FINCHAA SUGAR FACTORY

FINCHA

MECHANICAL MAINTENANCE MANUAL

FOR MILL HOUSE

PREPARED BY
SHREE RENUKA SUGARS LTD
INDIA
 MAINTENANCE MANUAL
FOR
CANE HANDLING, CANE PREPARATION, MILLINGPLANT, STEAM AND
POWER GENERATING PLANT

The ”MAINTENACE MANUAL FOR CANE HANDLING, CANE PREPARATION,

MILLING, STEAM AND POWER GENERATING PLANT” has been prepared
with a view to train Sugar Mill ‘Maintenance Team’ so as to maintain all
Equipment and Machinery so that the milling, process and power generation
perform to the extent of minimum losses, reduction in down time during “On
Season & Off Season” & ultimately resulting in optimum production of Quality
Sugar at a reduced cost.

Maintenance Procedures of Each Unit of SUGAR MILL have been described

under the following Heads in seriatim which forms an easy GUIDE for all Sugar
Mill maintenance Team members for development of their knowledge for
acquaintance and maintenance of Mill, Boiling House, Power House, Sugar
House etc.:

1. Equipment Description
2. On Season Maintenance Procedure

3. Check list after maintenance

4. Preventive maintenance during season

Simple Diagrams, Sketches, Thoughts, Ideas, Knowledge expressed in this
Maintenance Manual shall be helpful for Mill & Power House Operators to
Familiarize and Maintain the installed Equipment & Machinery. Pictorial
presentation of Equipment & Machinery of Mill is an easy way of delivering the
knowledge in a short duration. The Manual contains the views expressed by
‘qualified & leading stalwarts’ of Sugar Industry for the benefits of the Sugar
Mills as a whole.

This Manual is drafted in such a way that this single document which will
cater the need of Engineers, Chemists, Operators and the Workers as far as
maintenance of Sugar Mill Machinery and Equipment is concerned.
 TABLE OF CONTENTS

S. No. DESCRIPTION PAGE No.

I MAINTENANCE MANUAL FOR CANE HANDLING & FEEDING 5

ARRANGEMENT

1 Cane Tippler 5

2 Feeder Table 9

3 Cane Loader 12

4 Auxiliary Carrier & Main Cane Carrier 16

II MAINTENANCE MANUAL FOR CANE PREPARATORY 20

DEVICES
1 Cane Copper / Leveller 20

2 Cane Cutter 22

3 Fibroses 25

III MAINTENANCE MANUAL FOR MILLING PLANT 29

1 Mills 29

2 Prime Movers 38

IV MAINTENANCE MANUAL FOR STEAM GENERATING PLANT 43

1 Boiler 43

2 Economizer 52

3 Air Heater 52

4 ESP 53

5 Feed Water Pump 56

6 ID Fans 60
 7 Traval Grate 61

V MAINTENANCE MANUAL FOR POWER GENERATING PLANT 64

1 Turbo Generating Set 64

2 Alternator with Panels 69

VI ANNEXURE 107

1 Engineering Measurements 107

2 General Engineering Data 113

3 Fasteners 119

4 Properties of Carbon Steel 126

 CHAPTER - I

MAINTENANCE MANUAL
FOR
CANE HANDLING & FEEDING ARRANGEMENT

Cane handling is a most important activity of a Sugar Mill. Following are the
main tools usually used for handling of sugar cane. In some places Railways are
the main conveyance for cane transportation and Trolley Tippler, but fading
away with passage of time.

1. HYDRAULIC CANE UNLOADER / CANE TIPPLER

2. FEEDER TABLE

3. CANE LOADER

4. AUXILIARY CARRIER & MAIN CANE CARRIER

1. Hydraulic Cane Un-loader or Truck Tippler

1.1. Equipment Description

Truck Tippler a hydraulically operated platform used to un-load the cane
from Trucks in a very short time. The Cane loaded truck is parked on the
platform for unloading the cane into Auxiliary Carrier. Truck tippler
operator starts the hydraulic pump which operates upon double acting
hydraulic Cylinder and platform so as to cause tilting of platform along
with truck to about 500. This results in the slippage of cane from the
truck and as such get unloaded is about 2/3 minutes. For the protection
of truck and preventing against falling into the auxiliary carrier chain
slingss are tied up as shown in the line diagram.
Maintenance during off season is responsible for reduction in down time
of plant and to enhance the life of equipment.
Main Components of Truck Tippler are as under:

a. M.S. construction Platform.

b. Double Acting Telescopic Hydraulic cylinder.
c. High Pressure Hoses.
d. Hydraulic Oil Tank.
e. Hydraulic Oil Pump.
f. Motor for operating Hydraulic oil pump.
g. Flow control valve.
h. Direction change control valve.
i. Front Hooks.
j. Rear Stops.

Figure: General Arrangement of Truck Tippler

1.2. Off Season Maintenance Procedure
 Lift the platform and rest at inclined position by a temporary and rigid
support.
 Take out hydraulic cylinder. Check the condition of piston if any wear
& tear observed then repair it or replace.
 Replace the oil seal.
 Replace the suction filter.
 Pivoted pin to be checked and replaced if abnormal wear and tear.
 Check the pump working pressure if Hydraulic Pump is not capable to
generate rated pressure then replace it.
 Take out the oil from oil tank and clean the tank.
 Centrifuge the oil and then refill in the tank up to marked Max. Level.

1.3. Check list after Maintenance

 Limit switch and adjust accordingly.
 Working pressure after closing the valve.
 Check the pressure drop across the suction filter.
 Check the drain valve for manual dropping the platform.

1.4. Preventive maintenance during Season

Description Daily Weekly Monthly

Cleaning of filter yes Condition to be

checked

Monitoring the oil Yes yes yes

temperature

Replace of filter Pressure drop Check the condition

to checked of the Filter then take
decision for replacing.

Checked setting of yes Yes

limit switch
2. FEEDER TABLE

Equipment Description

Feeder Table is a cane feeding equipment which helps in feeding the cane
into the cane carrier as and when required and also fills up gaps left over
by other cane handling and feeding devices. The cane is unloaded over
the table first by the cane un-loader or suitable mechanism and then fed
into cane carrier .The drive for feeder table is generally a variable speed
type, may be either VFD or Eddy current coupling. The controlled
quantity of cane is fed to cane carrier with the assistance of variable
speed drives.

Feeder table (minimum 6 meters width and 7 meters length) is installed at

right angle to the cane carrier. Feeder table is of all steel robust sections
to with stand heavy vibrations and is fitted with 8 strands generally of
150mm pitch heavy duty steel drag type chains of minimum breaking
strength 40 tonnes. Feeder table is installed in a manner so that it is at a
reverse angle of 3 degree with horizontal and rises towards the cane
carrier, so as to achieve better control of cane flow.

Operator’s cabin at a suitable height is provided to have a clear view of

the cane being fed into the cane carrier. Variable speed gadgets provide
speed variations from 1 meter to 3 meters per minute.

General arrangement of a Feeder Table is shown on next page.

 Figure: General Arrangement of Feeder Table

Main Components of Feeder Table are:

a. Steel columns and Structure

b. Chains, Slats, Side Plates & Chutes
c. Drive and tail shaft
d. Cast steel or Fabricated sprocket wheels with machine cut teeth.
e. Couplings and rubber bushes.
f. Motor (Generally 25 BHP TEFC Squirrel cage) and starter
g. Reduction gear box
h. Eddy current coupling / VFD
i. Operator Cabin at a suitable Height.
2.0 Off Season Maintenance Procedure

2.1 Feeder Table Maintenance and Repairs

a. Dismantling of chain in pieces of two meter long and detach the

slats from chain.
b. Check the elongation of chain if exceed 5mm per meter then
dismantled into pieces. ( all the pin, bushes, roller and link plate to
be completely dismantled)
c. Cleaning all the pin, bushes links thoroughly.
d. Check the wear and tear of pin bushes links etc. Pins and Bushes
having abnormal wear and tear need to be replaced by new ones.
e. Assemble the all spare, pin, bushes & links followed by lubrication
by grease on pins and Bushes.
f. Lay chain and slats.
g. Inspect the bearings of all the driving and tail end shaft. Repair or
replace need based.
h. Sprocket teeth pitch to be checked any deviation reclaim by Welding
followed by grinding and set right the teeth profile, using a Temp-
plate.
i. Align Drives with driving shaft coupling.

2.2 Check list after maintenance

a. Check the elongation of assembled chain.
b. Check the diagonal centre distance of driving sprocket and tail end
sprocket that should be equal.
c. Check the alignment of driving shaft coupling with drive.

2.3 Preventive maintenance during season

Description Daily Weekly Monthly

 Cleaning of chain Yes

Replace Coupling Check if First check the

bolt and bushes coupling is noisy condition. If required
replace it.

Oil level of Yes Check oil level If dirty or low level

Reduction gear then replenish or
box replace

3. CANE UNLOADER

3.1. Equipment Description

Cane Un-loader feed the cane into the cane carrier for which motions are
controlled and operated by the operator from the un-loader cabin. The
grab is important equipment of cane un-loader. Two types of grabs are in
common use namely Mechanical Grab and Hydraulic Grab. The capacity
of a three motion cane un-loader is generally 5 tons SWL and 7tons SWL
for two motion cane un-loader.

Two motion Cane un-loaders are normally sling type. In each lift while
grab lifts 2.5 tonnes of cