : 1440 rpm
Gear box
Type : Planetary
Ratio : 20:1
The sulphured juice from the sulphiter shall overflow to the sulphured juice receiving
tank.

0507 Auto pH Control System
Quantity: 1 set
To control the pH of sulphured juice by varying the milk of lime quantity for optimum
chemical reaction in the juice sulphiter for achieving near steady clarification of juice
for best possible transmittancy and compact mud settling features and to maintain a
record for later reference.
Process & Control Philosophy:

Page - 15 / 154
BOILING HOUSE
a) To measure and control the lime flow as per juice flow.
b) Measure the pH of the sulphured juice at the out let of the sulphiter.
c) This pH signal is transferred to controller.
d) Controller compares the input signal with the set point and error signal is
generated.
e) The error signal is given to lime proportionate unit to add required quantity of
lime to the sulphiter.
Instruments and Control Units
a) pH electrode: One pH electrode and a transmitter for a pH range of 4 to 12

pH. It shall give an analogue output at 4 to 20 amps.
b) pH Indicator: 10 mm height LED display for final pH at juice sulphiter in the

control room. It shall give an analogue output at 4 to 20 amps
c) pH recorder: Multi point 24 hour pH recorder for a range of 0 to 14.
d) Controller: Proportional Integral and Differential Controller (PID)
e) Indication and recording: The system shall be provided with indicating digital
display for pH values measured at any given time with recording.
The system shall be provided with suitable lime proportionating unit.
3 Nos. pH electrodes shall be used, 1 # working, 1 # under regeneration, 1 # spare.

The electrodes are to be changed every day with the regenerated electrode.

0508 Sulphured Juice Receiving Tank
Quantity : 1 No.
Sulphured juice receiving tank, to receive sulphured juice from sulphiter, shall be of
carbon steel welded construction, vertical cylindrical, provided with top cover and
vent. This tank shall be provided with local and remote level indicators.
Capacity : 50 m3
Diameter : 4000 mm
Height : * 5000 mm

Page - 16 / 154
BOILING HOUSE
Thickness : * 12 mm
The tank shall be provided with outlet connection to suction of screened juice pump
and a drain connection.
Outlet connection : 300 NB

Drain connection : 80 NB
0509 Sulphured Juice Pump
To pump sulphured juice from the sulphured juice receiving tank to the flash tank
through juice heaters.

Capacity : 350 m3/h

Head : 70 mlc
Speed : 1450 rpm
Juice to be pumped
Viscosity : 5 cP
PH : 7.2 ± 0.3
Casing : Cast Iron
Seal : Gland
Drive:
Power : * 110 kW
Speed : 1450 rpm
Frame size : * As per vendor specs.


Page - 17 / 154
BOILING HOUSE
0510 Juice Flow Stabilization System
Quantity : 1 set
To control the raw juice, sulphured juice and clear juice flow to the process and to
reduce aberration in juice flow quantity. This system facilitates to control the process
parameters at optimum level.
Process & Control Philosophy:
a) Juice is pumped from the respective receiving tanks through flowmeter and
respective juice heaters. Juice flow is to be controlled before it enters the
heater.
b) Juice flow is measured by volumetric flowmeter.
c) The signal is transferred to PID controller.
d) Controller compares the input signal with the set point and error signal is
generated.
e) The error signal is given to control valve installed in bypass line of respective
juice pump delivery.
f) Control valve opens/closes according to the error signal.
g) Differential pressure type level sensors are installed in respective juice

receiving tanks and variation in level is compared to the set point and is
communicated to controller. Whenever the level increases/decreases beyond
a safe limit, an audio-visual signal will be given to the operator for appropriate
action.
Instruments and Control Units
a) Electronic controller : PLC consisting of digital/analog, input/output module,

and power supply module, user interface, panel-ware, annunciator etc.
b) Butter fly control valve with replaceable seat type with pneumatic/electronic
actuator and I/P converter
c) Pressure sensing level transmitter

Page - 18 / 154
BOILING HOUSE
0600 CLARIFICATION AND FILTRATION
0601 Flash Tank
Quantity : 1 No.
To receive hot sulphured juice from juice heater and feed to clarifier after flashing.
The flash tank shall be suitable for flashing the sulphured juice before admitting to
the clarifier.
Vertical, cylindrical, conical bottom, closed type flash tank shall be provided. The
flash tank shall be of carbon steel welded construction and fitted with vent pipe, juice
inlet and outlet connections. The flash tank shall be suitable to handle maximum
sulphured juice flow rate of 375 m3/h, at 103 C.
Height : * 3500 mm
Plate thickness : 16 mm
Juice shall enter the flash tank tangentially. Juice outlet pipe from the bottom shall be
connected to juice entry of clarifier through a 'U' bend to provide proper sealing
between the flash vapour and the liquid outlet. A drain connection with a gate valve
of 100 NB size is to be provided at the bottom most point of the outlet pipe. The
drainpipe shall be terminated in the clarifier sump box.
Vent pipe from the top of the flash tank should be extended above the building roof
by at least by 1 m. The vent pipe shall be designed to eliminate carry over of the
juice from the flash tank.
Pipe diameter:
Juice inlet : 250 mm
Juice outlet : * 450 mm
Vent pipe : * 800 mm
Drain : 100 mm

0602 Clarifier
0602-1 SRT Clarifier
Quantity : 1 No. (1 No. in each stream)
The “Short Retention Type” clarifier shall have single compartment with juice inlet,
juice outlet and mud outlet from the compartment. The clarifier shall be suitable for a
crushing capacity of 265 tch with 125 % sulphured juice.
Holding Volume : 240 m3

Page - 19 / 154
BOILING HOUSE
Retention time : 45 minutes
Height : *
Plate thickness : * mm
The juice withdrawal point shall be designed to minimise turbulence.
The clarifier shall be made of carbon steel plates having following minimum
thickness:
Bottom : * mm
Shell : * mm
Tray : * mm
Tray (top) : * mm
Top cover : * mm
Flocculating compartment: * mm
The continuous clarifier shall be complete with carbon steel flash tank, clear juice and
mud withdrawal gravity boxes with sleeves, telescope pipes and `O' rings, hinge type
squeezers, driving mechanism with variable speed drive head with motor consisting
of sprocket, chain and drive guards, all inside and outside clear juice piping, all inside
and outside mud piping, all valves and pipe fittings etc. and complete with peripheral
walkway, angle iron bracket supporting angles, piping for railing, rail support etc.
manholes, platform, railing, access ladder, sump tank with support, insulation
material, special electrodes required for site welding etc.
The clarifier shall be supported on a concrete structure. The supplier shall provide
the details of the concrete foundation.
0602-2 Rapi-Dorr Clarifier (Alternative to SRT Clarifier)
Quantity : 1 No.
The clarifier shall be of "444 " type or equivalent having four compartments with
separate juice inlet through the central shaft, separate juice outlet and separate mud
outlet from each compartment. The clarifier shall be suitable for a crushing capacity
of 265 TCH with 125 % sulphured juice.
Diameter : 12192 mm (40 feet)

Working volume approx. : 710 m3
Juice retention time : 2.25 h
There shall be two juice withdrawal points diametrically opposite in each

compartment to minimize turbulence. The juice withdrawal should be through take-off
pipe of semi - circular shape located inside each compartment of clarifier.
The flocculating compartment complete with skimmer and feed well shall be
provided.
The clarifier shall be made of mild steel plates having following minimum thickness:
Bottom : * 12 mm

Page - 20 / 154
BOILING HOUSE
Shell : * 8 mm with stiffners

Tray : * 10 mm
Tray (top) : * 8 mm
Top cover : * 8 mm
Flocculating compartment : * 8 mm
The continuous clarifier shall be complete with mild steel flash tank item 0601, clear
juice and mud withdrawal gravity boxes with sleeves, telescope pipes and `O' rings,
hinge type squeezers, driving mechanism with variable speed drive head with motor
consisting of sprocket, chain and drive guards, all inside and outside clear juice
piping, all inside and outside mud piping, all valves and pipe fittings etc. and
complete with peripheral walkway, angle iron bracket supporting angles, piping for
railing, rail support etc. 4 # manholes, one for each compartment, each manhole to
have platform, railing, access ladder; sump tank with support, insulation material,
special electrodes required for site welding etc. After installation the clarifier
compartments shall not have any warpage. All the pipe connections on to the
clarifier shell shall be connected with minimum 12 mm pads.
The clarifier shall be supported on a concrete structure. The supplier shall provide
the details of the concrete foundation.
0603 Flocculant Dosing System
For preparation and addition of flocculant in the clarifier.
The preparation tank shall be positioned above the dosing tank for gravity flow of the
flocculant solution. Suitable approach staircase and a platform shall be provided for
preparing the solution. From the dosing tank the flocculant solution shall be added to
the sulphured juice through the dosing pumps.
The polyelectrolyte solution should be added to the juice entry line of the clarifier i.e.
between flash tank and clarifier. One sampling connection with valve in the delivery
line of juice from flash tank to clarifier shall be provided.
0603-1 Flocculant Preparation Tank
Quantity : 1 No.
The tank shall be of Stainless steel (SS) construction, vertical and cylindrical shape
with open top.
Capacity : 2.4 m3.
Height : * 1400 mm
Thickness : 5 mm
An auto vibrator type doser shall be provided for adding measured quantity of
flocculant.

Page - 21 / 154
BOILING HOUSE
The tanks shall be provided with a compressed air Sparger system for uniform mixing
and agitation of the flocculant solution with one outlet connection and a drain
connection.
The preparation tank shall be positioned above the dosing tank for gravity flow of the
flocculant solution. Suitable approach staircase and a platform shall be provided for
preparing the solution.
0603-2 Flocculant Dosing Tank
Quantity : 1 No.
The tank shall be of Stainless steel (SS) construction, vertical and cylindrical shape
with open top with one outlet connection and a drain connection.
Capacity : 2.4 m3.
Diameter : * mm
Height : * mm
Thickness : 5 mm
0603-3 Flocculant Dosing Pump
From the dosing tank the flocculant solution shall be added to the sulphured juice
through the dosing pumps.
Type : Variable Speed, Metering Type

Capacity, each : 0 – 50 l/m
Head : 20 mlc
Material of construction :
Casing : CI
Impeller : SS
Shaft : SS
Sleeve : SS
Seal : * SS
Coupling type : * Std
Drive:
Motor : TEFC, Squirrel cage, AC VFD
Power : * 0.75 kW
Speed : 1450 rpm
Frame size : *
0604 Bagacillo Handling System

Page - 22 / 154
BOILING HOUSE
0604-1 Bagacillo Blower
Quantity : 2 Nos. (1 No. working & 1 standby)
For pneumatically conveying of bagacillo from the bagacillo chute below the bagasse
elevator to the mud feed mixer.
Capacity, each : 350 m3/min
Static pressure : 250 mm WG

Temperature : 30 – 40 °C
Material:
Casing : Carbon steel with wear plates
Impeller : Carbon steel
Shaft : EN-8
Drive:
Motor : TEFC squirrel cage suitable for 400 V, 3 phase, 50 Hz
Power : * 22.5
Speed : * 1450
The blower shall be complete with motor coupling, coupling guard and common base
frame of carbon steel welded construction.

0604-2 Bagacillo Piping
Quantity : 1 No.
From bagacillo blower to cyclone separator.
Pipe diameter : 500 mm

Material : Galvanized iron sheets, 16 SWG thick
Running length : * 60
The pipe shall be in 6 m lengths and flange jointed with sealing ring. Long radius
bends are to be used wherever necessary.
The pipe shall be supported after every 2.5 m length from the roof trusses/building
columns.

Page - 23 / 154
BOILING HOUSE
0604-3 Cyclone Separator
Quantity: 1 No.
For separating bagacillo particles at the rate of 3250 kg/h from the air-bagacillo
stream and discharge into the mud feed mixer, through a 2-way valve.
Material : Galvanized iron 16 SWG thick
Suitable supporting structure shall be provided. The vent connection shall be

extended to above the building roof at least by 1 m.

0605 Feed Mixer
Quantity : 1 No.
Feed mixer shall be of horizontal 'U' section, fitted with stirrer arms. The capacity of
mud mixer shall be suitable for catering feed to 3 Nos. of 14’ x 28’ vacuum filter.
Size:
Width : * mm
Length : * mm

Thickness : 10 mm
Stirrer drive:
Power : * 5.5 kW
Speed : * 1450
Reduction gear box:

Type : Planetary
Ratio : * 72.5:1
The mixer shall be placed at an elevation above the filter trough to permit the filter
feed to flow by gravity to vacuum filter and also the clarifier underflow by gravity from
clarifier mud overflow box to feed mixer. The bagacillo from cyclone separator and
mud from the clarifier shall be fed into the feed mixer. Proper easily removable cover
shall be provided to eliminate the bagacillo contamination in the air. Controlling slide
gate shall be provided at the outlet to regulate the mudflow to the vacuum filter.


Page - 24 / 154
BOILING HOUSE
0606 Rotary Vacuum Filter and Accessories
Quantity: 2 Nos.
Rotary cane mud vacuum filter shall be of 4.267 m Diameter x 8.534 m long (14 ft x
28 ft) with filtration area of 114 m 2 shall be installed at a height suitable to operate
from the platform level + 8.0 meters from factory floor level.
The unit shall consist of:
Drum, drumhead, internal piping shall be of AISI-304 grade. PP decking shall be

provided
Filtering Area : 114 m2 each

Size : 4267 mm dia. x 8534 mm long (14’ x 28’)
Drum Thickness : 5 mm
Drum head : 8 mm thick with carbon steel structural
reinforcement.
The screen shall be of AISI-304 grade with 100 holes/cm2, with 0.5 mm diameter
holes. Screen fixing should be by zigzag caulking strips only. The ovality of the
drum shall not be more than 3 mm.
The trunion shall be of gun metal with suitably lubricated bearings. Bearings material
of construction shall be either polypropylene or gunmetal.
The filter cake wash system shall consist of spray pipes with sufficient nozzles and
drip trays for efficient cake washing. A water strainer shall also be supplied.
Provision for steam washing of the drum shall be provided.
A segmented scraper with rubber strip and counterweights shall be provided. Care
shall be taken at the time of installation that the scrapper touches equally to the drum
such that the scraping of cake is uniform throughout the length of the drum.
The drum shall be driven by TEFC squirrel cage motor with arrangements for varying
the speed between 12 RPH and 36 RPH.
The trough shall be of carbon steel construction with 10 mm thick plate, fitted with
constant speed agitator, driven by a TEFC squirrel cage motor. The trough shall be
fitted with suitable overflow connection and quick operating drain valve.
The filter shall be equipped with centralized multi point lubrication system for
lubricating drum bearings, swivel unit bearings and valve heads. The filter should
preferably be connected to the trunion with linkage for driving the multi point pressure
lubricator.
The clear and cloudy filtrates withdrawal system shall be from both sides of the drum
with isolating globe valves consisting of bronze valve body, bronze wear plates and
stainless steel pipe plate.

Page - 25 / 154
BOILING HOUSE
The vacuum regulation for light and heavy side shall be through an automatic control
valve consisting of bronze valve body, bronze wear plates and stainless steel pipe
plate.
The internal piping shall be of stainless steel construction. The individual deck piping
shall be connected to a receiving pot and the outlet will be taken from the pot and to
be connected to the trunion.
Individual piping for clear and cloudy filtrates from both sides of filter shall be of
stainless steel and extended up to the respective filtrate receivers. Necessary flexible
hosepipes shall be provided in the filtrate piping.
The filter cake shall be discharged directly on the filter cake conveyor belt.
The vacuum filter shall be complete with pressure gauges at water inlet, vacuum
gauges at the valve heads. The gauges shall be of 150 mm diameter dial size.

0606-1 Vacuum Filtrate Receivers
Quantity : 2 Sets.
Two receivers for each Vacuum Filter, one for clear and one for cloudy filtrate.
Each receiver shall be made of 5 mm thick stainless steel plate fitted with gunmetal
vacuum release assembly.
One pneumatically operated automatic vacuum-regulating valve shall be provided.
The filtrate shall be discharged from the filtrate receivers to the filtrate collection tank,
at the FFL by gravity. The pipes shall be extended up to bottom of the tank for
maintaining necessary sealing.

0606-2 Entrainment Separator
Quantity : 2 Nos.
Entrainment separator of stainless steel construction to catch the entrained liquid

from the filter shall be positioned in the vacuum line between the vacuum filtrate
receiver and condenser. The tail pipe of the entrainment separator extended up to
bottom of the filtrate collection tank for maintaining necessary sealing.

Page - 26 / 154
BOILING HOUSE

0606-3 Filter Condenser
Quantity : 2 Nos.
Carbon steel fabricated counter current type condenser of suitable capacity with
stainless steel tail pipe and other accessories.
The condenser shall be made of 10 mm thick carbon steel plates complete with all
connections.
The condenser shall be located in the condenser platform (near evaporator

condenser). Water to condenser shall be taken from main injection water header.
The tail water piping shall be extended to the main condenser tail water header pipe.

0607 Filtrate Collection Tank
Quantity : 1 No.
Cylindrical vertical tank having approximate dimensions of 2800 mm diameter and

2000 mm height with a partition plate. Partition height should be minimum 800 mm.
Dimensions indicated are preferred ones.
Capacity : 15 m3 with a partition plate for sealing

Material : Stainless steel (SS 304)
Thickness : 5 mm

0608 Filtrate Transfer Pump
Quantity : 2 Nos. (1 working & 1 common standby)
To pump filtrate from filtrate collection tank to filtrate vibro screens.
Vertical centrifugal pump directly driven by an electric motor, both mounted on

carbon steel fabricated base frame.
Type : Vertical
Capacity, each : 60 m3/h
Head : 20 mlc

Page - 27 / 154
BOILING HOUSE
Speed : 1450 rpm
Liquid to be pumped:
Liquid : Filtrate
Viscosity : 50 cP
PH : 6.5 – 7.5
Suspended solids : 3%
Casing : Cast Iron
Seal : Gland
Drive:
Motor : TEFC, Squirrel cage suitable for 400 V, 3 phase, 50
Hz.
Power : * kW
Speed : 1450 rpm
Frame size : *
The pump shall be complete with coupling, motor, starter, and common base frame,

0609 Vacuum Pump
Quantity : 3 Nos. (2 working & 1 common standby)
To extract air from the system and create 200 mm absolute pressure.
Type : Water ring type

Capacity : 3200 m3/h
Pressure : 200 mm abs. suction and exhausting to atmosphere.
Sealing water temp. : 32 °C
Atmospheric pressure : 640 mm Hg
Rotor : Stainless steel
Casing : Cast iron, with epoxy coating inside
Drive:

Page - 28 / 154
BOILING HOUSE
Motor : TEFC squirrel cage suitable for 400 V, 3 Phase, 50 Hz

Power : * 90 kW
Speed : * 1450 rpm
The pump shall be complete with common base frame, coupling, coupling guard,
foundation bolts and sealing water connection, discharge manifolds, vacuum gauge,
silencer etc. The exhaust piping shall be extended to outside building. Complete
piping, valves, bends and fittings for suction and discharge sides shall be provided.

0610 Mud Recirculation Tank
Quantity : 1 No.
Vertical Cylindrical tank, with open top and conical bottom shall be provided. The
tank shall be of carbon steel construction.
Capacity : 15 m3
The tank shall be suitably reinforced and insulated with aluminium cladding. The tank
shall be installed on FFL. Necessary supports, foundation bolts and fitting shall be
provided.
The tank shall be provided with an outlet connection, 200 NB with valve to be
connected to suction of mud re-circulation pump. A drain connection, 100 mm NB
with valve shall also be provided. Exhaust steam coil shall be provided in the tank for
heating purposes.
0611 Mud Recirculation Pumps
To re-circulate the mud from the re-circulating tank to filter.
Centrifugal pump directly driven by an electric motor, both mounted on carbon steel
fabricated base frame shall be supplied.
Capacity : 60 m3/h
Head : 20 mlc
Speed : 1450 rpm
Liquid to be pumped:
Liquid : Filtrate mixed with bagacillo
Specific Gravity : 1.2
pH : 6.5 - 7.5

Page - 29 / 154
BOILING HOUSE
Solids : 50 %
Casing : Cast Iron
Impeller : Stainless Steel
Seal : Gland
Drive:
Motor : TEFC squirrel cage suitable 400 V, 3 phase, 50 Hz
Power : * 15 kW
Speed : 1450 rpm
The pump shall be provided complete with coupling, common base frame, coupling
guard and foundation bolts.

0612 Cake Wash Water Pump
To pump hot water from hot water header and spray over the filter cake.
Centrifugal pump directly driven by an electric motor, both mounted on a carbon steel
fabricated base frame.
Capacity : 15 m3/h
Head : 60 m
Speed : 1450 rpm
NPSH required : 1500 mm
Water to be pumped:
Temperature : 90 °C
pH : 7.0
Casing : Cast Iron
Seal : Mechanical
Drive:
Motor : TEFC squirrel cage suitable for 400 V, 3 phase, 50 Hz.
Power : * 15 kW
Speed : 1450 rpm

Page - 30 / 154
BOILING HOUSE
The pump shall be provided complete with common base frame, coupling, coupling

0613 Mud Belt Conveyor
Quantity : 1 No.
To transport filter cake discharged from the filter to the mud bin.
Capacity : 25 t/h
Belt speed : 25 m/min
Belt width : 600 mm
Length : To suit layout
Drive:
Power : * 5.5 kW
Speed : 1450 rpm
Reduction gear box:

Type : Planetary
Ratio : * 72.5:1
Service factor : 2.0
Drive shall have suitable speed reducing arrangement to operate the belt at 25 m/min
speed.
Belts shall be of suitable synthetic fabric with adequate tensile rating.
Trough idlers shall be of three-roller type with troughing rollers at 20° angle and
suitably placed with flat type return idlers. The trough idlers shall be fixed at
maximum 1500 mm centres and return idlers at maximum 3000 mm centres.
Suitable belt cleaner shall be provided at the discharge end.
The belt conveyor shall be installed at the working platform level + 8.0 meters from
FFL.

0614 Mud Bin
Quantity : 1 No.

Page - 31 / 154
BOILING HOUSE
For collection of filter cake discharged from the belt conveyor and feed to trailers.
Capacity : 10 t
Conical shape, open top, the bin shall be fabricated from 6 mm thick carbon steel
plate. The bin shall be suitably supported for discharging the mud to mud trailers.
Bottom opening of the bin shall be minimum 500 mm size, flanged end suitable to
provide a sliding gate door. The door shall be provided with chain and pulley
arrangement for easy opening and closing, suitable for operating from ground floor.
The discharge point shall be minimum at 3 m height from FFL.

0615 Filtrate Vibro Screen
Quantity : 3 Nos.
Circular, vibratory screens shall have SS-304, 60 mesh for screening of filtrate juice.
The diameter of the vibro screen shall be 1700 mm. Provisions shall be given to
adjust the vibratory motion of the unit.
Capacity, each : * 20 t/h

Material : SS 304
Mesh : 60 mesh
Drive:
Type : Vibratory motor
Power : * 1.5 HP


Page - 32 / 154
BOILING HOUSE
0616 Filtrate Clarification System (Optional)
Quantity : 1 set
The system shall be designed to avoid the re-circulation of the solids, and bagacillo
back to the process, through the filtrate from rotary vacuum filters.
Process Data :
Input Material : Screened Filtrate from Rotary Vacuum Filters
Quantity : 120 m3/h
pH : 6.5 – 7.0
Brix : 13  2
Purity : 80 – 83
The system shall be provided with complete automation. The main features of the
system should include:
- Retention time in the Filtrate clarifier shall be very short, of the order of 15
minutes.
- Bagacillo and other suspended solids shall be completely removed from the
system.
- The pH of the filtrate shall be always maintained at higher value by adopting
elaborate automation.
- The treated filtrate should be suitable to be sent to the evaporators along with
clear juice from clarifier outlet for further processing.
The supplier shall submit a detailed write up, explaining the process, with
material/energy balance of the system. The write up shall be backed up with
adequate amount of material flow sheets, P & I diagrams, etc for better
understanding. Datasheets of the various chemicals and equipment to be used for
the filtrate clarification system shall be submitted for evaluation.
The supplier should clearly mention the principle of operation of the filtrate
clarification system (Whether Sedimentation / Floatation).
The treated filtrate coming from the filtrate clarification system shall be of the
following quality:
Flow rate : 120 m3/h

Temperature : 73  2 °C
pH : 6.5 – 7.0
Brix : 12  2
Purity rise : 3.5 – 4 units
Ash removal : 10 % minimum
Turbidity Reduction : 85 – 90 %
Suspended solids removal: 95 – 98 %

Page - 33 / 154
BOILING HOUSE
- The treated filtrate juice shall be free of any suspended solids

- The capacity of the existing clarifier should increase by 15 %.
- There should not be any rise in the CaO content from the untreated filtrate to
clarified filtrate.
0700 MILK OF LIME AND SO2 GAS PREPARATION
0701 Lime Elevator
Quantity : 1 No.
Inclined, rubber belt and bucket type to elevate quick lime from factory floor level to
feeding hopper of lime slaker, installed at + 8.0 m platform level.
Capacity : 3 t/h
Type : Rubber Belt and Bucket type
Speed : 30 m/min (maximum)
Bucket:
- Dimensions : * 250x150x120 mm
- Capacity : *3 kgs.
- No. of buckets : * 50 Nos.
- Material : * MS:IS-2062
Bearings : Ball/roller
Centre distance : As per layout

between shafts
Drive:
- motor : TEFC squirrel cage suitable for 400 V, 3 phase, 50 Hz.
- Power : * 2.2/3.7 kW
- Speed : 1450 rpm
Gear box:
- Type : Planetary

0702 Lime Slaker
Quantity : 1 No.
Revolving drum type slaker shall be used for slaking the quick lime with hot water
and discharge as milk of lime.
The lime slaker shall be of carbon steel construction made from 10 mm thick plate
with two rolled steel tyres around the drum and supported by 4 trunion rollers. The
slaker shall be complete with all necessary mixing devices and water inlet. A suitable

Page - 34 / 154
BOILING HOUSE
rotary screening device and discharge chute for removing larger pieces of unslaked
material shall be provided at the discharge of the slaker.
The unit shall be complete with supporting steel work. The capacity of the slaker shall
be 2500 kg/h of quick lime.
The slaker shall be driven by an electric motor through reduction gearing, final drive
being through a pinion on to a toothed rim on the slaker drum
Capacity : 2500 kg/h

Thickness : 10 mm
Speed of the drum : 6–8 rpm
Drive :
- Motor : TEFC , Squirrel Cage , 400 V, 3ph, 50Hz.
- Power : * 3/10 kW
- Speed : 1450 rpm
Reduction Gear Box:

Type : Planetary
Service Factor : 2.0

0703 Grit Elevator
Quantity : 1 No.
Belt conveyor to convey the grit collected from lime slaker to outside building suitable
to discharge into a trailer.
Capacity : 1 t/hr
Type : Trough
Material : Belt
Thickness : 8 mm
Speed : 25 m/min
Belt width : 450 mm
Belts shall be of suitable synthetic fabric with adequate tensile rating.
Trough idlers shall be of three-roller type with troughing rollers at 20° angle and
suitably placed with flat type return idlers. The trough idlers shall be fixed at
maximum 1500 mm centres and return idlers at maximum 3000 mm centres.
Suitable belt cleaner shall be provided at the discharge end.

Page - 35 / 154
BOILING HOUSE

0704 Milk of Lime (MOL) Vibro Screen
Quantity : 3 Nos.
Circular, vibratory screens shall have SS-304, 60 mesh for screening milk of lime.
The diameter of the vibro screen shall be 1700 mm. Provisions shall be given to
adjust the vibratory motion of the unit.
Capacity, each : *5 t/h

Diameter : 1700 mm
Material : SS 304
Mesh : 60 mesh
Drive:
Type : Vibratory motor
Power : * 1.5 HP

0705 Milk of Lime Storage Tanks
Quantity : 2 Nos.
To store milk of lime. Hydrated lime and water are added to the tank to prepare milk
of lime of required density.
Cylindrical, vertical, open tank shall be of carbon steel welded construction.
Capacity, each : 35 m3
Height : * 3000 mm
Stirrer Speed : 29 rpm
Drive:
- motor : TEFC squirrel cage suitable for 400 V, 3 phase, 50 Hz.
- Power : * 2.2/10
- Speed : 1450 rpm
Gear box:
- Type : Planetary

Page - 36 / 154
BOILING HOUSE
The tank shall be complete with TEFC squirrel cage motor coupled to reduction gear
for operating the paddle type stirrer, suspended from a bolt-on frame on the top of
the tank.

0706 Milk Of Lime Pumps
To transfer milk of lime from milk of lime storage tank to lime proportionating unit.
Rubber lined Rotary or Plunger type pumps directly driven by an electric motor, both
mounted on carbon steel fabricated base frame. Grit catcher shall be placed in the
suction line of each pump.
Type : Rubber lined, semi open with expelling vane

Capacity : 25 m3/h
Head : 30 mlc
Speed : 1450 rpm
Liquid to be pumped : Milk of lime
Casing : Ni hard / CI with rubber lined
Impeller : Ni hard / CI with rubber lined
Seal : Gland
Coupling type : Tyre type/spacer type love joy
Drive:
- Motor : TEFC, squirrel cage suitable for 400 V, 3 phase, 50 Hz.
- Power : * 11
- Speed : 1450 rpm
The pump shall be provided complete with coupling, motor, starter, common base
frame, guards and foundation bolts.

0707 Sulphur Burner
0707-1 Sulphur Burner for Juice Sulphitation

Page - 37 / 154
BOILING HOUSE
Film type sulphur burner should be capable of continuously burning 120 - 200 kg/h of
standard quality sulphur and suitable for producing sulphur di-oxide gas at a
concentration of 10 +/- 2 % V/V.
Type : Film type with automation
Burning capacity : 120 - 200 kg/h
Steam consumption : * kg/h

Water consumption : * kg/h
Air Consumption : * kg/h
The burner shall preferably comprise the following installation:
- Molten sulphur dosing pump with AC VFD – 2 Nos. (1 W + 1 SB)

- Combustion chamber, refractory lined, filled with refractory bricks.
- After burner
- Coolers to cool the gas up to 70 °C.
- All interconnecting SO2 gas piping, up to header outlet with isolating valves.
- Platform around SO2 gas piping.
- Complete automation.

0707-2 Sulphur Burner for Syrup Sulphitation
Film type sulphur burner should be capable of continuously burning 70 - 200 kg/h of
standard quality sulphur and suitable for producing sulphur-di-oxide gas at a
concentration of 10 +/- 2 % V/V.
Type : Film type with automation

Burning capacity : 70 - 200 kg/h
Steam consumption : * kg/h

Water consumption : * kg/h
Air Consumption : * kg/h
The burner shall preferably comprise the following installation:
- Molten sulphur dosing pump with AC VFD – 2 Nos. (1 W + 1 SB)

- Combustion chamber, refractory lined, filled with refractory bricks.
- After burner
- Coolers to cool the gas up to 70 °C.
- All interconnecting SO2 gas piping, up to header outlet with isolating valves.
- Platform around SO2 gas piping.

Page - 38 / 154
BOILING HOUSE

0707-3 Sulphur Melter for Burners
Quantity : 1 No.
The melter shall be common for both burners of juice and syrup sulphitation, suitable
for melting standard quality sulphur of net capacity 400 kg/h.
The melter shall be made of carbon steel construction, provided with heating coils
and suitable insulation.
Saturated steam at 6 kg/cm2 (g) pressure will be available for melting at the inlet of
the melter.
Net melting capacity : 300 kg/h
The melter shall be complete with:

- Platform around melter gas piping.

0708 Air Dehumidifier
To dry air for the above burners.
Type : Refrigerated
Removal of moisture : upto + 4 ºC dew point
Capacity, each : suitable for 1600 m3/h sulphur burner
Power Consumption : * kW/h

0709 Air Blower
0709-1 Air Blower for Juice Sulphitation
Type : Rotary

Page - 39 / 154
BOILING HOUSE
Free air capacity : 1600 m3/h

Delivery pressure : 1.0 kg/cm2 (g)
Noise level : Not above 90 db
Speed : *
Efficiency : *
Drive:
- Type : * TEFC sq.cage
- Power : * 75 kW
- speed : * 1440 rpm
The Blower shall be complete with flexible coupling, guard and electrical starter/
switches.
Supply shall be fully assembled unit with motor and blower mounted on a common
base plate. Necessary holding down and foundation bolts shall be supplied.

0709-2 Air Blower for Syrup Sulphitation
Type : Rotary
Free air capacity : 1600 m3/h
Delivery pressure : 1.0 kg/cm2 (g)
Noise level : Not above 90 db
Speed : *
Efficiency : *
Drive:
- Type : * TEFC sq.cage
- Power : * 75 kW
- speed : * 1440 rpm
The Blower shall be complete with flexible coupling, guard and electrical starter/
switches.
Supply shall be fully assembled unit with motor and blower mounted on a common
base plate. Necessary holding down and foundation bolts shall be supplied.

0800 JUICE HEATING & EVAPORATION
0801-1 Juice Heater (Tubular Type)

Page - 40 / 154
BOILING HOUSE
Quantity: 10 Nos.
Vertical, multipass, dynamic steam/vapour jacketed, tubular juice heater of carbon

steel construction. The heater shall confirm to following specification:
Heating surface area : 370 m2 each

No. of tubes per pass : 32
No. of passes : 14

Plate thickness:
- Body : 12 mm
- Tube plate : 32 mm
- Cover plate : 32 mm
The juice heater shall be designed to provide the partition plates in the top and the
bottom cover plates for diverting the juice from one pass to another.
Stainless steel welded tubes, annealed, confirming to ASTM A-249 shall be used for
the heating surface.
Tube holes suitable for following SS tubes:
Outside diameter : 45 mm
Thickness : 18 SWG
Length : 6000 mm
Ligament of tube holes shall be minimum 12 mm.
Heating surface area shall be calculated on the basis of mean diameter of tubes and
length in contact with the heating medium.
Each heater shall be provided with flanged nipples for the following connections. All
flanges shall conform to BS 10, Table D.
Safety valve fitting : 80 NB - 1 No.

Steam / Vapour inlet : * NB - 1 No.
Juice inlet : 250 NB - 1 No.
Juice outlet : 250 NB - 1 No.
Condensate : 150 NB - 2 Nos.
Cold water-calandria : 100 NB - 1 No.
Non-condensable gas : 80 NB - 4 Nos.
Vent in top cover plate : 25 NB - 14 Nos.
Drain bottom cover : 40 NB - 14 Nos.
For Vapour line juice heater the vapour inlet and outlet diameter shall be * mm
Nipple without flange for steam/vapour entry and exit.
Each heater shall be provided with easy opening device for cover plates.

Page - 41 / 154
BOILING HOUSE

0801-2 Clear Juice heater (Plate type)
Quantity : 2 Nos.
Single/double pass stainless steel plate type heat exchanger shall be provided for
clear juice heating in two stages as given below:
a) Clear juice 1st stage heating (CJ1) from 95 to 110 C in first plate type heat
exchanger (PTHE) using quintuple 1st effect vapour at 117 0C.
b) Clear juice 2nd stage heating (CJ2) from 110 to 115 C in 2nd PTHE using
exhaust steam at 122 0C.
Type : Plate type

Juice flow rate : 350 m3/h
Juice inlet/outlet size : * 200 mm
Gasket : AL-EPDM, suitable to withstand 130 ºC temperature.
Both the PTHE’s shall be located on Evaporator staging at + 8.0 m level. The PTHE’s
shall be free standing on the evaporator staging. Holding down bolts if required shall
be included in the scope of supply
The plate type heater shall be designed to provide turbulent flow with minimum
pressure drop across the plate pack. The corrugations & clearance between adjacent
plates shall be suitable to promote uniform distribution of juice and avoid clogging.
The PTHE frame, shall be suitable for mounting additional plates to increase the
heating surface during expansion. A suitable mechanism shall be provided to add /
dismantle the plates during cleaning / replacement. The frame shall be suitable for
outdoor application. The pressure plates shall be of sufficient thickness to avoid
warping and suitable for additional plates.
An elaborate cleaning in place (CIP) arrangement consisting of valves, pumps &

chemical holding tanks shall be provided for insitu cleaning of PTHE’s. The supplier
shall provide details of the various equipment and utilities required for insitu cleaning
of the PTHE. The CIP arrangement shall be common for both the PTHE’s
Sealing gaskets for PTHE shall be of special EPDM material suitable for exhaust
steam at 1.5 kg/cm2(g) pressure and 130 0C temperature. The gaskets shall be
preferably press fitted onto the exchanger plates instead of glued fitting. The glue
material shall also be suitable for exhaust steam at 1.5 kg/cm2 (g) and 130 0C
The plate holding bolts shall be suitable for additional plates which will be added to
the plate pack for future expansion.

Page - 42 / 154
BOILING HOUSE
The Bolts & Nuts shall be of SS 316 construction. The exposed portion of the bolts
shall be sheathed in a suitable PP/HDPE sheath to protect the bolt threading. Special
tools required for dismantling/ assembling of the PTHE shall be separately indicated.
The configuration of the plate pack shall be suitable to provide uniform pressure drop
of juice across all the plates for proper distribution of juice. The entry loss for juice
shall be indicated.
The Supplier shall enclose complete technical literature in the form of drawings,
catalogues technical papers etc describing the salient feature of PTHE along with the
Contract
P & ID & control schematics of CIP system for PTHE shall also be included.
0801-3 Liquid-Liquid Heat Exchanger
Quantity: 1 No.
Each heat exchanger should be suitable for heating 375 m3/h of sulphured juice from
65 C to 75 C by means of condensate water.
Process Material : Sulphured Juice

Temperature : 65 C
Brix : 13.0 to 16.0
0802 JH Condensate Extraction System
0802-1 Condensate Receiver No.1
Quantity: 1 No.
One condensate receiver is to be provided to collect condensate from Sulphured

juice 3rd stage heater, Clear juice 1st stage heater.
The Condensate receiver, horizontal & cylindrical, of Carbon steel construction,

located at 4.5 m height above FFL, shall be:
Diameter : 1500 mm
Length : 1800 mm
The condensate vessel shall have following connections with flanged nipples. All
flanges shall conform to BS-10, Table D.
Condensate inlet from the heater : 100 mm - 6 Nos.

Condensate outlet to pump : 125 mm - 1 No.
Equalizing connection : 200 mm - 1 No.
Drain connection : 50 mm - 1 No.

Page - 43 / 154
BOILING HOUSE
Re-circulation connection : 80 mm - 1 No.

Sight glass : 200 mm - 1 No.
Light glass : 200 mm - 1 No.

0802-2 Condensate Pump for Receiver No.1
Quantity: 2 Nos. (1 working & 1 standby)
To pump condensate from condensate receiver No.1 to hot water tank.

Capacity : 65 m3/h
Head : 30 m
Speed : 1450 rpm
Condensate to be pumped
pH : 6.5 – 7.5
Temperature : 125 C (max)
Casing : Cast Iron
Seal : Gland
Drive:
Power : * 9.3/11kW
Speed : 1450 rpm
Frame size : *

Quantity: 1 No.

Page - 44 / 154
BOILING HOUSE
One condensate receiver is to be provided to collect condensate from Raw juice 2 nd

and 3rd stage heaters.

Diameter : 1500 mm
Length : 1800 mm
flanges conform to BS-10, Table D.
Condensate inlet from the heater : 100 mm - 6 Nos.

Equalizing connection : 200 mm - 1 No.
Re-circulation Connection : 80 mm - 1 No.


Capacity : 65 m3/h
Head : 30 m
Speed : 1450 rpm
pH : 6.5 – 7.5
Casing : Cast Iron
Seal : Gland

Page - 45 / 154
BOILING HOUSE
Drive:
Motor : TEFC, Squirrel cage suitable for 400V, 3 phase, 50 Hz
Power : * 9.3/11 kW
Speed : 1450 rpm
Frame size : *

Quantity: 1 No.
One condensate receiver is to be provided to collect condensate from Raw juice 1st
stage heaters.

located at FFL, shall be:
Diameter : 1500 mm
Length : 1800 mm
flanges conform to BS-10, Table D.
Condensate inlet from the heater : 100 mm - 3 No.

Equalizing connection : 100 mm - 1 Nos.
Re-circulation Connection : 80 mm - 1 No.



Page - 46 / 154
BOILING HOUSE
Capacity : 25 m3/h
Head : 30 m
Speed : 1450 rpm
pH : 6.5 – 7.5
Casing : Cast Iron
Seal : Gland
Drive:
Power : * 5.5/5 kW
Speed : 1450 rpm
Frame size : *

0803 Clear Juice Column
Quantity: 1 No.
Vertical, cylindrical, closed top with vent shall be provided to receive the clear juice
from the SRT clarifier.
Capacity : 50 m3
Height : Above juice overflow box of clarifier
Diameter : * 2100 mm (approx.)
Height : * 16000 mm (approx)
Plate thickness : * 12/14 mm
The tank shall be provided with a vent pipe of 100 mm diameter at the top, sufficient
number of sight and light glasses, juice inlet, juice outlet, water inlet and drain
connections. The vent pipe shall be extended above juice overflow box of clarifier.

Page - 47 / 154
BOILING HOUSE
0804 Clear Juice Pump
To pump clear juice from the clear juice column to Quintuple 1st effect evaporator
through juice heaters.

Capacity : 350 m3/h

Head : 60 mlc
Speed : 1450 rpm
Juice to be pumped
Viscosity : 5 cP
PH : 6.9 ± 0.2
Casing : Cast Iron
Seal : Gland
Drive:
Power : * 83/90kW
Speed : 1450 rpm
Frame size : *

0805 Evaporator Station
Quantity: 2 sets (1 working & 1 standby)
The distribution of heating surfaces shall be as follows:
1st Effect (Semi-kestner) : 3000 m2

2nd Effect (Semi-kestner) : 3500 m2
3rd Effect : 1000 m2

Page - 48 / 154
BOILING HOUSE
4th Effect : 1000 m2

5 Effect
th
: 1000 m2
2
Exhaust steam at 1.50 kg/cm (g) will be used for evaporator.
0805-1 First Effect
Quantity: 2 Nos. (1 no. in each set)
Heating Surface Area: 3000 m2
Long tube rising film type vessel (Semi-kestner) of carbon steel welded construction
shall be in two parts, i.e. a calandria and a catchall installed one beside the other.
The catchall shall have chevron type separator of carbon steel construction.
The carbon steel plate thickness of various parts shall be as below:
Tube plate : 36 mm
Bottom saucer : 24 mm
Body shell : 20 mm
Calandria shell : 20 mm
Top cone : 22 mm
Catchall shell : 20 mm
Catchall internals : 16 mm
SS304 plates for Chevron separator shall be of 1.20 mm thick.
Tube details:
Thickness : 18 SWG
Length : 6000 mm
The unit shall be complete with the matching flanges for the following connections
and accessories. All flanges shall conform to BS-10, Table D.
Connections & Accessories Size (mm) Quantity
a) Juice inlet & Outlet connection 350 2 Nos.

b) Re-circulation connection 350 1 No.
c) Condensate connection 150 4 Nos.
d) Non condensable gas connections 100 3 Nos.
65 2 Nos.
e) Cold water connection (body & 150 2 Nos.
calandria)
f) Wash out connection 200 1 No.
g) Soda circulation valve connection 150 1 No.

Page - 49 / 154
BOILING HOUSE
h) Hot water connection for catchall 100 1 No.

i) Vapour release connection 300 1 No.
j) Safety valve on calandria 150 1 No.
k) Pressure equalisation 200 1 No.
l) Exhaust connection in calandria 200 1 No.
for open soda boiling
One matching flange connection for steam valve, * 1400 mm size, shall be provided.
One matching flange connection for isolating valve in the vapour pipe leading to 2 nd
effect, equal to the size of vapour inlet to 2nd effect shall be provided before the inlet
of 2nd effect calandria.
Suitable arrangement shall be provided for easy and quick opening of top cover of
the calandria during cleaning operation.
A platform around the calandria at the top shall be provided for opening the cover
bolts. The cover bolts shall be of “EYE” bolt type.

0805-2 Second Effect
Quantity: 2 Nos. (1 No. in each set)
Long tube rising film type vessel (Semi-kestner) of carbon steel welded construction
shall be in two parts, i.e. a calandria and a catchall installed one beside the other.
The catchall shall have chevron type separator of carbon steel construction.
Tube plate : 36 mm
Body shell : 20 mm
Top cone : 22 mm
SS304 plates for Chevron separator shall be of 1.20 mm thick.
Tube details:
Thickness : 18 SWG

Page - 50 / 154
BOILING HOUSE
Length : 4000 mm
a) Juice connection for inlet & Outlet 350 2 Nos.

b) Re-circulation connection 350 1 No.
c) Condensate connection 150 4 Nos.
d) Non condensable gas connections 100 3 Nos.
65 2 Nos.
e) Cold water connection (body & calandria) 150 2 Nos.
f) Wash out connection 200 1 No.
g) Soda circulation connection 150 1 No.
h) Hot water connection for catchall 100 1 No.
i) Vapour release connection 300 1 No.
j) Safety release connection on calandria 150 1 No.
k) Exhaust connection in calandria for open 200 1 No.
soda boiling
One matching flange connection for isolating valve in the vapour pipe leading to 3 rd
effect, equal to the size of vapour inlet to 3 rd effect shall be provided before the inlet
of 3rd effect calandria.
Suitable arrangement shall be provided for easy and quick opening of top cover of
the calandria during cleaning operation.
A platform around the calandria at the top shall be provided for opening the cover
bolts. The cover bolts shall be of “EYE” bolt type.

0805-3 Third Effect
Sealed down-take type vessel shall be of carbon steel welded construction. The unit
shall have an efficient centrifugal type SS304, 1.2 mm thick, vapour liquid separator.
The parallel height of vapour space shall be 5000 mm above the top tube plate.
Tube plate : 32 mm

Page - 51 / 154
BOILING HOUSE
Body shell : 20 mm
Vapour belt : 20 mm
Top cone : 22 mm
SS welded tubes, annealed, confirming to ASTM A-249 shall be used for the heating
surface.
Tube details:
Thickness : 18 SWG
Length : 2000 mm
a) Juice Outlet connection 200 1 No.

b) Condensate connection 150 1 No.
c) Non condensable gas connections 80 4 Nos.
d) Cold water connection (body & calandria) 150 2 Nos.
e) Wash out connection 150 1 No.
f) Soda circulation connection 100 2 Nos.
g) Hot water valve for catchall 100 1 No.
h) Exhaust connection in calandria for open 100 1 No.
soda boiling
i) Vapour release connection above catchall 300 1 No.
j) Safety connection on calandria 150 1 No.
k) Vacuum breaking 100 1 No.
One flanged nipple for isolating valve in the vapour pipe leading to 4 th effect, equal to
the size of vapour inlet to 4th effect shall be provided before the inlet of 4 th effect
calandria.

0805-4 Fourth Effect

Page - 52 / 154
BOILING HOUSE
shall have an efficient centrifugal type SS304, 1.2 mm thick, vapour liquid separator.
Tube plate : 32 mm
Body shell : 20 mm
Vapour belt : 20 mm
Top cone : 22 mm
surface.
Tube details:
Thickness : 18 SWG
Length : 2000 mm

f) Soda circulation connection 150 1 No.
g) Hot water connection for catchall 100 1 No.
soda boiling
i) Vacuum breaking connection 100 1 No.
j) Vapour release connection above catchall 300 1 No.
k) Safety connection on calandria 150 1 No.
One flanged nipple for isolating valve in the vapour pipe leading to 5 th effect, equal to
the size of vapour inlet to 5th effect shall be provided before the inlet of 5 th effect
calandria.


Page - 53 / 154
BOILING HOUSE
0805-5 Fifth Effect
shall have an efficient centrifugal type, SS304, 1.2 mm thick, vapour liquid separator.
Tube plate : 32 mm
Body shell : 20 mm
Vapour belt : 20 mm
Top cone : 22 mm
surface.
Tube details:
Thickness : 18 SWG
Length : 2000 mm

f) Soda circulation connection 150 1 No.
g) Hot water connection for catchall 100 1 No.
soda boiling
j) Vapour release connection above catchall 300 1 No.
k) Safety connection on calandria 150 1 No.

Page - 54 / 154
BOILING HOUSE

0805-6 External Saveall
In addition to the vapour liquid separator inside the effect, an external saveall of
chevron type shall be provided in the vapour pipe of the 5 th effect to condenser. Body
of save-all shall be of carbon steel construction of 12 mm thick and the chevron
separator shall be of SS plates of 1.50 mm.
The juice collected in the saveall shall be sent back to the 5th effect through a proper
sealing bottle. The sealing bottle shall be provided with sight and light glasses.
The unit shall have following connections with flanged nipples. All flanges shall
conform to BS-10, Table D.
a) Juice connection (Inlet & outlet of sealing bottle and 50 3 Nos.

outlet of saveall)
b) Vacuum breaking connection 50 1 No.
c) Hot water connection for saveall 50 1 No.
d) Cold water connection for saveall 50 1 No.
General
Heating surface area shall be calculated on the basis of mean diameter of tubes and
length in contact with the heating medium.
All the bottom saucers are to be welded to the calandria.
The evaporator set shall be complete in every respect with fittings for satisfactory
operation.
Each effect shall be provided with effective juice distribution coil in the bottom saucer.
Each effect shall be provided a vapour release pipe at the top, 300 mm size, with
blind flange for open soda boiling.
Both calandria and vapour space shall be provided with 300 mm dial type
temperature gauges, with suitable thermo well. The temperature gauges shall be
easily replaceable during working.
Both calandria and vapour space shall be provided with 300 mm dial type pressure
gauges, compound gauges and vacuum gauges as required. 1st & 2nd effect shall
be provided with pressure gauges. 3rd effect shall be provided with compound
gauges. 4th & 5th effects shall be provided with vacuum gauges.

Page - 55 / 154
BOILING HOUSE
Sufficient number of sight and light glasses of minimum 200 mm size shall be
provided in each effect for observing the operation.
A hand hole, 250 mm size, with blind flange shall be provided in the body, above top
tube plate and near to the front sight glass, for using during cleaning of heating
surfaces.
Manholes of 500 mm size shall be provided in calandria, bottom saucer and body for
maintenance. A small platform with access ladder shall be provided for the manhole
in the body.
The internal surfaces of evaporator body and ducting shall be epoxy coated after
proper surface preparation. The epoxy paint shall be suitable to withstand vapour
temperature of ~ 120 °C.
0806 Evaporator Condensate System
0806-1 Condensate Receiver for First Effect
Quantity: 2 Nos. (1 No. for each set)
One condensate receiver is to be provided to collect condensate from Quintuple 1 st

effect and clear juice 2nd stage heater.

Diameter : 1200 mm
Length : 1500 mm
flanges shall conform to BS-10, Table D.
Condensate inlet from the heater : 100 mm 2 Nos.

Condensate inlet from first effect : 250 mm 1 No.
Condensate outlet to pump : 250 mm 1 No.
Equalizing connection : 200 mm 1 No.
Drain connection : 80 mm 1 No.
Sight glass : 200 mm 1 No.
Light glass : 200 mm 1 No.

0806-2 Condensate Pump for First Effect
Quantity: 4 Nos. (1 working & 1 standby for each set)
To pump condensate from condensate receiver to deaerator tank.

Page - 56 / 154
BOILING HOUSE

Capacity : 140 m3/h

Head : 70 m
Speed : 1450 rpm
pH : 6.5 – 7.5
Casing : Cast Iron
Seal : Mechanical

Drive:
with VFD.
Power : * 75/55kW
Speed : 1450 rpm
Frame size : *

0806-3 Flash Vessel for Second Effect
One flash vessel is to be provided to collect condensate from Quintuple 2nd effect.
The flash vessel, horizontal & cylindrical, of Carbon steel construction, located at 4.5
m height above FFL, shall be:
Diameter : 1200 mm
Length : 1500 mm

Page - 57 / 154
BOILING HOUSE
The flash vessel shall have following connections with flanged nipples. All flanges
shall conform to BS-10, Table D.
Condensate inlet from second

effect : 250 mm 1 No.
Condensate outlet to 3rd effect
flash vessel : 250 mm 1 No.
Flash connection : 200 mm 1 No.
Condensate inlet connections shall be provided from top of the flash tank with the
inlet pipe sealed in water and condensate outlet connection shall be taken from the
flash tank through a funnel type arrangement which is extended upto the centre of
the tank.

0806-4 Flash Vessel for Third Effect
One flash vessel is to be provided to collect condensate from Quintuple 3 rd effect.

Diameter : 1200 mm
Length : 2500 mm
Condensate inlet from third Effect : 200 mm 1 No.

Condensate inlet from 2nd effect : 200 mm 1 No.
Condensate outlet to 4th effect
the tank.

Page - 58 / 154
BOILING HOUSE

0806-5 Flash Vessel for Fourth Effect
One flash vessel is to be provided to collect condensate from Quintuple 4th effect.
Diameter : 1200 mm
Length : 2500 mm
Condensate inlet from 4th effect : 150 mm 1 No.

Condensate inlet from third effect : 250 mm 1 No.
Condensate outlet to 5th effect
the tank.

0806-6 Flash Vessel for Fifth Effect
One flash vessel is to be provided to collect condensate from Quintuple 5th effect.
Diameter : 1200 mm
Length : 2500 mm

Page - 59 / 154
BOILING HOUSE
Condensate inlet from fifth effect : 150 mm 1 No.

Condensate inlet from 4th effect : 250 mm 1 No.
Condensate outlet to condensate
pump header : 250 mm 1 No.
Re-circulation connection : 80 mm 1 No.
the tank.

0806-7 Condensate Pump for Fifth Effect.
Quantity: 4 Nos. (1 working & 1 standby in each set)
To pump condensate from condensate receiver to hot water tank.

Capacity : 140 m3/h

Head : 30 m
Speed : 1450 rpm
pH : 6.5 – 7.5
Casing : Cast Iron
Seal : Gland

Page - 60 / 154
BOILING HOUSE
Drive:
With VFD.
Power : * 75 kW
Speed : 1450 rpm
Frame size : *

0807 Syrup Receiving Tank
Syrup receiving tank, to receive unsulphured syrup from evaporator, shall be of

carbon steel welded construction, vertical cylindrical, provided with top cover.
Diameter : 1200 mm
Height : 1500 mm
Thickness : 16 mm
The tank shall be provided with outlet connection to suction of syrup pump,
equalising connection to last body of evaporator and a drain connection.
Inlet : 200 NB
Equalising connection : 150 NB
Sight Glass : 200 NB
Light Glass : 200 NB
Re-circulation Connection: 80 NB
0808 Syrup Extraction Pump
Quantity: 4 Nos. (1 working & 1 standby in each set)
To pump syrup received from the evaporator to the unsulphured syrup storage tank.
Horizontal centrifugal pump directly driven by an electric motor, both mounted on a

Capacity : 70 m3/h
Head : 30 m
Speed : 1450 rpm

Page - 61 / 154
BOILING HOUSE
Syrup to be pumped
pH : 5.5 - 6.5
Viscosity : 75 cP
Casing : Cast Iron
Impeller : Stainless steel (Open type)
Seal : Gland
Drive :
Motor : TEFC Squirrel cage suitable for 400 V, 3 phase, 50 Hz.
Power : * 22/15kW
Speed : 1450 rpm
Frame size : *
0809 Unsulphured Syrup Storage Tank
Quantity: 1 No.
Unsulphured Syrup receiving tank, to receive unsulphured syrup from syrup

extraction pump, shall be of carbon steel welded construction, horizontal cylindrical,
provided with top cover and vent. The tank shall be provided with stiffeners for side
plates and level indicators for local and remote level indication.
Capacity : 80 m3
Diameter : 4000 mm
Length : 6400 mm

Shell thickness : 16 mm
Side plate thickness : 18 mm with stiffeners
The tank shall be provided with outlet connection to top of syrup sulphiter
0810 Sulphured Syrup Transfer Pump
Quantity: 2 Nos. (1 No. working & 1 standby)
To pump syrup received from the sulphiter to the syrup supply tanks at pan floor.

Page - 62 / 154
BOILING HOUSE
Horizontal centrifugal pump directly driven by an electric motor, both mounted on

Capacity : 70 m3/h
Head : 30 m
Speed : 1450 rpm
Syrup to be pumped
pH : 4.8 – 5.2
Viscosity : 75 cP
Casing : Cast Iron
Seal : Gland
Drive :
Motor : TEFC Squirrel cage suitable for 400 V, 3 phase, 50 Hz.
Power : * 22/15kW
Speed : 1450 rpm
Frame size : *
0811 Syrup Sulphiter
Quantity: 2 Nos. (1 working, 1 standby)
The continuous syrup sulphiter capable of processing syrup of 65 Brix shall be of
carbon steel construction.
The syrup sulphiter shall be installed near the juice sulphiter.
Syrup sulphitation vessel shall be provided with gas absorption tower (stack gas
recovery tower) of carbon steel construction complete with SO 2 absorption
arrangement.
The sulphitation unit shall have minimum twenty minutes retention time 265 tch crush
rate.
Working volume : 18 m3
Diameter : 4000 mm
Working height : 1500 mm
Plate thickness :

Page - 63 / 154
BOILING HOUSE
Shell : 16 mm
Bottom plate : 20 mm
Top plate : 12 mm
The unit shall have sufficient light and sight glasses to observe performance.

0812 Syrup Clarification System (Optional)
Quantity: 1 set.
Capacity : Suitable for 120 m3/h of syrup at 60 brix.
Process Data :
Input Material : Unsulphured syrup from the evaporators
Quantity : 120 m3/h
pH : 6.2 – 6.5
Brix : 62  2
Purity : 82 – 85
The system shall be provided with complete automation. The main features of the
system should include:
- Retention time in the syrup clarifier shall be very short

- The sugar loss across the system should be minimal.
The supplier shall submit a detailed write up, explaining the process, with
material/energy balance of the system. The write up shall be backed up with
adequate amount of material flow sheets, P & I diagrams, etc for better
understanding. Datasheets of the various chemicals and equipment to be used for
the syrup clarification system shall be submitted for evaluation.
The supplier should clearly mention the principle of operation of the clarification
system
The treated syrup coming from the syrup clarification system shall be of the following
quality:
Flow rate : 120 m3/h

Temperature : 70  2 °C
pH : 6.2 – 6.5
Brix : 62  2
Purity rise : 0.5 – 1 unit
Ash removal : 20 % minimum

Page - 64 / 154
BOILING HOUSE
Turbidity Reduction : 85 – 90 %
Colour removal : 50 %
CaO removal : 20 % minimum
0813 Caustic Soda System
0813-1 Caustic Soda Tank
Quantity: 1 No.
Rectangular tank, closed top shall be of carbon steel fabricated construction:
Capacity : 80 m3
Length : * mm
Width : * mm
Height : * mm
Plate thickness : * mm
The tank will be provided with a manhole at the top for feeding caustic soda walkway
and access staircase.
A heating coil using exhaust steam shall also be provided in the tank.
0813-2 Caustic Soda Pump
To pump caustic soda solution from caustic soda tank to all evaporator bodies and
return to caustic soda tank.
Horizontal centrifugal pump directly driven by an electric motor, both mounted on

Capacity : 60 m3/h
Head : 20 m
Speed : 1450 rpm
Liquid to be pumped : Caustic Soda

Temperature : 85 – 95 O
C
pH : 12
Casing : Cast Iron
Impeller : Bronze
Shaft : *
Sleeve : Bronze
Seal : Gland
Drive:

Page - 65 / 154
BOILING HOUSE
Power : * 11 kW
Speed : 1450
0814 Steam Pressure Stabilization system
Quantity: 1 set
0814-1 Overflow Surplus Valve (OSV-1)
Quantity: 2 Nos.
Automatic surplus overflow valve to be installed in the exhaust line bleeding to pans
to bleed excess exhaust steam into pan vapour line.
Capacity of steam flow : 35 t/h.

Size : 350 x 450 NB
Inlet steam condition
- Pressure : 1.5 kg/cm2 (g)

- Temperature : Saturated
The pressure in the vapour line is normally maintained at 0.7 kg/cm2 (g).
The valve shall be with cast iron/carbon steel body having carbon steel internals.
Pressure Controls
Pneumatically operated up-stream control shall be provided with electronic pressure

transmitters for following duty conditions:
Impulse shall be taken from the up-stream side and the valve shall be set:
- to open at pressure 1.55 kg/cm2 (g)

- to close at pressure 1.45 kg/cm2 (g)
Accuracy of control: +/- 0.02 kg/cm2 (g)
The controls shall be supplied with air piping, valves and fittings from the air
compressor
Dial type pressure gauges, both at the upstream and down-stream side of the valve
and a pressure recorder for the up-stream side shall be provided.
The valve shall be installed at a convenient location near the pan station in the
exhaust pipe line.

Page - 66 / 154
BOILING HOUSE
The system shall be complete with bypass arrangement with piping and valves.
A butterfly valve, of suitable size shall be provided in the by-pass line for manual
operation during any problem in the surplus valve.
0814-2 Overflow Surplus Valve (OSV-1A)
Quantity: 2 Nos. (1 No. in each body)
Automatic surplus overflow valve to be installed in between the vapour line bleeding
to ‘C’ pans to bleed excess vapour into ‘A + B1 + B2’ pan vapour line.

Size : 500 x 600 NB
- Pressure : 0.4 kg/cm2 (g)

- Temperature : Saturated
The pressure in the vapour line is normally maintained at 0.3 kg/cm2 (g).
The valve shall be with cast iron/carbon steel body having stainless steel internals.
Pressure Controls


compressor

Page - 67 / 154
BOILING HOUSE
Quantity: 2 Nos. (1 No. for each body)
Automatic surplus overflow valve to be installed in the vapour outlet line of 2 nd effect
to maintain a constant up-stream pressure.

Size : * 1000 x 1000 NB
Up-stream pressure to be maintained is about 0.3 kg/cm2 (g)
The valve shall be with cast iron body/carbon steel having stainless steel internals.
Pressure Controls


compressor
The valve shall be installed at a convenient location near the evaporator station in the
vapour outlet pipeline of 2nd effect.
Quantity: 1 No.
Specification is similar to item 0813-3 except for the following :
The valve shall be fitted at the farthest end of pan vapour line for blowing off excess
vapour in the vapour pipe.
Capacity of steam flow : 10 t/h

Size : * 400 x 400 NB

Page - 68 / 154
BOILING HOUSE
Pressure : 0.4 kg/cm2 (g)

Temperature : Saturated
The valve shall be set to open at a set point between 0- 0.6 kg/cm2 (g)
0814-5 Relief Valve (RV-1)
Quantity: 1 No.
To maintain a constant pressure in the pan vapour line and release the excess
vapour.
The valve shall be installed in the pan vapour line at the end of the consumption
point. Outlet pipe lines of the valve shall be extended to above the building roof
atleast by 1 m.
The valve shall conform to:
Type : Dead weight type

Capacity : 10 t/h
Size, NB : * 250 mm (Inlet)
: * 300 mm (Outlet)
The valves shall be set suitably for maintaining a constant pressure in the vapour line
at 0.35 kg/cm2 (g)
The valve shall be with cast iron/carbon steel body having stainless steel internals.
0814-6 Pan Vapour Control Valve (PVCV)
Quantity: 9 Nos. (1 No. for each pan)
Eccentric disc butterfly type control valve to be installed in the calandria of each
vacuum pan to maintain the up-stream pressure.
Capacity of steam/vapour flow : 30 t/h

Size : * mm
The valve shall be with cast iron body having stainless steel internals.
Pressure Controls



Page - 69 / 154
BOILING HOUSE
compressor
The valve shall be installed at the inlet vapour pipe of each pan calandria.
A steam/vapour valve, of suitable size shall be provided in the by-pass line for
manual operation during any problem in the control valve.
0900 GRAINING AND CRYSTALLIZATION PLANT
0901 Syrup & Molasses Storage Tanks
Quantity: 1 Set (16 Tanks in set)
For storage of syrup, melt and molasses on pan floor.
Cylindrical, horizontal tanks shall be of carbon steel welded construction and located
at 2 m level above pan floor.
The tanks shall receive molasses in the tanks from respective molasses pumps at
the floor level in centrifugal station. Each tank shall be provided with a manhole and
vent at the top and cat ladder inside the compartment.
Description No. of tanks Total, Volume , m3
Syrup 4 160
Melt 2 80
A Light 1 40
A Heavy 4 160
B1 Heavy 2 80
B2 Heavy 1 40
C Light 2 80
The tanks shells are to be adequately reinforced.
Suitable walkway, 1000 mm wide at the top, to cover all tanks and access staircases
at convenient locations are to be provided.
Steam heating coil is to be provided in each tank for using preferably 1 st effect
vapours.
Each tank is to be provided with one 150 NB outlet connection and one 150 NB drain
connection at the bottom.

Page - 70 / 154
BOILING HOUSE

0902 Molasses Conditioners and Holding Tanks
0902-1 AH Molasses Conditioner
Quantity: 1 No.
Vertical, cylindrical type AH molasses conditioner shall receive molasses from

storage tanks and discharge into AH molasses holding tank. The conditioner shall be
provided with a stirrer and exhaust steam and hot water connections. Automatic brix
and temperature control system shall be provided to maintain the desired brix and
temperature of the molasses.
Capacity : 12 m3
Height : * 3000 mm
0902-2 AH Molasses Holding Tank
Quantity: 1 No.
Vertical, cylindrical tank for storing conditioned molasses before feeding in to

continuous pan. A level sensor shall be provided in the tank. The level shall be
controlled by operating the AH molasses feed valve to the molasses conditioner from
the storage tank.
Diameter : 3300 mm
Height : * 4300 mm
0902-3 B1H Molasses Conditioner
Quantity: 1 No.
Vertical, cylindrical type B1H molasses conditioner shall receive molasses from
storage tanks and discharge into B1H molasses holding tank. The conditioner shall
be provided with a stirrer and exhaust steam and hot water connections. Automatic
brix and temperature control system, shall be provided to maintain the desired brix
and temperature of the molasses.
Capacity : 5 m3
Diameter : 2400 mm
Height : * 1500 mm
0902-4 B1H Molasses Holding Tank
Quantity: 1 No.

Page - 71 / 154
BOILING HOUSE
Vertical, cylindrical tank for storing conditioned molasses before feeding in to pan. A
level controller shall be provided in the tank. The level shall be controlled by
operating the B1H molasses feed valve to the molasses conditioner from the storage
tank.
Diameter : 2800 mm
Height : * 2500 mm
0902-5 B2H Molasses Conditioner
Quantity: 1 Nos.
Vertical, cylindrical type B2H molasses conditioner shall receive molasses from
storage tanks and discharge into B2H molasses holding tank. The conditioner shall
be provided with a stirrer and exhaust steam and hot water connections. Automatic
brix and temperature control system, shall be provided to maintain the desired brix
and temperature of the molasses.
Capacity : 5 m3
Diameter : 2400 mm
Height : * 1500 mm
0902-6 B2H Molasses Holding Tank
Quantity: 1 No.
operating the B2H molasses feed valve to the molasses conditioner from the storage
tank.
Diameter : 2800 mm
Height : * 2500 mm
0902-7 CL Molasses Conditioner
Quantity: 1 No.
Vertical, cylindrical type CL molasses conditioner shall receive molasses from

storage tanks and discharge in to CL molasses holding tank. The conditioner shall be
provided with a stirrer and exhaust steam and hot water connections. Automatic brix
and temperature control system, shall be provided to maintain the desired brix and
temperature of the molasses.
Capacity : 5 m3
Diameter : 2000 mm
Height : * 2000 mm
0902-8 CL Molasses Holding Tank
Quantity: 1 No.

Page - 72 / 154
BOILING HOUSE
operating the CL molasses feed valve to the molasses conditioner from the storage
tank.
Diameter : 2200 mm
Height : * 4200 mm
0903 Vacuum Pans
0903-1 Batch Pans for ‘A’ Massecuite Seed
Quantity: 1 No.
The batch pan shall be designed for:
Capacity : 80 t
Type : Calandria type with central down take.
S/V ratio : 6.6 m2/m3
Graining/Strike volume : 35 % preferable but not to exceed 37%
Downtake diameter/ top

Tube plate diamenter : 40 % (maximum)
Strike level above

top tube plate : 1400 mm (maximum)
SS welded and annealed tubes confirming to ASTM A – 249 be used for the heating
surface.

Length : 900 mm
Thickness : 16 SWG
Ligament of tube holes : 16 mm
The pan shall have parallel vapour belt and the height of vapour belt should be 3000
mm above the top tube plate.
The bottom saucer shall be welded to calandria shell. Effective feed distribution
arrangement should be provided in the bottom saucer.
The pan shall be provided with two steam entry points, 180 apart, with vapour jacket
in the calandria shell.
Carbon steel plate thickness of various parts shall be as follows:
Tube plate : 32 mm

Page - 73 / 154
BOILING HOUSE
Vapour belt : 16 mm
Top cone : 18 mm
Saveall : 14 mm
Saveall internals : 12 mm
The pan shall be fitted with a centrifugal type saveall designed to have a maximum
vapour velocity of 45 m/s at maximum evaporation rate.
Each pan shall be provided with following fittings, valves and gauges:
Fittings
# Fittings Size (mm) Quantity
a) Sight and light glasses 200 sufficient number

b) Gun metal proof stick 1 No.
c) Stainless steel basin 500 1 No.
d) Man holes with hinged type 500 3 Nos.
closing doors (one fitted in the
vapour belt one in bottom cone
and another in calandria)
e) SS volume measurning scale 100 1 No.
# Connections & Accessories Size (mm) Quantity
a) Condensate outlet 150 2 Nos.

b) Main feed inlet 200 1 No.
c) Syrup/molasses inlet on feed box 200 3 Nos.
d) Non condensable gas 80 4 Nos.
e) Cold water (body & calandria) 150 2 Nos.
f) Wash out 200 1 No.
g) Cut-over connection 250 1 No.
h) Exhaust/vapour steam washing 150 1 No.
connection
j) Hot water inlet on feed box 100 1 No.
k) Movement water inlet on feed box 50 1 No.
l) Hot water inlet for sight glass 25 1 No.
washing
m) Steam inlet on feed box 50 1 No.
n) Air vent 150 1 No.
o) Vapour outlet * 1400 1 No.
p) Safety valve 150 1 No.
q) Catchall washing 100 1 No.
Nipples without flange of suitable size shall be provided for vapour inlet to calandria

Page - 74 / 154
BOILING HOUSE
Massecuite Discharge Valves – 1 No.
Pneumatically / hydraulically operated massecuite discharge valves of suitable size,

shall be provided for each pan. The valve shall be operated through a control box
installed at pan floor in front of each pan.
Gauges
# Gauges Size (mm) Quantity
a) Dial type pressure gauge for 200 1 No.

calandria, Range 0 - 2 kg/cm2(g)
b) Dial type pressure gauge for 200 1 No.
vapour belt, Range 0 - 1 kg/cm2(a)
c) Dial type temperature gauge one 200 2 Nos.
each for calandria and vapour belt
Range 0 – 150 °C
Each pan shall be provided with one syrup/molasses feed box 200 mm NB,
connecting the outlet pipe line of storage tanks and the pan.

0903-2 Batch Pans for ‘A’ Massecuite
Quantity: 3 Nos.
Capacity : 100 t
Downtake diamenter/ top

Tube plate diameter : 40 % (maximum)
Strike level above top

tube plate : 1400 mm (maximum)
surface.

Length : 900 mm

Page - 75 / 154
BOILING HOUSE
Thickness : 16 SWG
Ligament of tube holes : 16 mm (minimum)
The pan shall be provided with two steam entry points, 180° apart, with vapour jacket
Tube plate : 36 mm
Vapour belt : 20 mm
Top cone : 22 mm
Saveall : 20 mm
The pan shall be fitted with a centrifugal type save all designed to have a maximum
Each pan shall be provided with following fittings and gauges:
Fittings

b) Gun metal proof stick 1 No.
c) Panman’s Stainless steel basin. 1 No.
20”
e) SS volume measuring scale 100 1 No.


Page - 76 / 154
BOILING HOUSE

connection
washing
Massecuite Discharge Valves – 2 Nos.

Gauges

calandria,
Range: 0 - 2 kg/cm2(g)
b) Dial type pressure gauge for 200 1 No.
vapour belt,
Range: 0 - 1 kg/cm2 (a)
Range: 0 – 150 O C

0903-3 Batch Pan ‘B1’ ‘B2’ & ‘C’ Graining
Quantity: 1 No.

Page - 77 / 154
BOILING HOUSE
Capacity : 80 t
Downtake / top Tube plate diameter : 40 % (maximum)
Strike level above top tube plate : 1400 mm (maximum)
surface.

Length : 900 mm
Thickness : 16 SWG
Ligament of tube holes : 16 mm (minimum)
The pan shall have parallel vapour belt and the height of vapour belt should be
suitable to accommodate the mechanical circulator.
Tube plate : 32 mm
Vapour belt : 16 mm
Top cone : 18 mm
Saveall : 12 mm
Fittings

b) Gun metal proof stick (within the 1 No.

Page - 78 / 154
BOILING HOUSE
graining volume)

Page - 79 / 154
BOILING HOUSE

connection
washing
Massecuite Discharge Valve – 1 No.

Gauges

calandria,
Range: 0 - 2 kg/cm2(g)
b) Dial type pressure gauge for vapour 200 1 No.
belt,
Range: 0 - 1 kg/cm2(a)
Range 0 – 150 °C.

Page - 80 / 154
BOILING HOUSE

Mechanical Circulator for Pans
Make : *
Impeller
Type : Four Bladed Kaplan Type
Diameter : *
Thickness : *
Hub
Diameter : *
Thickness : *
Shaft
Type : Solid/ Tubular
Diameter : *
Thickness : *
Shaft : *
Hub : *
Impeller : Bronze / Carbon steel
Sealing Arrangement : Stuffing Box
Drive Motor
Type : TEFC, squirrel cage, suitable for AC VFD
Make : *
Power : *
Speed : *
Speed reduction
Type : Planetary gear box
Ratio : *
Service factor : 2.0 (minimum)

0903-4 Continuous Pan for ‘B1’ Massecuite Boiling
Quantity: 1 No.
Continuous vacuum pan shall be of modern design with all standard accessories/
fittings mounted over it. Design of this continuous pan shall be suitable for proper

Page - 81 / 154
BOILING HOUSE
exhaustion of feed molasses under vacuum boiling conditions and simultaneous

withdrawal of massecuite.
Massecuite to be boiled : B1 Massecuite

Capacity, each : 40 t/h
Heating Surface Area : * 920 m2
Type : Continuous, Fixed Calandria
Design Duty Conditions
For B1 continuous pan
B1 massecuite target purity : 75.0

B1 massecuite Brix : > 94.0
B1 massecuite crystal size : 500 microns
B1 grain source : A heavy molasses
B1 grain size : 200 microns
Steam at the inlet of calandria:

Pressure : 0.12 kg/cm2(g)
A heavy molasses purity : 75.0
Continuous pan shall be designed for above given output rate of respective
massecuite having sufficient heating surface area.
Surface area to volume ratio is about: 9.5 - 10 m2/m3
The overall dimensions of pan
Width : * 5312 mm
Length : * 11530 mm
Height : * 7300 mm
The calandria of each pan shall be divided into three separate modules, each with
independent steam control, non-condensable gas and condensate outlets. Each
module shall be capable of being isolated and operated on either exhaust or vapour
independent of the other module(s).
The body of each continuous pan shall typically be arranged into a number of cells
separated by short baffles to promote plug flow and uniform mean residence time
with in the pan. Each cell shall have feed, movement water and steam inlets beneath
the pan calandria.
Number of cells : *
The pans shall be fabricated from carbon steel plates of following thickness
minimum:

Page - 82 / 154
BOILING HOUSE
Shell : 18 mm
End plates : 20 mm
Pan bottom cone : 22 mm
Top & bottom tube plate : 36 mm
Internal partition plates : 16 mm
Saveall : 16 mm
The pans shall have sufficient vapour space above the nominal working level and will
be fitted with efficient entrainment separators designed to ensure that there is no
carryover to the condenser at the maximum evaporation rate.
Each pan calandria tube plate shall be suitably drilled to accommodate Standard
ERW tubes.
The specifications of tubes for each pan shall be as follows:
Tube OD : 102 mm
Thickness : 16 SWG
Length : 900 mm
Material : SS 304
Number of tubes : *
Ligament of tube holes : 16 mm
Provision shall be made for the first cells of the individual pan to be drained back to
the seed vessel and for the final cells of pan to be dropped to the respective
massecuite receivers on pan shut down. Steaming out connections shall be fitted to
the body of each drain valve.
An automatic spray wash system shall be incorporated with in the pan to control the
build up of encrustation on the pan internals.
Seed shall be metered into the continuous pan from the seed vessel using screw
type positive displacement pumps. Seed material and grain size are specified above,
however the Supplier shall mention the quantity of seed to be pumped to the
continuous pan.
The seed shall be brought to pan temperature in the first cell and fed on syrup/
molasses from the second cell onwards. Final exhaustion and heavy up of
massecuite shall be undertaken in the final cells of the pan on water.
Pan design shall allow control of the pan operating level, normally 0.4 to 0.6 m above
the calandria. However, the supplier has to confirm the exact level.
Massecuite discharging arrangement to receiving crystalliser shall ensure the

vacuum to be maintained in the continuous pan.
Fittings shall be supplied for each continuous vacuum pan as specified below. It must
be noted that any fittings necessary for the easy, efficient and safe operation of the
pan shall also be included whether or not specified herein. Auto-control valves to the

Page - 83 / 154
BOILING HOUSE
pan body shall be pneumatically actuated and shall have flanged connections.
Manual feed / movement water isolation valves shall be threaded.
Valves for the continuous pan shall include but not limited to:
1. Pan steam flow control valve per module

2. Pan steam isolation valve per module
3. Condensate drain isolation valve per module
4. Non-condensable gas line isolation valve per module
5. Pan steam out control valve, auto and manual
6. Vacuum breaking valves, auto and manual
7. Pan feed control valve & isolation valves per cell
8. Pan movement water control valve & isolation valve per cell
9. Seed entry valve
10. Seed re-circulation valve
11. Main water fill auto & isolation valves per module
12. Main drain valve per module
13. Drain steam out isolation valve
14. Spray water auto valve
15. Sight glass spray wash manual isolation valves per cell
Other fittings shall include but not limited to:
1. Calandria pressure gauge per pan module

2. Calandria condensate level gauge per pan module
3. Pan vacuum gauge
4. Pan vacuum transducer
5. Pan temperature gauge
6. Pan temperature transducer
7. RF probes per cell for brix sensing.
8. Electromagnetic flow transducer per feed stream
9. Projection microscope to view crystal growth
10. Spray nozzles one per sight glass
11. Spray nozzles to reduce encrustation
12. Sight and light glasses with frames and glasses. The sight glasses shall be
arranged with a minimum of three per cell on the working face of continuous
pan, vertically arranged from the operating level, and at the seed entry and
massecuite product weir. Lighting shall enable inspection of massecuite
working level along with entire length of the continuous pan, and of product
discharge.
13. Manholes to provide access to pan module and entrainment space; minimum
diameter 500 mm with hinged quick release covers. Covers are to be self-
centering and with multi point clamping.
14. A gunmetal or stainless steel proof stick to sample from the down comer in
each cell; a stainless steel sugar boiler’s sink shall also be fitted beneath the
proof-stick.

Page - 84 / 154
BOILING HOUSE
15. The pan shall be provided with suitable vapour out let connection to
condenser.
General Arrangement drawing of continuous vacuum pan shall be submitted along

with the offer.
AUTOMATION
Radio Frequency (RF) probes shall be used to indicate super-saturation in pan-

boiling operations. Super-saturation in continuous vacuum pan cell shall be
controlled by the rate of syrup or molasses addition. Pan mass balance strategy shall
be used for online calculation of syrup or molasses flow set points to attain target
massecuite purity.
An automation of continuous pan shall include PLC based SCADA system with
industrial grade Personal Computer (PC) and printer.
Control strategy shall allow complete automation of continuous pan boiling during
normal operation, with minimal manual input required for starting up, shutting down
and boiling out sequences.
Following parameters shall be monitored and clearly represented on the control

system monitors:
1. Grain feed flow rate indication & control

2. Molasses flow rate indication & control
3. Molasses / seed ratio control
4. Condensate flow measurement with Integrator
5. Pan vacuum indication & control
6. Massecuite flow/level control
7. Steam flow indication control
8. Molasses level indication in pan supply tank
0903-5 Batch Pan for ‘B2’ Massecuite Boiling
Quantity: 1 No.
Capacity : 80 t

Strike level abovetop tube plate : 1400 mm (maximum)
surface.

Page - 85 / 154
BOILING HOUSE

Length : 900 mm
Thickness : 16 SWG
Ligament of tube holes : 16 mm (maximum)
The pan shall be provided with two steam entry points, 180° apart, with vapour jacket
Tube plate : 32 mm
Vapour belt : 16 mm
Top cone : 18 mm
Saveall : 12 mm
The pan shall be fitted with a centrifugal type save all designed to have a maximum
Fittings

graining volume)
c) Panman’s Stainless steel basin. 1 No.
20”

Page - 86 / 154
BOILING HOUSE

connection
washing
Massecuite Discharge Valves – 1 No.

Gauges

calandria,
Range: 0 - 2 kg/cm2 (g)
belt,
Range: 0- 1 kg/cm2 (a)
Range:0 – 150 °C

0903-6 Batch Pan ‘C’ Massecuite Boiling

Page - 87 / 154
BOILING HOUSE
Quantity: 2 Nos.
Capacity : 80 t
Strike level above top tube plate : 1400 mm (maximum)
surface.

Length : 900 mm
Thickness : 16 SWG
Ligament of tube holes : 16 mm (maximum)
The pan shall have parallel vapor belt and the height of vapour belt should be
suitable to accommodate the mechanical circulator.

Tube plate : 32 mm
Vapour belt : 16 mm
Top cone : 18 mm
Saveall : 12 mm
Fittings

Page - 88 / 154
BOILING HOUSE

graining volume)

connection
washing
Massecuite Discharge Valve – 1 No.

Gauges

calandria,

Page - 89 / 154
BOILING HOUSE
Range: 0 - 2 kg/cm2 (g)

belt,
Range: 0- 1 kg/cm2 (a)
Range: 0 – 150 °C
Mechanical Circulator for Pans
Make : *
Impeller
Type : Four Bladed Kaplan Type
Diameter : *
Thickness : *
Hub
Diameter : *
Thickness : *
Shaft
Type : Solid/ Tubular
Diameter : *
Thickness : *
Shaft : *
Hub : *
Impeller : Bronze / Carbon steel
Sealing Arrangement : Stuffing Box
Drive Motor
Type : TEFC, squirrel cage, suitable for AC VFD
Make : *
Power : *
Speed : * rpm
Speed reduction
Type : Planetary gear box
Ratio : *
Service factor : 2.0 (minimum)

Page - 90 / 154
BOILING HOUSE

0904 Massecuite Distribution Pipe
Quantity: 1 Set
For conveying massecuite from pans to crystallisers by gravity.
Closed pipe steam jacketed system (with isolating butterfly valves) of carbon steel
welded construction shall be provided below the pans for quick dropping of
massecuite from pans to the header.
Pipe diameter for

Massecuite : 1000 mm
Pipe thickness : 8 mm
Nipple with flanges (the flanges shall conform to BS-10, Table D) for provision of
isolating butterfly valves shall be provided in the closed pipe to drop the massecuite
in any of the receiving crystallisers below the ‘A’, ‘B2’ and ‘C’ massecuite
crystallisers.
From 'B2' massecuite receiving crystallisers, the massecuite is to flow to cooling

crystallisers by gravity, through suitable size headers, with sufficient slope.
From 'B1' & ‘C’ massecuite receiving crystallisers, the massecuite is to flow to
respective vertical crystallisers by pumping
For conveying massecuite from crystallisers to Centrifugals by gravity.
From 'A' crystallisers the massecuite is to flow to the pug mill of centrifugal machines,
by gravity through suitable size headers.
From 'B1' & 'C' vertical crystallisers, the massecuite is to flow to the header of
respective centrifugal machines, by gravity.
Massecuite distribution header shall be horizontal, cylindrical pipe, Mild steel, 8 mm

thick, welded construction and suitable for accommodating machines. Bottom half
portion of the header is to be provided water jacketing arrangement. End plates are
to be bolted construction. A opening in the top for massecuite inlet and a manhole
with bolted flange are to be provided.
0905 Pan Condensate System
0905-1 Pan Condensate Receiving Tank
Quantity: 2 Nos. (1 No. for Good Condensate & 1 No. for Sweet
condensate)

Page - 91 / 154
BOILING HOUSE
Horizontal, cylindrical condensate receiving tank, for pans of carbon steel

construction shall be:
Capacity, each : 12 m3
Length : * 3500 mm
Plate thickness : 16 mm with stiffeners
The condensate receiving tanks shall have inlet connections individually from each
pan with flanged nipples (flanges shall conform to BS-10, Table D) for isolating
valves for diverting the condensate from pans to any one tank, equalizing line is
connected to main vapour line and outlet connection to the condensate pumps. A
drain connection of 150 mm NB with blind flange shall be provided.
The tank shall be located at 2.5 m level from FFL to provide sufficient NPSH for the
pump.
0905-2 Pan Condensate Pump
Quantity: 3 Nos. (2 Nos. working & 1 common standby)
To pump condensate from pan condensate tank to imbibition.

Capacity : 80 m3/h
Head : 40 m
Speed : 1450 rpm
pH : 6.5 – 7.5
Casing : Cast Iron
Seal : Gland
Drive
Power : * 18.5 kW
Speed : 1450 RPM
Frame size : *

Page - 92 / 154
BOILING HOUSE

0906 Seed Crystalliser
Quantity: 1 No.
For storing dry seed.
Horizontal, U shape, open top, crystallizer shall be of carbon steel construction and
fitted with stirrer. End plates are to be suitably reinforced.
The crystallizer shall confirm to:
Net working capacity : 70 t
Plate thickness :
Shell : 12 mm
End plates : 16 mm
Stirrer speed : 60 RPH
Stirrer drive :
Power : *
Speed : 1450
Reduction gear, 1st stage:

Ratio : * suitable
Type : Planetary gear
Service factor : 2.0 (min)
The crystallizer shall be provided with a nipple connection with flange size 300 mm
NB (the flange shall conform to BS-10, table D) for connecting to the main cutover
line of the pan floor.

0907 Vacuum Crystalliser
0907-1 ‘A’ Vacuum Crystalliser (1 No.)

0907-2 ‘B1’ Vacuum Crystalliser (1 No.)
0907-3 ‘B2’ Vacuum Crystalliser (1 No.)
0907-4 ‘C’ Vacuum Crystalliser (1 No.)

Page - 93 / 154
BOILING HOUSE
Quantity: 4 Nos.
For storing the grain cutting from 'A' massecuite seed, ‘B1’, ‘B2’ & ‘C’ grain vacuum
pans.
Horizontal, cylindrical crystallizer shall be of carbon steel construction and fitted with
stirrer. End plates are to be suitably reinforced.
The crystallizer shall conform to
Net working Capacity, each : 90 t
The net capacity shall be upto the top sight glass centre which shall be 200 mm
below the top.
Plate thickness
Shell : 12 mm
End plates : 20 mm
Stirrer drive :
Power : * 5.5 kW
Speed : 1450
Reduction gear:
Make : *
Ratio : * suitable
The crystallizer shall be provided with following fittings,

Page - 94 / 154
BOILING HOUSE
Fittings
a) Sight and light glasses 200 6 Nos. (min)

b) Light glass with light & reflector 200 2 Nos.
c) Man hole 500 2 Nos.
d) Cutover connection 300 1 No.
e) Vacuum connection 150 1 No.
f) Vacuum breaking 100 1 No
g) Exhaust steam out 150 1 No.
h) Sight glass washing 25 1 No.
i) Water 100 1 No.
j) Wash out 100 1 No.
k) Dial type Vacuum gauge, Range- 200 1 No
0 - 1 kg/cm2 (a)
A staircase and walkway, 1000 mm wide, is to be provided for each crystallizer for
approaching to the man hole at the top of the crystallizer.

0908 'A' Receiving Crystalliser for 100 t Pan
Quantity: 3 Nos.
To receive 'A' massecuite drop from ‘A’ massecuite distribution pipe and feed to the
pugmill of 'A' centrifugal machines.
Horizontal, U-shape, open top, air cooled crystallizer shall be of carbon steel
construction. The crystalliser shall be fitted with efficient stirrer of sturdy construction
for continuous working. End plates are to be suitably reinforced.
Each crystallizer shall conform to:
Plate thickness :
Shell : 16 mm
End plates : 20 mm
Stirrer drive :
Power : * 9.3 kW
Speed : 1450
Reduction gear:
Make : *

Page - 95 / 154
BOILING HOUSE
Ratio : * suitable
Each crystallizer shall be provided with a nipple with flange 300 mm size (the flange
shall conform to BS-10, table D) for massecuite discharge.
The crystallizers are to be installed in the crystallizer floor below 'A' massecuite pans.

0909 ‘B’ & ‘C’ Receiving Crystallisers
0909-1 ‘B1’ Receiving Crystalliser for Continuous Pan
Quantity: 1 No.
To receive 'B1' massecuite from continuous vacuum pans.
Shell : 12 mm
End plates : 16 mm

Stirrer drive :
Power : *
Speed : 1450
Reduction gear:
Make : *
Ratio : * 5.5 kW
The crystallizers are to be installed in the crystallizer floor.

Page - 96 / 154
BOILING HOUSE

0909-2 ‘B2’ Receiving Crystalliser
Quantity: 2 Nos.
To receive ‘B2’ massecuite from vacuum pans.
Shell : 12 mm
End plates : 16 mm
Stirrer drive :
Power : * 5.5 kW
Speed : 1450
Reduction gear:
Make : *
Ratio : *


Page - 97 / 154
BOILING HOUSE
0909-3 ‘C’ Receiving Crystallisers
Quantity: 2 Nos.
To receive ‘C’ massecuite from respective vacuum pans.
Shell : 12 mm
End plates : 16 mm
Stirrer drive :
Power : * 5.5 kW
Speed : 1450
Reduction gear:
Make : *
Ratio : *

0909-4 Liquidation Crystalliser for Continuous Pan
Quantity: 1 No.
To receive 'B1' massecuite when continuous pans are liquidated.

Page - 98 / 154
BOILING HOUSE
Shell : 12 mm
End plates : 16 mm
Stirrer drive :
Power : * 5.5 kW
Speed : 1450
Reduction gear:
Make : *
Ratio : *

0909-5 Sweet Water Tank
Quantity : 1 No.
Horizontal, cylindrical tank of mild steel with closed top and vent for storing
continuous pan washings before pumping to molasses storage tanks. A level sensor
shall be provided in the tank.
The tank shall be located at a suitable elevation to receive the continuous washings
by gravity.
Capacity : 100 m3
Length : * 8000 mm
Plate thickness : *8 mm
0909-6 Sweet Water pumps

Page - 99 / 154
BOILING HOUSE
To pump sweet water from sweet water tank.

Capacity : 60 m3/h
Head : 40 m
Speed : 1450 rpm
pH : 6.5 – 7.5
Casing : Cast Iron
Seal : Mechanical

Drive:
with VFD.
Power : * 15/18.5 kW
Speed : 1450 rpm
Frame size : *


Page - 100 / 154
BOILING HOUSE
0910 Massecuite Pumps
0910-1 ‘B1’ Massecuite Seed Pump for Continuous pans
Quantity: 2 Nos.
To pump ‘B1’ seed from ‘B1’ vacuum crystalliser to ‘B1’ continuous Pan at a
controlled flow rate.
Capacity : 50 t/h
Type : Screw type
Net delivery head : 30 m
Material to be pumped : ‘B1’ Seed

Brix : 90
Purity : 74 – 76
pH : 5.5 - 6.5
Viscosity : 3100 P
Suction pipe size, NB : * mm

Delivery pipe size, NB : * mm
Pump Speed : * 308 rpm
Casing : Cast iron
Rotor : Nitrile/Special EPDM
Drive :
Motor : TEFC squirrel cage for 400 V, 3 phase, 50 Hz with VFD
Power : * suitable kW
Speed : 1450 rpm
Reduction gearbox :
Type : Helical
Make : *
Ratio : *
Pump shall be supplied fully assembled with motor, starter, gearbox, couplings,
guards on a common base plate and complete with foundation/ holding down bolts.

Page - 101 / 154
BOILING HOUSE
0910-2 ‘C’ Massecuite Pumps
Quantity: 2 Nos. (1 No. working & 1 No. standby)
To pump ‘C’ massecuite from ‘C’ receiving crystalliser to ‘C’ vertical crystalliser.
Capacity : 40 t/h
Type : Rota type
Material to be pumped : ‘C’ massecuite

Brix : 101 ° (max)
Purity : 50 – 55 (‘C’ massecuite)
pH : 5.5 - 6.5
Viscosity : 3100 P (approx)

Pump Speed : 24 rpm
Casing : Cast iron
Rotor : Cast Iron with bronze tip.
Drive:
Motor : TEFC squirrel cage for 400 V, 3 phase, 50 Hz
Power : * 30 kW
Speed : 1450 rpm
Reduction gearbox:
Type : Helical
Make : *
Ratio : * suitable

Page - 102 / 154
BOILING HOUSE
0910-3 ‘B1’ Massecuite Pump
To pump ‘B1’ massecuite from ‘B1’ receiving crystalliser to ‘B1’ vertical crystalliser.
Capacity : 50 t/h
Type : Rota type
Material to be pumped : ‘B1’ massecuite

Brix : 90 °
Purity : 74 – 76
pH : 5.5 - 6.5

Pump Speed : 36 rpm
Casing : Cast iron
Drive:
Power : * 22 kW
Speed : 1450 rpm
Reduction gearbox :
Type : Helical
Make : *
Ratio : * suitable

Page - 103 / 154
BOILING HOUSE
0910-4 ‘B1’ & ‘C’ Liquidation Pumps
To pump ‘B1’ and ‘C’ massecuite from respective vertical crystallisers during
liquidation.
Capacity : 40 t/h
Type : Rota type
Material to be pumped : ‘B1’ Massecuite

Brix : 98 O (max)
Purity : 75
Temperature : 45 – 55OC
pH : 5.5 - 6.5
Material to be pumped : ‘C’ Massecuite

Brix : 101 O (max)
Purity : 50 – 55
Temperature : 45 – 55OC
pH : 5.5 - 6.5

Speed : * 36 rpm
Casing : Cast iron
Drive :
Power : * 18.5 kW
Speed : 1450 rpm
Reduction gearbox :
Type : Helical
Make : *
Ratio : * suitable

Page - 104 / 154
BOILING HOUSE
0911 Vertical Crystalliser
0911-1 ‘B1’ Vertical Crystalliser
Quantity: 1 No.
To cool the 'B1' massecuite received from strike receiver.
Mono type vertical, cylindrical vessel shall be of carbon steel welded construction
fitted with stationery cooling coils of having a net capacity of 300 tons.
Alternatively, twin type vertical crystalliser of capacity 150 t per cell, can be
considered.
The vessel shall have a conical bottom, connected to the main vessel of vertical
crystalliser. Massecuite is fed at the top of the main vessel to flow downwards in the
crystalliser by gravity while cooling. The cooled massecuite flows upwards through
the 4 riser pipes attached to the vertical crystalliser vessel and feed the pug mill of 'B'
centrifugal machines, through gutters. Inter connecting pipe with water jacket shall be
included in the scope of supply.
Diameter of the crystalliser not to exceed 4.5 m.
Stationary cooling coils are to be fitted for flow of cooling water counter current to
flow of massecuite. The cooling coils shall be suitably designed to have minimum
pressure drop across the coils. Valves are to be provided as necessary for bypassing
any coil in case of leakage, during working.
The crystalliser shall conform to the following specification:
Net capacity : 300 t each or 2 cells of 150 t each
Massecuite cooling : 65 C to 50 C

Cold water temperature : 35 C
Plate thickness :
Shell bottom portion : 16 mm
Shell middle portion : 16 mm
Shell top portion : 12 mm
Bottom cone plate : 16 mm
Stirrer drive :
Power : * 7.5 kW
Speed : 1440 rpm
Reduction gear:
Make : *
Ratio : *

Page - 105 / 154
BOILING HOUSE

Cooling coils
Heating surface area : * 215 m2
Diameter : * 65 mm
Material : ERW class 'C' conforming to IS:1239 part 1 or
equivalent.
Following fittings shall be included:
Temperature gauges for massecuite inlet, massecuite outlet, water inlet and water
outlet. Capillary type, 200 mm diameter dial and range: 0 – 120 C.
Sufficient number of manholes, 500 mm size, for easy maintenance.
Valves and cocks as necessary for bypassing coils in case of leakage.
Vertical parallel slide gate valve for massecuite outlet in the main vessel, suitably
designed to control the outlet flow of massecuite.
Parallel slide gate valve for liquidation of massecuite fitted at the bottom most part of
the crystalliser, and connected to the suction of liquidation pump.

0911-2 ‘C’ Vertical Crystalliser
Quantity: 1 Set.
To cool the 'C' massecuite received from strike receiver.
Twin type, vertical, cylindrical vessel shall be of carbon steel welded construction
fitted with stationery cooling coils of having net capacity of 200 tons of C massecuite
in each vessel.
The vessels shall have conical bottom, inter-connected at the bottom by a

rectangular hot water jacketed port for two vessels of vertical crystalliser. Massecuite
is fed at the top of one vessel. A distributor is to be provided in this vessel for uniform
distribution of massecuite.
Massecuite flow shall be downward in the vessel and upward in the second vessel
and feed the pug mill of 'C' fore worker centrifugal machines by overflow, through
closed jacketed pipes.
Diameter of the crystalliser not to exceed 4.5 m.

Page - 106 / 154
BOILING HOUSE
Stationary cooling coils are to be fitted for flow of cooling water counter current to
flow of massecuite. The cooling coils shall be suitably designed to have minimum
pressure drop across the coils.
A closed circuit cooling and reheating by water shall be provided.
The crystalliser shall confirm to the following specification :
Net capacity : 2 cells of 200 t each
Massecuite cooling : 65 C to 45 C
Massecuite heating : 50 C
(if necessary)
Cold Water temperature : 35 C

Hot water temperature : 60 C
Plate thickness :
Shell bottom portion : 16 mm
Shell middle portion : 16 mm
Shell top portion : 16 mm
Bottom cone plate : 16 mm
Stirrer drive :
Power : * 9.3 kW
Speed : 1440 rpm
Reduction gear:
Make : *
Ratio : *
Cooling coils :
Heating surface area : * 283 m2
Diameter : * 65 mm
Material : ERW class 'C' conforming to IS:1239 part 1 or
equivalent.
Following fittings shall be included:
Temperature gauges for massecuite inlet, massecuite outlet of the vessel,

massecuite temperature after cooling, massecuite outlet of the vessel, cold water
inlet, cold water outlet, hot water inlet and hot water outlet. Capillary type, 200 mm
diameter dial, and range: 0 - 120 C.
Sufficient number of manholes, 500 mm size, for easy maintenance.

Page - 107 / 154
BOILING HOUSE
Valves and cocks as necessary for bypassing coils in case of leakage.
Vertical parallel slide gate valve for massecuite outlet in the second vessel of
crystalliser suitably designed to control the outlet flow of massecuite.
Parallel slide gate valve for liquidation of massecuite fitted at the bottom most part of
the crystalliser, preferably at the inter- connection massecuite pipe and connected to
the suction of liquidation pump.

0912 Cooling System for Vertical Crystallisers
Quantity: 1 Set
0912-1 Hot Water Surge Tank
Quantity: 1 No.
For closed circuit re-circulation of crystalliser reheating water, arranged to raise the
water temperature to 60 C by using exhaust steam 1.5 kg/cm2 (g).
Cylindrical, vertical, conical bottom, closed top tank shall be of carbon steel
construction. The tank receives crystalliser outlet cold water.
Net capacity: : * 3.1 m3

Diameter : 1500 mm
Height on parallel sides : 1750 mm
Plates thickness : 8 mm
The surge tank shall have inlet connections from the crystalliser outlet of coldwater
circuit and outlet connection to hot water circulation pumps. Tank shall also be
provided with an inlet connection from the process condensate tank for make up. An
overflow connection from the surge tank is to be provided.
The tank shall be fitted with a heating coil for heating the water by exhaust steam.
The inlet steam pipe is to be fitted with suitable steam valve and a non-return valve.
0912-2 Hot Water Circulation Pump for Vertical Crystallisers
Quantity: 2 Nos.
To pump the water from crystalliser outlet of cold water circuit through the heating
coils of vertical crystallisers and transient heaters in centrifugal station.


Page - 108 / 154
BOILING HOUSE
Capacity : 125 m3/h

RPM : 1450
Water to be pumped :
Sp. Gravity : 1.0
pH : 7.0
Casing : Cast iron
Seal : Mechanical/Gland
Drive :
Motor : TEFC squirrel cage suitable for 400 V, 3 phase, 50 Hz.
Power : * 45 kW
Speed : 1450 rpm
The pump shall be provided complete with coupling, common base frame, guard and
foundation bolts.
0912-3 Cold Water Surge Tank
Quantity: 1 No.
Cylindrical, vertical, conical bottom, closed top tank shall be of carbon steel
construction. The tank receives hot cooling water from vertical crystallisers outlet of
cold water circuit.
Net capacity: : * 3.1 m3

Diameter : 1500 mm
Height on parallel sides : 1750 mm
Plates thickness : 8 mm
The surge tank shall have an inlet connection from the crystalliser outlet hot water
and outlet connection to cold water circulation pumps. Tank shall also be provided an
inlet connection from the factory service water source (cold water) for make up. An
overflow connection from the surge tank is to be provided.

Page - 109 / 154
BOILING HOUSE
0912-4 Cold Water Circulation Pump for Vertical Crystallisers
Quantity: 2 Nos.
To pump crystalliser outlet hot water through the cooling coils of 'B1' & 'C' vertical
crystallisers.

Capacity : 125 m3/h

Speed : 1450 rpm
Water to be pumped :
Sp. Gravity : 1.0
PH : 7.0
Casing : Cast iron
Seal : Mechanical
Drive :
Motor : TEFC squirrel cage for 400 V, 3 phase, 50 Hz.
Power : * 45 kW
Speed : 1450 rpm
The pump shall be provided complete with coupling, common base frame, guard and
foundation bolts.
0912-5 Cooling Tower for Vertical crystalliser cooling system
Quantity: 1 No.
For closed circuit recirculation of crystalliser outlet hot water, arranged for cooling the
water temperature down to 35 C with PP / UV stabilised PVC fills shall be provided
along with basin to collect cool water.
Capacity : 125 m3/h

Type : Induced draft

Cold water temperature : 32 C
Design wet bulb temperature : 27 C
Fan Type : Axial Flow
Fan Motor Type : TEFC squirrel cage, induction

Page - 110 / 154
BOILING HOUSE
The design of cooling towers shall be suitable to provide a maximum drift loss of 0.3
% of the inlet water flow. The air pressure drop across the eliminators shall be kept to
a minimum by providing a proper number of airflow direction changes across the
eliminators. The water collected in the eliminators shall return to the tower basin and
shall not mix with the discharge air stream. Eliminators shall be of multi-pass
herringbone type or angular honeycomb arrangement.
An efficient water distribution system shall be provided for uniform distribution of

water across the cross section of the fills. The pressure drop across the distribution
system shall not exceed 15 mwc.
Maximum approach temperature between the cold water outlet & design wet bulb
temperature should not exceed 5 0C. Suitable blow down arrangement shall be
provided.
Necessary screens shall be provided in the cooling tower cold water outlet.
In order to prevent growth of algae and to maintain pH of water in the cooling water
system chemical dosing is to be provided at suitable points. Provision shall be made
for shock dosing at about 3 ppm or appropriate depending on the type and strength
of chemical used.
Fan drives shall be totally enclosed squirrel cage induction electric motors with
reduction gears. The gears shall be of spiral bevel, helical or worm type. The gear
reduction may be of single or multi-stage. All gear drives shall be of enclosed type
and shall operate in oil bath. Remote oil level indicators, fill and drain lines shall be
provided. The service factor of the gear drive with electric motor shall be appropriate
for the application.
0913 Overhead Tanks
0913-1 Hot Water Overhead Tank (2 Nos.)

0913-2 Cold Water Overhead Tank (2 Nos.)
0913-3 Drinking Water Overhead Tank (1 No.)
Quantity: 5 Nos.
Rectangular tank with partition shall be carbon steel construction.
Capacity of tank : 30 m3 each

The tank shall be installed at such a height that it should be possible to fill the pan
completely with water by gravity from these tanks.
One cold water tank shall be used exclusively for power house and other for process
requirements. Suitable partition shall be provided in the cold water tank.
Drinking water tank shall be, sand blasted and lined with epoxy coating or ‘Sintex’ for
drinking purpose only.

Page - 111 / 154
BOILING HOUSE
0914 Cooling Tower for Condensate cooling
Quantity: 1 No.
To cool the surplus hot condensate water. The cooling tower shall be located above
the clarified water storage tank. Specification of cooling tower shall be as follows:
Capacity of each tower : 75 m3/h

Type : Induced draft
Cold water temperature : 32 C
Design wet bulb temperature : 27 C
Fan Type : Axial Flow
Fan Motor Type : TEFC squirrel cage, induction
The design of cooling towers shall be suitable to provide a maximum drift loss of 0.3
% of the inlet water flow. The air pressure drop across the eliminators shall be kept to
a minimum by providing a proper number of airflow direction changes across the
eliminators. The water collected in the eliminators shall return to the tower basin and
shall not mix with the discharge air stream. Eliminators shall be of multi-pass
herringbone type or angular honeycomb arrangement
Maximum approach temperature between the cold water outlet & design wet bulb
temperature should not exceed 5 0C. Suitable blow down arrangement shall be
provided.
Necessary strainer screens shall be provided in the cooling tower cold water outlet.
In order to prevent growth of algae and to maintain pH of water in the cooling water
system chemical dosing is to be provided at suitable points. Provision shall be made
for shock dosing at about 3 ppm or appropriate depending on the type and strength
of chemical used.
Fan drives shall be totally enclosed squirrel cage induction electric motors with
reduction gears. The gears shall be of spiral bevel, helical or worm type. The gear
reduction may be of single or multi-stage. All gear drives shall be of enclosed type
and shall operate in oil bath. Remote oil level indicators, fill and drain lines shall be
provided. The service factor of the gear drive with electric motor shall be appropriate
for the application.
0915 Service Water Pump

Capacity : 600 m3/h

Head : 30 m
Speed : 1450 rpm

Page - 112 / 154
BOILING HOUSE
Liquid to be pumped
PH : 6.5 – 7.5
Temperature : 35 °C (max)
Casing : Cast Iron
Seal : Gland
Drive:
Motor : TEFC, Squirrel cage for 400 V, 3 phase, 50 Hz
Power : * 90 kW
Speed : 1450 rpm
Frame size : *

1000 CENTRIFUGAL STATION
1001 'A' Massecuite Centrifugals
Quantity: 4 Nos.
For single curing of 'A' massecuite and to separate white sugar that shall be dried
and bagged. One battery of machines consisting of 4 machines shall be provided.
Fully automatic recycling, flat bottom, suspended centrifugal machines, with A.C.
variable frequency drive or alternatively D.C. drive shall be provided for single curing
of 'A' massecuite.
Each machine shall conform to the following technical specification:
Conforming Standard : BS:767-1987 or IS:4092
Nominal average capacity : 1750 or 2250 kg per charge
Number of cycles per hour : 20 - 22
Process material : 'A' massecuite

Page - 113 / 154
BOILING HOUSE
Hydrometric Brix : 92.00

Apparent Purity : 90.00
Spinning Speed, Maximum : * 1210 rpm
Gravity factor : * 1150 (approximately)
Power consumption : 1.0 - 1.25 kWh/cycle
Basket size:
Diameter (Inside) : * 1500 mm
Height (Inside) : * 1150 mm
Depth of Lip : * 230 mm
Basic preferred construction specification of the machine is outlined hereunder. The

machine offered by the supplier should be at least equivalent or have superior
specification.
Note: The Supplier should submit the detailed specification of each major items
indicated below, highlighting the salient features of the design. This is very essential
for evaluation.
Basket: Basket shall be totally stainless steel welded and machined construction
ensuring perfect concentricity and safe running of the machine. Sufficient number of
reinforcing rings made of high tensile strength stainless steel shall be shrunk fitted to
the basket. The basket hub (spider hub) shall have adequate sugar discharge area.
Optimum number of drainage holes shall be provided to ensure efficient discharge of
molasses and for long working life of the basket. After drilling holes, the basket shall
be statically and dynamically balanced.
Screen: Triple lining system, comprising of bottom supporting screen, intermediate

screen and front working screen, all made of stainless steel, shall be preferred.
Shaft: Shaft shall be made of high tensile strength forged alloy steel and designed
for dynamic stability. The lower end of the shaft is bolted to the basket hub and
suspended from the bearing housing.
Coupling: The coupling shall be suitably designed to allow gyratory movement of

rotating basket and ensure high fidelity of performance.
Suspension Head: The suspension head, supporting the bearing housing and
basket, shall be made of suitable material.
Bearing: Bearing housing between the suspension head (stationary part) and
centrifugal spindle (rotating part) shall be made of cast steel, and supported by
rubber buffer seat. The bearing assembly shall be suitably designed for long and
maintenance free life. Suitable Grease lubrication shall be followed for the bearings
with necessary safety features.

Page - 114 / 154
BOILING HOUSE
Mechanical Brake: In addition to normal regenerative electrical breaking, a

mechanical brake shall be provided for emergency. The mechanical brake shall be
pneumatically operated.
Monitor Casing: Stainless steel fabricated construction with removable top to

facilitate spindle and basket maintenance. Flanged inspection and cleaning cover on
front facing shall be provided. Top cover shall be of sufficient thickness and stiffened
to take required load. Buffers shall be provided to absorb the shocks due to
wobbling.
Plough / Discharger: Plough / Discharger shall be fully automatic, pneumatically

operated in sequential, consisting of vertical guide shaft with strong and larger shoe
having replaceable tips. The system should be suitable for effective removal of sugar
from the screen without damaging the screen. Necessary interlock shall be provided
to operate the discharger only at the specified lower speed.
Sugar Discharge Valve: Sugar discharge valve shall open during discharging of
sugar and close tightly to the basket bottom opening during the rest of the operation.
The valve shall be operated by pneumatic control system. An interlock shall be
provided to open the valve only during discharging of sugar.
Discharge Chute: To be provided at the bottom of monitor casing for directing the
sugar discharged on to sugar hopper conveyor.
Massecuite Feeding System: Double butterfly valve system shall be provided for
massecuite feeding from pug mill to machine. The valves shall be leak proof type and
operated pneumatically. The first valve should be flush with the pug mill to minimize
choking with settled sugar. The second valve shall prevent any dripping of
massecuite into the basket. Water washing arrangement should be provided between
two valves and operated through the control system after each massecuite feeding
Charge Regulator: Charge regulator of suitable design to control the massecuite

filling for every charge shall be provided. Details of charge regulator functioning shall
be furnished by the supplier.
Water Washing System: Water washing system shall be provided for screen
washing, sugar layer washing, curb washing in monitor casing and feed pipe
washing.
The washing system shall consist of strainers, solenoid valves, spray pipes, nozzles
etc.
The sugar layer washing nozzles shall be suitably designed for uniform and effective
washing to cover whole surface of sugar layer in the basket.
Provision shall be made in the automatic controls for double washing of sugar layer
in one cycle.
Molasses Separator: Double butterfly valves type molasses separator shall be

provided for separation of ‘A’ heavy and ‘A’ light molasses. Both molasses shall be

Page - 115 / 154
BOILING HOUSE
delivered through either individual pipes or individual gutters to respective molasses

tanks, located behind the ‘A’ centrifugal station.
Solenoid Valves: A set of valves, pneumatic cylinders and limit switches as

necessary for the automatic function of centrifugal machine shall be provided.
Air & Water Piping: Air and water piping necessary for above system shall be
included in the scope of supply from the nearest existing air and water headers in the
centrifugal station.
Supplier should specify the quantity and quality of air and water requirement clearly
so that the Purchaser shall make necessary arrangement to provide the same.
Electrical:
Alternative – 1:
Drive Motor: The drive shall consist of a totally enclosed fan cooled electric motor,
squirrel cage, vertical mounted, suitable for operation on 415 V, 50 Hz, 3 phase
supply. The motor shall be with IP 55 protection, Class ‘F’ insulation and temperature
rise restricted to Class ‘B’.
Variable Frequency Controller: The variable frequency controller for speed control
system shall be provided for adjusting the speeds at the desired level for each
function.
Spinning speed : 1200 - 1500 rpm (1000 to 1100)

Charging speed : 150 - 230 rpm (150 to 200)
Ploughing speed : 40 - 70 rpm (30 to 50)
The system shall be designed with electrically regenerative braking during the
retardation cycle.
The variable frequency controller shall be provided in a dust and vermin proof vertical
free standing panel with IP 44 protection with forced ventilation.
The supply voltage will be 400 V, 3 ph ± 10 % with 50 Hz frequency and variation of

± 3 %. The controller shall work with pulse width modulated system providing
adequate torque over the entire speed range by variation of output voltage and
frequency.
Harmonic level shall be maintained within IEE 519 acceptable limits. Input harmonic
filter and output sinusoidal filter of suitable design shall be included.
Alternative – 2:
DC Drive with Thyristor Control:
Electric drive motor shall be vertical mounted D.C. forced air cooling Thyristor
control. Insulation The motor shall be with IP 54 protection, armature insulation of

Page - 116 / 154
BOILING HOUSE
Class ‘F’ and field insulation of Class ‘B’. Field should be shunt stabilized wit h
laminated core suitable for operating on 240 V AC, single phase output of 200-240
DC variable volt.
Suitable charging, intermediate, spinning and ploughing speed shall be selected.

Suitable lubricating and cooling system shall be provided.
The system shall provide adequate torque over the entire speed range by variation of
output voltage and frequency.
For either case the following electricals and accessories shall be provided.
Incoming Panel:
The incoming panel, suitable for ten machines, pug mill and sugar hopper conveyor
shall be provided with the following:
- ACB of adequate capacity

- Ammeter with selector switch
- Voltmeter with selector switch
- kW meter
- kWh meter to measure the net power consumed by the machines
- Necessary fuses
- Indicating lamps
- Overload and short circuit current protection
- Earth fault
- Any other feature as necessary
Control Panel:
The control panel shall be self supporting, floor mounting type and made of sheet
steel reinforced with angle iron frame works with single front door and pick off covers
on back side.
The features of control panel shall include a built-in microprocessor unit with PLC
(Programmable Logic Controller) to control the duty cycle operations and to
memorize and treat abnormal detection of operation. An input device to command
mode of operation to settle the operation schedule and an output device to operate
each terminal correctly shall be provided. The application merit should include Higher
reliability, Higher safety, providing flexible sequence, better performance and Less
maintenance. Provision shall be made for operation of machines in sequence.
Following Automatic controls, but not limited to, for the duty cycle of the centrifugal,
controls of limit switches and interlocks shall be provided.
a) Controls for:
1. Monitoring charging time

2. 1st sugar wash delay
3. 1st sugar wash duration

Page - 117 / 154
BOILING HOUSE
4. 2nd sugar wash delay

5. 2nd sugar wash duration
6. Molasses separation
7. Spinning
8. Charging valves operation.
9. Upper dwell for plough
10. Lower dwell for plough
11. Screen wash delay
12. Screen wash duration
13. Curb wash delay
14. Curb was duration
15. Feeding chute wash duration
16. Charge regulator
b) Controls for limit switches:
1. 1st Feeding valve open/close

2. 2nd feeding valve close/open
3. bottom valve close/open
4. plough swing in/out
5. plough up/down
6. wobbling
7. brake release
c) Interlocks or failure of safety devices
1. Plough interlock with specified speed

2. Motor overload protection
3. Anti wobbling switch
4. Non operation of charge regulator alarm
5. Brake pad release inter-lock
6. Plough fluttering
7. Oil pump for bearing lubrication
d) Master control panel shall be provided with ammeter, tachometer etc., and
sequence interlocking of the machines in the battery.
A time cycle graph indicating the various operations during the cycle should be
submitted along with the Contract.

Page - 118 / 154
BOILING HOUSE
Operator Control Console – Alternative 1:
Operator control console, mounted near each machine shall have necessary push
buttons, signal lamps for various operations, fault annunciator, ammeter and rpm
meter. It shall also have facility for auto or manual operation through change over
switch.
Following components, but not limited to, are to be provided in the operator control
console:
a) Change over switch for auto/manual operation.
b) Push buttons for various manual operations.
c) Mimic display
d) Signal lamps (in different colours) shall be provided for:
1. Control voltage on
2. Charging
3. Acceleration
4. Spinning
5. Electrical braking
6. Discharging
7. Molasses separation
8. Wash water application
e) Fault annunciator, audio-visual type for malfunctioning if any, during the cycle
for main functions.
Operator Control Console – Alternative 2:
A touch screen type panel with electronic controls covering all the above functions
mentioned shall be provided. The panel should be dust and moisture free, preferably
IP 65 protection.
Cabling: All interconnecting power and control cabling between the main incoming
panel and the machines and accessories are included in the scope of this Contract.
Tools and Tackles: Special tools, & Instruments etc., necessary for assembly,
erection and maintenance of the centrifugal machine shall be included in the scope of
supply and should specially include, but not limited to, the tools required for:
- Assembly and dismantling of bearings in the bearing housing.
- Fitting and securing the backing screen.

Page - 119 / 154
BOILING HOUSE
Supporting Structure & Platform:
Supporting structure and platform shall be for each battery comprising of supports for
four machines, pug mill and other accessories as required, including operator
platform and access staircase.
The operator platform shall be maintained at + 4.0 m level, atleast 2000 mm clear
space on working front and 1500 mm clear space at the back of machine. Access
staircase shall have width at least 1000 mm.
A separate platform of 650 mm width with approach staircase shall be provided at the
molasses outlet level, below the main platform, for catering maintenance of butterfly
valves. A separate platform of 650 mm width with approach staircase from the
operator platform shall be provided to top of pug mill level.
An air-conditioned control room shall be provided for accommodating electrical and

control panels.
Pug Mill: Pug mill shall be horizontal, cylindrical (or ‘U’ shaped), open top of mild
steel welded construction and suitable for accommodating 4 machines. A stirrer shall
be provided in the pug mill driven by electric motor through suitable planetary
reduction gearbox.
Technical Specifications/Drawings/Brochures:
Contracts must be accompanied with full technical specifications, literature,

brochures and drawings, covering at least the following:
- Overall assembly drawing of machine with supporting structure, operating

platform.
- General layout drawing of battery.
- Drawing showing design highlights of:
a) basket
b) plough
c) Suspension with oscillation damper
d) bearings and lubrication system
- Brief description giving salient features of basic construction of machine

components.
- Control schematics.
- Brief description of complete automatic recycling operation.

Page - 120 / 154
BOILING HOUSE
1002 Super Heated Wash Water System
Quantity: 1 No.
Each super heated wash water system shall be suitable for four ‘A’ massecuite batch
type centrifugal machines of capacity 1750 or 2250 kg/charge and 22 cycles per
hour.
The system shall consist of a surge tank, heat exchanger, pumps and piping.
1002-1 Surge Tank
Quantity: 1 No.
The surge tank is to receive hot water from the process hot water main header near
the centrifugal station. The hot water will be pumped through the heat exchanger to
the main water feeding header of the centrifugal machines. The excess water in the
system shall return to the surge tank through an surplus overflow valve.
The surge tank, vertical, cylindrical, closed tank shall be circular of carbon steel
construction, properly insulated and installed at minimum + 2.5 m height from FFL.
Level controller shall be provided for controlling the make up water inlet to maintain
the level in the tank. The tank shall be provided with safety valve.
Capacity : * m3
1002-2 Superheated Wash Water Heater
Quantity: 1 No.
To heat the hot water and pumping to four ‘A’ centrifugal machines in each battery,
as mentioned above, for wash water application.
Capacity : * t/h
Heating surface Area : * m2
The system shall be provided with a shell & tube type heat exchanger to heat the hot
water from 80 C to 120 C using saturated steam at 6 kg/cm2 (g).
The heat exchanger shall be fitted with necessary accessories like thermostatic
control for steam supply for heating, temperature and pressure gauges & relief valve.
The heat exchanger and the super heated wash water piping, from the surge tank to
pump and then to centrifugal machines feeding header and return line to the surge
tank, shall be thermally insulated with Aluminium cladding.
Temperature gauge, pressure gauge and overflow surplus valve shall be fitted in the
pipeline. The overflow surplus valve is to be fitted in the main water header pipeline
to maintain a line pressure at 6 kg/cm 2 (g). The excess water is returned to the surge
tank.

Page - 121 / 154
BOILING HOUSE
1002-3 Superheated Wash Water Pump
To pump hot water through the heat exchanger to the centrifugal machines.

mild steel fabricated base frame.
Capacity : * m3/h
Head : 100 mlc
Speed : 1450 rpm
NPSH Required : 1.5 m

Temperature : 120.0 C
pH : 7.0
Material of Construction
Casing : Cast Iron

Impeller : Stainless Steel
Type of Seal : Gland with cooling arrangement
Drive Motor:
Type : TEFC, squirrel Cage, for 400 V, 3 ph, 50 Hz

supply
Power : * kW
Speed : * rpm
The motor shall be provided with coupling, common base frame of mild steel
construction, coupling guard, motor guard & foundation bolts etc.
1003 Instrument Air System Assembly
The instrument air system shall be complete with receiver and an air drier, to supply
oil and moisture free air for the pneumatic control of various operations in the
centrifugal station and other instruments in the milling station and boiling house.
Instrument Air quality shall conform to the standard as per ISA-S7.3- 1975 (Rev.
1981)
1003-1 Air Compressor
Quantity: 2 Nos. (1 Working and 1 standby)

Page - 122 / 154
BOILING HOUSE
The air compressor shall be suitable for following specification:

Type : Receiprocating
Delivery pressure : 7 kg/cm2 (g)

Speed : * 570 rpm
Drive Motor:
Type : TEFC, Squirrel cage suitable for 400 V, 3 ph, 50 Hz.
Power : * 67 kW
RPM : 1450
Speed reduction type : *
The pneumatic system installation shall be complete with:
- Air intake filter

- Pneumatic pressure regulator
- Safety valve
- Pressure gauge panel mounted for each stage
- Coolers as required
- Necessary piping from compressor to air receiver.
1003-2 Air Receiver
Quantity: 1 No. (common for 2 compressors)
One common air receiver suitable for the air compressors shall be provided,
complete with fittings of pressure gauge, relief valves, etc.:

Capacity : 3 m3
Dimensions (D x H) : * 1500 mm x 1750 mm
1003-3 Air Drier
Quantity: 2 Nos. (One for each compressor)
For dehumidifying ambient air suitable for quality standard for instrument air. The
dehumidified air outlet of the dryer shall be connected to the suction of the air
compressors through a header.
Design duty conditions:

Air inlet flow rate : 600 m3/h
Ambient temperature : 40 ºC (maximum)
Altitude : 1550 m above msl
Relative humidity : 85 %
Dryer shall be as follows:

Page - 123 / 154
BOILING HOUSE
Type : Silica Gel or equivalent
Arrangement : Duplex arrangement, one unit operating and the

other unit under regeneration
Capacity : 600 m3/h of free air at local conditions.
Regeneration :
- medium : Steam/Hot air
- pressure : *
- temperature : *
Material of Construction : *
The system shall be designed for fully automatic operation and shall have humidity
indicator on the dehumidified airline.
The Supplier shall include the steam pressure and temperature control equipment
required for regeneration system. Saturated steam at 6 kg/cm 2(g) pressure shall
available for tapping.
Note: The specifications are indicative of a preferred system. The Supplier may offer
an alternative design, such as refrigeration system, heatless system, etc., which
satisfies the process and system parameters.
1004 AH Molasses Receiving Tank
Quantity: 1 No.
Carbon steel, horizontal cylindrical tank to receive molasses from A massecuite

centrifugal machine.
Capacity : 8 m3
Length : * 2600 mm

Thickness : 8 mm
The tank shall be provided with outlet connection to suction of molasses pump and a
drain connection.
Outlet connection : * 100 NB

1005 AH Molasses Pump
Quantity: 2 Nos.(1 working and 1 standby)

Page - 124 / 154
BOILING HOUSE
To pump molasses from AH molasses receiving tank located near centrifugal

machines to AH molasses storage tanks at pan floor. The pump shall comprise of
metallic single helical rotor and a fixed double helical polymer part as stator.
The specification shall confirm to:
Capacity : 50 m3/h
Type : Screw
Net delivery head : 25 mlc
Suction pipe size, NB : * 200

Delivery pipe size, NB : * 200
Liquid to be pumped : Molasses from ‘A’ centrifugal machine

Casing : Cast iron
Connecting rod : Stainless Steel
Rotor : Stainless Steel
Stator : Nitrile Rubber
Drive:
Power : * 15 kW
Speed : * 1440 rpm
Reduction gear box / V belt Pulley:

Type : * Helical
Std. size No. : *
Ratio : * suitable
Pumps are to be supplied fully assembled with motor, starter, gear box, couplings,
guards on a common base plate and to be complete with foundation/ holding down
bolts.
1006 AL Molasses Receiving Tank
Quantity: 1 No.
Carbon steel, horizontal cylindrical tank to receive molasses from A massecuite

centrifugal machines.
Capacity : 6 m3
Height : * 2000 mm

Page - 125 / 154
BOILING HOUSE
Thickness : 8 mm
drain connection.
Outlet connection : * 100 NB

1007 AL Molasses Pump
Quantity: 2 Nos. (1 working and 1 standby)
To pump molasses from AL molasses receiving tank located near centrifugal

machines to AL molasses storage tanks at pan floor. The pump shall comprise of
metallic single helical rotor and a fixed double helical polymer part as stator.
The specification shall confirm to:
Capacity : 20 m3/h
Type : Screw
Net delivery head : 25 mlc
Suction pipe size, NB : * 150 mm

Delivery pipe size, NB : * 150 mm
Liquid to be pumped : Molasses from ‘A’ centrifugal machines

Casing : Cast iron
Connecting rod : Stainless Steel
Rotor : Stainless Steel
Stator : Nitrile Rubber
Drive :
Power : * 5.5 kW
Speed : * 1440
Reduction gear box / V belt Pulley:

Type : *
Std. size No. : *
Ratio : * 20:01
Pumps are to be supplied fully assembled with motor, starter, gear box, couplings,
guards on a common base plate and to be complete with foundation/ holding down
bolts.

Page - 126 / 154
BOILING HOUSE
1008 ‘B’ & ‘CA’ Continuous Centrifugal Machines
1008-1 ‘B1’ Continuous Centrifugal Machine
Quantity: 4 Nos.
Process material : ‘B1’ massecuite

Average capacity : 14 t/h

Screen size : 0.06 x 2.75 mm
Gravity factor : 2000 (minimum)
Type / Model : * UC 1500
Basket: Basket of conical shaped, preferably of single piece casting, shall be made
from special quality stainless steel and accurately machined. Stainless steel
accelerating cone and effective screen clamping ring shall be provided. Horizontal
slits of sufficient area should be provided in the basket for effective drainage of
molasses. Inclination of the basket shall be 30. Operating speed shall be
approximately in the range of 1400 to 1700 rpm. Supplier should specify the
recommended operating speed and the design speed.
Backing Screen: Backing screen shall be of stainless steel in woven construction.

The design of the backing screen should permit unrestricted flow of fluids inside of
the basket and provide a perfectly flat and rigid support for the working screen with
least reduction to the open area of the working screen.
Working Screen: Working screen shall be of pure nickel with hard chrome plating of
0.3 mm thickness. The divergent slot through the screen thickness shall have the
apertures 0.06 mm x 2.75 mm. The screen area should be minimum 13% of basket
area.
Shaft: Shaft of forged steel or chromium molybdenum steel shall be suitably fitted
with the basket base and for mounting coupling at the other end.
Bearing Housing: Bearing housing of alloy steel shall be provided with top bearing
of (cylindrical) roller type and bottom bearing of 4 point contact ball bearing. Grease
lubrication system shall be provided with proper sealing arrangement.
Monitor Casing: The monitor casing shall be of mild steel construction and shall be
provided with:
- Separate compartments for sugar & molasses with proper sealing rings.

Page - 127 / 154
BOILING HOUSE
- Molasses outlet connection. For the common machine, arrangement for

diverting the molasses either to B-heavy or C-light molasses tank shall be
provided.
- Baseplate for rigidly mounting the monitor casing to the supporting structure.
- Support for bearing housing.
- Support for drive motor.
- Tensioning arrangement for driving belts.
- Bolted inspection door for attending ‘V’ belt and driven pulley.
- Removable inner top cover.
- Inspection doors, hinged type.
- Sugar sampler.
- Water and steam washing arrangement.
- Sugar discharge chute in bolted assembly to the monitor casing.
Massecuite Feeding System: Feeding system shall be of center feed type and
consisting of:
- Isolating valve, knife edge type, cast iron body with stainless steel working
parts, minimum 250 mm NB size.
- Iris type valve shall be of variable orifice type to ensure massecuite feed at
center.
- Regulating valve shall be of regulated flat slide with electric actuator for
automatic massecuite dosing control.
- Double walled stainless steel feed tube with provision for admitting steam in
annular space of the tube and water to the central core of the incoming
massecuite.
- Massecuite heater / accelerator cup located at the dead center of the basket.
- Interconnecting massecuite piping from existing pugmill to the feed tube.
- Instrumentation / Automation shall be provided to Iris type massecuite feeding

valve, to provide uniform flow of massecuite by sensing the electric current
drawn by the drive motor. The controller should be provided with facility to
adjust the feed by providing motor current set point.
Washing / Steaming System: Washing/steaming system shall comprise of:

Page - 128 / 154
BOILING HOUSE
- Manifolds for steam and water, of stainless steel pipes
- Gate valves for flow control in stainless steel.
- Flow meters in stainless steel.
- Strainers in stainless steel.
- Sprays, pipes and nozzles in stainless steel.
- Main stop valve in stainless steel.
- Flexible pipes in wire braided rubber hose.
- Stop valve for steam wash ring of sugar compartment in stainless steel.
Driving System: Driving system shall be of 'V' belt and pulley type, driven at the
bottom. The “V” belts shall be of wedge type (SPB) conforming to BS:3790 to suit the
pulleys. Driven pulley shall be on a separate shaft and coupled to basket spindle
through a flexible coupling.
Drive: The basket shall be driven by a vertically mounted, squirrel cage induction
motor, suitable for 400 V, 3 phase, 50 Hz supply, through pulleys and ‘V’ belt.
Power : * 90 kW
Speed : 1450 to 1500 rpm
Molasses Discharge: Molasses discharge pipes, of mild steel construction,

individually for B-heavy and C-light molasses shall be provided below the machines
for receiving molasses from each machine. The discharge pipes shall be provided
with outlet connections for B-heavy and C-light molasses, extending to receiving
tanks.
Incoming Panel: The main incoming panel, common for all continuous machines,
suitable for eight machines shall be provided with the following:
- ACB of adequate capacity

- Ammeter with selector switch
- Voltmeter with selector switch
- Necessary fuses
- Indicating lamps
- Overload and short circuit current protection
- Any others as necessary
Motor Control Panel: Motor Control Panel shall be of sheet metal fabricated with
interlocking doors and detachable side plates. The control panel shall be designed
for symmetrical fault level of 35 k amps (rms) for one second. All components shall
be front mounting type for ease of maintenance, operation and control.

Page - 129 / 154
BOILING HOUSE
The control panel, of IP 54 protection shall mount switch gear, signal lamps, safety
devices for tripping motor in case of high temperature motor winding, high
temperature of bearing and excessive vibration of machine, etc.
Operator Panel: The operator panel, mounted near each machine shall have
start/stop push button, ammeter, "ON" signal lamp.
Cabling: All inter-connecting cabling between the main incoming panel and the
machine and accessories are included in the scope of supply.
Tools and Tackles: Special tools & Instruments etc., necessary for assembly,
erection and maintenance of the centrifugal battery offered shall be included in the
scope of supply and should specially include, but not limited to, the tools required for:
- Assembly and dismantling of bearings in the bearing housing.

- Fitting and securing the screen.
- Mounting rings required for fitting the backing and working screen.
Supporting Structure & Platform: Separate supporting structure for 4 Nos. ‘B1’
centrifugal, shall be provided with separate massecuite feeding header and machine
accessories as required, including operator platform & access staircase.
The operator platform, at minimum 4.00 m level from FFL should provide for atleast
2000 mm clear space on working front and 1500 mm clear space at the back of the
machines of the battery. Access staircase is to be about 1000 mm wide.
A suitable platform should be provided near the massecuite feeding header with
proper approach from centrifugal platform.
Technical Specifications/Drawings/Brochures: Contract must be accompanied

with full technical specifications, literature, brochures, drawings, covering at least the
following:
- Overall assembly drawing of machine with supporting structure-operating

platform, indicating the overall dimensions, over footing details, frame size
details, load data, etc.
- General layout drawing of battery.
- Drawing showing design highlights of:
a) basket.
b) bearings and lubrication system.
c) vibration damper arrangement and location.
- Brief description giving salient features of basic construction of machine
components.
1008-2 ‘B2’ Continuous Centrifugal Machines

1008-3 ‘CA’ Continuous Centrifugal Machines
Quantity: 4 Nos.
Each battery shall consist of two machines ‘B2’ massecuite, one machine for ‘C After’
curing and one machine as common standby for ‘B2’ and ‘CA’

Page - 130 / 154
BOILING HOUSE
Process material : ‘B2’ massecuite


Process material : ‘C fore’ magma


Type / Model : *
Other specification shall be similar to Item No. 1008-1, for ‘B1’ centrifugals.
1009 B Magma Mixers
1009-2 ‘B1’ Magma Mixer
Quantity: 1 No.
Magma mixer shall be suitable for 4 Nos. of machines. The mixer shall have an
efficient paddle type stirring arrangement.
Horizontal, U shaped, double paddle type magma mixer shall be located below the
centrifugal machines. The drive for magma mixer shall consist of planetary gear box
& electric motor, so as to achieve a final rated speed, around 16 rpm.
Material of construction : Carbon steel
Thickness:
- Shell : 8 mm
- End plates : 10 mm

Page - 131 / 154
BOILING HOUSE
The magma mixer shall be provided with overflow box on both sides along with outlet
pipe. The magma mixer should be designed for homogeneous mingling of the sugar.
1009-2 ‘B2’ Magma Mixer
Quantity: 1 No.
Each magma mixer shall be suitable for 2 Nos. of machines. The mixer shall have an
Other specification shall be similar to Item No. 1009-1, for ‘B1’ magma mixer.
1010 ‘B’ Magma Pump
1010-1 ‘B1’ Magma Pump
To pump ‘B1’ magma from magma mixer to sugar melter or to seed crystalliser at
pan floor.
Horizontal rotary pump consisting of elliptical section rotor keyed to steel shaft and
spring loaded scrapper. The material of construction of rotor and scrapper assembly
shall be suitable to ensure smooth working. The pump shall be driven by a motor &
gearbox unit. Flexible couplings shall be used between pump/gearbox and gearbox/
motor connections. The bare pump, reduction gearbox & motor shall be mounted on
a common carbon steel base frame.
The specification shall confirm to
Capacity : 25 t/h
Type : Rota type
Material to be pumped : B1 Magma

Brix : 90
Purity : 95
Temperature : 45 – 55 ºC
Viscosity : 3100 P
Suction pipe size, NB : * 200 mm

Delivery pipe size, NB : * 200 mm
Speed : 120 rpm
Casing : Cast iron

Page - 132 / 154
BOILING HOUSE
Drive :
Motor : TEFC squirrel cage for 400 V, 3 phase, 50 Hz
Power : * 7.5 kW
Speed : 1450 rpm
Reduction gearbox
Type : Helical
Ratio : * suitable
Service factor : 2.0 Min
1010-2 ‘B2’ Magma Pump
To pump ‘B2’ magma from magma mixer to sugar melter or to seed crystalliser at
pan floor.
Other specification shall be similar to Item No. 1010-1, for ‘B1’ magma pump.
1011 B Molasses Receiving Tanks
1011-1 ‘B1’ Molasses Tank
Quantity: 1 No.
Other specification shall be similar to Item No. 1006, for ‘AL’ molasses tank.
1011-2 ‘B2’ Molasses Tank
Quantity: 1 No.
1012 B Molasses Pumps
1012-1 ‘B1’ Molasses Pump
Other specification shall be similar to Item No. 1007, for ‘AL’ molasses pump.
1012-2 ‘B2’ Molasses Pump

Page - 133 / 154
BOILING HOUSE
1013 C- After Magma Mixer
Quantity: 1 No.
1014 C-After Magma Pump
To pump ‘CA’ magma from magma mixer to sugar melter.
1015 CL Molasses tank
Quantity: 1 No.
1016 CL Molasses Pump
1017 'C Fore' Continuous Centrifugal Machine
Transient heater of suitable capacity for each machine shall be provided to heat the
massecuite from 45 °C to 55 C (maximum) using hot water at 60 °C. Transient
heater is interposed between the massecuite feeding header pipe and machine, with
suitable isolating valves.
Process material : ‘C’ massecuite



Page - 134 / 154
BOILING HOUSE
Other specification shall be similar to Item No. 1008-1, for ‘B1’ centrifugals.
1018 C- Fore Magma Mixer
Quantity: 1 No.
1019 C-Fore Magma Pump
To pump ‘CF’ magma from magma mixer to ‘C’ after worker machines massecuite
feeding header.
1020 Final Molasses Receiving Tank
Quantity: 1 No.
Other specification shall be similar to Item No. 1004, for ‘AH’ molasses receiving
tank.
1021 FM Pump Below Machines
Other specification shall be similar to Item No. 1005, for ‘AH’ molasses pump.
1022 Final Molasses Weighing Scale
Quantity: 1 No.
To weigh Final molasses from C massecuite centrifugal machines.
Properties of fluid to be handled
Liquid : Final molasses

Automatic electronic weighing system for weighment of final molasses is a load cell
system, having maximum capacity of 5 t/tip. The capacity can be adjusted at site,
depending upon the crushing rate.
Capacity of each tip : 5 t (max)

Page - 135 / 154
BOILING HOUSE
Flow rate : 26 t/h

Number of tips/hr (Max) : *
Accuracy : ± 0.25% of full scale reading
The system shall be complete with suitable feed tank, weigh tank, load cell system,
batching controller, control valves.
Feed tank:
Capacity : * 6.0 m3
Size, L x W x H : * 2000 x 2000 x 1500 mm

Thickness : 8 mm
Weigh Tank:
Capacity : * 5.7 m3
Height : * 1500mm

Thickness : 8 mm
Loadcell System: The Load Cell system shall consist of following:
Load Cells
Batching Controller
MIS Software
The batching controller shall be connected to the DCS. An MIS software would log
the weight of the molasses tipped in each tipping. It would also generate reports for
various queries. Facility for setting/changing of weight per tip for the scale shall be
provided in the software which shall be incorporated in the DCS.
Following reports shall be available from the MIS software:
Hourly tipping report

Shift wise Tipping Report (Shift Timings to be entered in the software)
Daily Tipping Report.
Query Based (From Date To Date) Report.
All the above reports shall have following fields :
Sr. No.
Date
Time
Net Weight of the molasses batched

Page - 136 / 154
BOILING HOUSE
Cumulative Weight of the molasses batched

Status of each batch.
Control Valves:
Charging valve : 1 No. (fitted in top tank)

Discharging valve : 1 No. (fitted in weigh tank)
Size : 400 mm
Type : Butterfly, Eccentric seat type
Body : Cast Iron
Wetted parts : SS, AISI 304
Gland housing : SG Iron
Gland packing : Multi layer Teflon impregnated Asbestos + rubber
Seat ring : Glass filled Teflon
1023 Weighed Final Molasses Receiving Tank
Quantity: 1 No.
Carbon steel, vertical cylindrical tank to receive molasses from final molasses
weighing scale.
Capacity : 15 m3
Height : * 2800 mm

Thickness : 8 mm
drain connection.
Outlet connection : * NB
1024 FM Pump Below Weighing Scale
1025 Sugar Melter
Quantity: 1 No.

Page - 137 / 154
BOILING HOUSE
Vertical, cylindrical tank of continuous type melter for melting sugar lumps and
magma sugars shall be of carbon steel construction and fitted with stirrer, drive, input
bowl, screen etc.
Capacity, for melting : 50 t/hr

Stirrer drive :
Power : * 3.7 kW
Speed : 1440 rpm
Reduction gear box

Type : Planetary
Ratio : * suitable
The melter is to be provided with nipples and flanges for following fittings:
Outlet connection, 150 NB : 1 No.
Steam heating coil, 50 NB : 1 No.
Steam inlet pipe, 80 NB : 1 No.
Hot water inlet connection, 50 NB : 1 No.
Drain connection, 100 NB : 1 No.
Exhaust steam at 1.3 kg/cm2 (g) pressure shall be used for melting.
1026 Melt Pump
Quantity: 2 Nos. (1 W + 1 SB)
To pump melt from melter to melt storage tank located at pan floor.

common carbon steel fabricated base frame.
Capacity : 60 m3/h
Head : 30 mlc
Speed : 1450 rpm
Sugar Melt to be pumped:

pH : 5.5 - 6.5
Viscosity : 75 cP

Page - 138 / 154
BOILING HOUSE
Casing : Cast Iron
Seal : Gland
Drive:
Motor : TEFC, squirrel cage for 400V, 3 phase, 50 Hz.
Power : * 15 kW
Speed : 1450 rpm
Frame size : *
1027 Centrifugal House overhead crane
Quantity: 1 No.
Three motion electrically operated overhead travelling crane suitable for indoor
installation, conforming to class II as per IS:3177 (1977) and IS:807 or equivalent
specifications shall be provided in the centrifugal house.
The crane span shall be to suit the centrifugal house building span of 18 m. The
gantry length shall be approximately 180 m, suitable for covering complete
centrifugal house.
Capacity, SWL : 5 t
Height of lift : 13 m
Height to top of rail : 14 m
Main hoist speed : 2 m/min
Long travel speed : 10 m/min
Cross travel speed : 10 m/min
Main hoist motor should be squirrel cage TEFC and long travel and cross travel
motors should be slip ring TEFC. All motors should be of crane duty.
Drive Type of motor kW Rating
Hoisting drum TEFC sq. cage * 1 hour

Long travel TEFC slip ring * 1/2 hour
Cross travel TEFC slip ring * 1/2 hour
Auxiliary hoist TEFC sq. cage * 1/2 hour
All gear boxes shall be totally enclosed, dust proof, helical type with designed service
factor of 2.0. All couplings shall be of flexible gear type / centrifugal type. All brakes
shall be of Electro-hydraulic thruster operated type.

Page - 139 / 154
BOILING HOUSE
Crane should be provided with a creep speed facility while hoisting at maximum
capacity to allow the heavier loads to be slowly and carefully handled. The crane
operation shall be from ground floor through pendent push button station moving
along with the crab/remote control operation.
The Supplier will provide the loading data and span details to enable the purchaser to
arrange suitable design columns for the crane.
Crane bridge box type carbon steel welded construction having walkways on both
side with hand railing, rails for trolley, LT assembly, cross conductors, power rails
and collectors system for supply of electric power to the trolley bridge movement.
1028 Final Molasses Handling
1028-1 Final Molasses Storage Tank
Quantity: 3 Nos.
Carbon steel constructed final molasses storage tank shall be provided to store final
molasses outside the factory building.
Capacity : 8000 m3
Diameter, (approx.) : 31.0 m

Height : 9.6 m
The tank shall be fabricated according to IS 5521: 1980 or equivalent standard.
Plate thickness to be used to fabricate the tank shall be as per the relevant standard.
The tank shall be provided with the following accessories & fittings:
- Molasses outlet
- Outlet discharge valve
- Drain or wash out valve
- Molasses inlet
- Thermometer
- Manhole
- Safety railing
- Vent pipe or chimney
- Sampling connection
- Water spray coil
- Suitable painting
- Ladder outside the tank
- Level indicator
The tank shall be tested as per IS 5521:1980 or equivalent, before operation.
1028-2 Final Molasses Loading Tank

Page - 140 / 154
BOILING HOUSE
Quantity: 1 No.
Horizontal, cylindrical tank shall be of carbon steel construction, installed at + 5 m

height from ground level for storing final molasses from storage tank for feeding to
the molasses tanker directly by gravity. Suitable structure shall be provided, with a
platform of 1 m width around the tank and an approach staircase from ground level.
Capacity : 30 m3
Height : * 4350 mm

Thickness : 8 mm
drain connection.
Outlet connection : 400 NB (* 200 mm)

1028-3 Final Molasses Transfer Pump
Quantity: 4Nos. (1 No. each for each FM tank & 1 No. common standby)
To fill loading tank and also for recirculation of final molasses in the final molasses
storage tank, to be installed near to individual final molasses storage tank.
1100 SUGAR HANDLING, DRYING & BAGGING
1101 Sugar Hoppers
1101-1 Sugar Receiving Hopper
Quantity: 1 No.
To convey the sugar discharged from the centrifugal machines to the belt conveyor
before sugar dryer.
Sugar Conveying capacity: 50 t/h

Type : Vibratory
Effective width : 1.5 m

Length : 12.0 m
The hopper shall be made from carbon steel plates and the plates are pressed to
shape in sections and preferably jointed by riveted joints. The hopper shall not be
welded on longitudinal seams. The hopper shall be supported on rubber buffers on
both sides.

Page - 141 / 154
BOILING HOUSE
The hopper shall be driven by two vibratory motors, installed on both sides of hopper
for creating conveying motion. Proper unbalance adjustment shall be provided in the
motor.
The Supplier should submit load data details of the hopper for enabling the
Purchaser to carry out foundation design.
1101-2 Plain Tray Hopper
Quantity: 1 No.
To convey the sugar discharged from the fluidised bed dryer to the sugar elevator.
Sugar Conveying capacity: 50 t/h

Type : Vibratory
Effective width : 1.5 m

Length : 12.0 m
Other specification shall be similar to Item No. 1110-1, for receiving hopper.
1101-3 Belt Conveyor (BC-1) between Hopper & Drier
Quantity: 1 No.
To convey the sugar discharged from the sugar-receiving hopper to fluidised bed
dryer.
Capacity, each : * 50 t/h (* 50 t/h as per amendment)
Belt:
Type : Trough type
Material : Food grade
Width : 1000 mm
Length : To suit layout
Belt speed : 25 m/min (max)
1101-4 Belt conveyor between FBD and hopper before elevator (BC-2) - Deleted
Quantity: 0 Nos. (To be provided in the second stream)
To convey the sugar discharged from the fluidised bed dryer to the sugar elevator.
Other specification shall be similar to Item No. 1110-3, for belt conveyor.
1102 Fluidised Bed Sugar Dryer/ Rotary Sugar Dryer
Quantity: 1 No.

Page - 142 / 154
BOILING HOUSE
To dry the sugar received from belt conveyor and then cooling to obtain the sugar
suitable for bagging.
The sugar dryer shall be designed for the following duty condition:
Capacity : 50 t/h
Sugar :
Initial moisture : 1.5 % (Approx.)

Final moisture : 0.04 %
Initial temperature : 60 ºC approx.

Final temperature : 8 ºC above cooling air temperature
The supply shall be complete with hot and cold air blowers, air heater, for the system
functional. Exhaust steam at 1.3 kg/cm2 (g) shall be used for air heating.
A detail specification with drawing, highlighting the salient feature of the system
should be submitted.
Note: The supplier can offer rotary dryer, as an alternative, for same capacity and
duty conditions. Detailed specifications of rotary dryer, if offered, should be
submitted.
1103 Sugar Elevator
Quantity: 2 Nos.
Vertical, belt and bucket type for feeding dried sugar discharged from the dryer, to
sugar grader. The buckets should be of self discharging type for the given velocity of
the belt.
The elevator shall confirm to:
Capacity : 30 t/h
Rubber belt:
Type : *
Speed : * 69 (30 m/min (max) as per bid document )
Bucket:
Dimensions : * 410 x 200 x 2.5
Capacity : *
No. of buckets : * 135
Material : *
Bearings : Ball/roller
Center distance : ~ 25 m between shafts

Page - 143 / 154
BOILING HOUSE
Drive:
Motor : TEFC squirrel cage, with VFD, suitable for 400 V, 3
phase supply.
Power : * 11 kW
Speed : 1450 rpm
Reduction Gear box :

Type : * Worm (Planetary as per bid document)
Std. No. : *
Ratio : * suitable
Chutes for receiving sugar from dryer, and feeding to graders, with diverter plates are
to be included.
1104 Sugar Grader
Quantity: 2Nos.
Vibrating sizer with three decks, capable of screening lumps and separation of dust.
The graders shall be installed above the sugar bins.
Each grader shall confirm to:
Capacity of grading : 30 t/h
Vibrator type : Mechanical/ electrical
Screen:
Material : Stainless steel
Width : *
Length : *
Drive:
Motor : TEFC squirrel cage, for 400 V, 3 phase,50 Hz.
Power : * 22 kW
Speed : * 960 rpm
The grader shall include the following:
Sugar distributor for distributing the sugar over full width of grader screen.
Lumps separation arrangement.
Magnetic separator for each chute.
Supporting structure, platform and ladders, inter-connecting platform between two

graders.
Clear height under the grader, not less than 2500 mm, for conveying the respective
graded sugar to respective sugar distribution conveyors.

Page - 144 / 154
BOILING HOUSE
Sugar collection compartments, chutes and flap valves, one each for lumps, product
sugars and dust.
1105 Sugar Distribution Belt Conveyors
Quantity: 1 Set
To receive and distribute sugar to sugar bins. All belt conveyors shall be located
above the sugar bins.
Capacity, each : 40 t/h
Belt:
Type : Trough type
Width : * 800 mm
Length : * 8000 mm (To suit layout)
1106 Sugar Bins
Quantity: 2 Nos.
Rectangular, Vertical, conical bottom & top shall be of Mild steel construction for
storing sugar received from the grader through distribution belt conveyor.
Capacity, each : 250 t
Bulk density of sugar : 850 kg/m3
1107 Sugar Weighing and Bag Filling System
Quantity: 4 Nos. (2 Nos. for each bin)
For sugar filling and weighing of sugar in bags.
The system shall include:
Automatic(electronic) bag filling and weighing system.
To fill and weigh 50 kg of sugar in synthetic fibre bags, at the rate of 600 bags/h
each, or to fill and weigh 100 kg of sugar in synthetic fibre bags, at the rate of 300
bags/h each.
.
Weighing Capacity : 50/100 kg per bag

Bagging capacity : 600/300 bags/h
1107-1 Sugar Bag Check Weighment Scale

Page - 145 / 154
BOILING HOUSE
Quantity: 3 Nos.
A mobile, platform electronic type weighing scale, with LED display shall be provided
for check weighment of sugar bags. The scales shall be located at convenient
places, one in sugar bagging house and one in each sugar godown.
Capacity : 100 ± 2 kg
1108 Slat Conveyor
Quantity: 2 Nos. (1 No. below each bin)
Slat conveyors below sugar bins for conveying the weighed sugar bags through
stitching machines to sugar bag belt conveyor.
The conveyor shall be driven by electric motor complete with pedal operated
switches.
Capacity : 600 bags/h

Width : 550 mm
Length : to suit the layout.
1109 Bag Stitching Machines
Quantity: 5 Nos. (2 Nos. in each slat conveyor & 1 No. common standby)
For stitching weighed sugar bags, 50 kg bags or 100 kg sugar bags.
Electrically operated double row stitch, bag stitching machines, each should be
suitable for handling minimum 600 bags per hour.
1110 Dry Seed Belt Conveyor
Quantity: 1 No. (To suit layout)
To convey dry seed received from sugar grader to dry seed crystallizer, installed in
pan floor.
Capacity : 25 t/h
Type : Trough type
Belt width : 1000 mm
Length : * 20000, 30000, 30000 mm (To suit layout)
Drive:
Motor : TEFC squirrel cage, for 400 V, 3 phase, 50 Hz.
Power : * 3.7, 5.5, 5.5 kW
Speed : 1440 rpm
1111 Rori Sugar Melter

Page - 146 / 154
BOILING HOUSE
Quantity: 1 No.
Vertical, cylindrical tank of continuous type melter for melting sugar lumps and
magma sugars shall be of carbon steel construction and fitted with stirrer, drive, input
box, screen etc.
Capacity, for melting : 10 t/hr

Stirrer drive:
Power : * 2.2 kW
Speed : 1450 rpm
Reduction gear:
Type : Planetary
Ratio : *
The melter is to be provided with nipples and flanges for following fittings:
Outlet connection, 150 NB : 1 No.

Steam heating coil, 50 NB : 1 No.
Steam inlet pipe, 80 NB : 1 No.
Hot water inlet connection, 50 NB : 1 No.
Drain connection, 100 NB : 1 No.
Exhaust steam at 1.3 kg/cm2 (g) pressure shall be used for melting.
1112 Rori Melt Pump
To pump melt to main melter at centrifugal station.

Capacity : 10 m3/h
Head : 30 mlc
Speed : 1450 rpm
Sugar Melt to be pumped:

PH : 5.5 - 6.5
Viscosity : 75 cP
Casing : Cast Iron

Page - 147 / 154
BOILING HOUSE

Seal : Gland
Drive:
Motor : TEFC, squirrel cage, for 400 V, 3 phase, 50 Hz.
Power : * 5.5 kW
Speed : 1450 rpm
Frame size : *
The pump shall be complete with coupling, motor, starter, common carbon steel base
frame, guard and foundation bolts.
1113 Dust Collection System
Quantity: 1 No.
The dust collector system shall cover the following dust generating sources:
Sugar hopper transfers

Sugar dryer
Sugar dryer discharge
Elevator feed and discharge points
Sugar grader
Sugar bin
Suction hoods shall be suitably located adjoining the dust sources.
The dust collector system shall consist of an efficient wet scrubber, collection tank,
recirculation pump, syrup pump, tank level control system, makeup water control
valve, timer arrangement for diverting the syrup to melter tank, exhaust fan etc.
Control dampers at each suction hood and necessary ducting shall be provided.
P & I diagram showing all the equipment & control loops shall be submitted.
G.A drawings of the critical items in the system shall be submitted.
Dust collection : shall not be less than 500 kg/day
1114 Sugar Bag Handling System
Quantity: 1 set
The system consists of belt conveyors from sugar house to individual sugar godowns
for conveying sugar bags. In each sugar godown, a belt conveyor shall run on one
side of the wall at a height of around 5.5 m for full length. The sugar bags from the
main belt conveyor shall be diverted to the respective sugar godown belt conveyor.

Page - 148 / 154
BOILING HOUSE
The bags shall be stacked by diverting the bags from the sugar godown conveyor
through stackers and mobile belt conveyors.
A walk way shall be provided on one side of the conveyor for catering maintenance.
The system is to be designed suitable to site plan layout with respect to sugar house
and sugar godowns.

Type : * Flat type
Belt width : * 650 mm (1000 mm as per bid document)
Lengths : * 45000, 125000, 65000, 75000 mm (To suit layout)
Drive:
Power : * 5.5, 19, 7.5, 7.5 kW (for each conveyor)
speed : * 1450 rpm
The conveyor outside the building shall be totally covered, including the side
walkway, so that no rain water enters. Suitable supporting structure shall be provided
for the conveyor and walkway.
1115 Stacker & Portable belt conveyors
1115-1 Stacker set 16’
Quantity: 2 Nos.
To stack and destack sugar bags in the sugar godown.
Capacity : * 600 bags/h

Boom length : 16 feet
Slat width : * 650 mm
Delivery height : * 4000 mm
Drive:
Power : * 3.7 kW
speed : * 1450 rpm
Gear box:
Type : * Planetary
Ratio : *
1115-2 Stacker set 32’
Quantity: 2 Nos.

Page - 149 / 154
BOILING HOUSE
To stack and destack sugar bags in the sugar godown.

Boom length : 32 feet
Slat width : * 650 mm
Delivery height : * 10000 mm
Drive:
Power : * 5.5 kW
speed : * 1450 rpm
Gear box:
Type : * Planetary
Ratio : *
1115-3 Portable conveyors 3.5 m
Quantity: 2 Nos.
To convey the sugar bags inside the godown.

Type : * Flat
Belt speed : * 21 m/min
Belt width : * 650 (1000 mm as per bid document)
Belt length : 3500 mm
Belt material : * Food grade
Tensile rating : * 315 KN
Quality, grade : * M-24
Drive:
Power : * 2.2 kW
Speed : * rpm
Reduction Gear box:

Type : Planetary
Ratio : *
Quantity: 2 Nos.

Type : * Flat

Page - 150 / 154
BOILING HOUSE

Belt width : * 650 mm
Belt material : * M-24
Quality, grade : * M-24
Drive:
Power : * 2.2 kW
Speed : * 1450 rpm
Reduction Gear box:

Type : * Planetary
Ratio : *
Quantity: 2 Nos.

Type : * Flat
Belt width : 1000 mm
Belt material : * M-24
Quality, grade : * Food quality
Drive:
Power : * 2.2 kW
Speed : * 1450 rpm
Reduction Gear box:

Type : * Planetary
Ratio : *
1200 CONDENSING PLANT
1201 Evaporator Condenser
Quantity: 2 Nos. (1 No. for each evaporator set)
To condense vapours from last effect of evaporator.

Page - 151 / 154
BOILING HOUSE
The condenser shall be of stainless steel construction with multi jet and spray, single
water entry to suit to automation and confirm to the following duty conditions.
Condensing capacity : 20 t/h (nominal)
Type : Multi jet and spray, Single Entry

Pressure in condenser : 110 mm Hg abs.
Inlet water temperature : 32 C
Water consumption : 57 kg/kg vapour (maximum)
Temperature difference : 10 C (maximum)

(Thot water – Tcold water)
Plate thickness:
Shell : *6 mm
Bottom cone : *5 mm
Overall Dimensions:
Height : * mm
Shell diameter : * 1100 mm
Vapour belt diameter : * 1112 mm
Vapour inlet size : * 1100 mm

Tail pipe size : * 190 mm
Water inlet size : * 300 mm
Mataerial of construction:
Body and all internals : SS 304
Thickness : * 6/5 mm
The condenser should preferably be of SS 304 construction and latest design
The condenser shall be provided with necessary fittings such as water inlet
connection, non-condensable gas outlet connection, tail pipe, vapour inlet
connection, vacuum gauge, pressure gauge at water inlet, etc.
The tail pipe shall be provided with capillary type temperature gauge, suitable to read
the temperature from condenser platform. Provisions are to be kept in the tail pipe
for installing RTD.
1202 Pan Condensers
1202-1 Condensers for ‘A’ Massecuite seed Pan (80 t – 1 No.)
Quantity: 1 No.
To condense vapours from vacuum pan.

Page - 152 / 154
BOILING HOUSE
Condensing capacity : * 15 t/h (nominal)
Other specification shall be similar to Item No. 1201, for Evaporator Condenser.
1202-2 Condensers for ‘A’ Massecuite Pan (100 t)
Quantity: 3 Nos.
Overall Dimensions:
Height : * mm
Shell diameter : * mm
Vapour belt diameter : * mm
Vapour inlet size : * mm

Tail pipe size : * mm
Water inlet size : * mm
1202-3 Condensers for ‘B’ & ‘C’ Graining Pan (80 t – 1 No.)
Quantity: 1 No.
1202-4 Condensers for ‘B1’ Massecuite Continuous Pan (40 t/h – 1 No.)
Quantity: 1 No.
Overall Dimensions:
Height : * mm
Shell diameter : * 1300 mm
Vapour belt diameter : * suitable mm

Page - 153 / 154
BOILING HOUSE
Vapour inlet size : * 1300 mm

Tail pipe size : * suitable mm
Water inlet size : * 250 mm
1202-5 Condensers for ‘B2’ Massecuite Pan (80 t - 1 No.)
Quantity: 1 No.
1202-6 Condensers for ‘C’ Massecuite Pan
Quantity: 2 Nos.
1203 Air Ejector
Quantity: 3 Nos.
To create and maintain required vacuum in vacuum crystallisers and removal of NCG
from calandria. Water shall be tapped from the main injection water header.
Type : Single entry water jet ejector
Air extraction capacity : 2.5 kg/min
The tail pipe is connected to the same common horizontal pipe for evaporator and
pan condensers.
1204 Injection Water Pump
Quantity: 4 Nos. (3 Nos. working & 1 Nos. standby)
To pump injection water from cold water channel to condensers and ejectors.

Page - 154 / 154
BOILING HOUSE
Vertical centrifugal pump driven by electric motor, both mounted on carbon steel
fabricated base frame.
Type : Vertical/Horizontal type

Capacity : 2250 m3/h
Head : 27 m
Speed : 980 rpm
Liquid to be pumped : Injection water

pH : 7.0
Casing : Cast iron
Seal : Gland
Coupling type : Tyre type/spacer type love joy
Drive:
Motor : TEFC, Squirrel cage, for * V,3 ph, 50 Hz.
Power : * 225 kW
Speed : * 980 rpm
1205 Hot and Cold Water Channel
Quantity: 2 Nos.
Once through system shall be followed for the injection water system. The cold water
shall be drawn from nearby irrigation canal to the main reservoir, for supplying water
to injection water pit. The condenser tail water shall be sent back to the irrigation
canal.
The injection water pump pit shall be of RCC construction for accommodating the
pumps.
The condenser tail water shall be discharged into a hot water channel, which will
discharge the water into an open canal outside the factory boundary.
Width : * mm
Length : To suit layout.

Boiling House

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Boiling House

Uploaded by

Copyright:

Available Formats

WSSF-USI TECHNICAL SPECIFICATION Section VI-D

0500 JUICE TREATMENT AND CLARIFICATION............................................................7

** marked details to be filled in & confirmed during Detailed Engineering

0701 Lime Elevator.......................................................................................................33

** marked details to be filled in & confirmed during Detailed Engineering

0813-1 Caustic Soda Tank........................................................................................64

** marked details to be filled in & confirmed during Detailed Engineering

0910-4 ‘B1’ & ‘C’ Liquidation Pumps.......................................................................103

** marked details to be filled in & confirmed during Detailed Engineering

1016 CL Molasses Pump............................................................................................133

** marked details to be filled in & confirmed during Detailed Engineering

** marked details to be filled in & confirmed during Detailed Engineering

0500 JUICE TREATMENT AND CLARIFICATION

0501 Juice Measurement

0501-1 Juice Weighing Scale

Capacity : 6.5 t/tip

Properties of fluid to be handled

Liquid : Screened Juice

The Load Cell System shall consist of following:

Dummy load cell :

** marked details to be filled in & confirmed during Detailed Engineering

Followings are provided on the batching controller panel:

Facility for calibration of tare weight shall also be provided

** marked details to be filled in & confirmed during Detailed Engineering

Following reports shall be available from the MIS software:

Hourly tipping report

All the above reports shall have following fields :

A GA drawing shall be submitted indicating the major dimensions suitable for

0502 Check Weighment System

0502-1 Check Weighment Tank

** marked details to be filled in & confirmed during Detailed Engineering

0502-2 Check Weighing Scale

Type : Platform Scale, Load cell type

0503 Phosphate Dosing System

0503-1 Phosphate Preparation Tank

Supplier should specify the following parameters

Stirrer type : * Arm

** marked details to be filled in & confirmed during Detailed Engineering

0503-2 Phosphate Dosing Tank

Supplier should specify the following parameters

Stirrer type : * Arm

** marked details to be filled in & confirmed during Detailed Engineering

0503-3 Phosphate Dosing Pump

Quantity : 2 Nos. (1 No. working & 1 No. standby)

Type : Metering Type

A GA drawing shall be submitted indicating the major dimensions suitable for

0504 Raw Juice Buffer Tank

Material : Carbon steel

Outlet connection : 300 mm NB

** marked details to be filled in & confirmed during Detailed Engineering

0505 Weighed Juice Pump

Quantity : 2 Nos. (1 working & 1 standby)

Horizontal centrifugal pump directly driven by electric motor, mounted on carbon

Capacity : 350 m3/h

Coupling type : Tyre type

A GA drawing shall be submitted indicating the major dimensions suitable for

0506 Juice Sulphiter

** marked details to be filled in & confirmed during Detailed Engineering

Main Reaction Tank:

Stirrer speed : 72 rpm

A GA drawing shall be submitted indicating the major dimensions suitable for

0507 Auto pH Control System

Process & Control Philosophy: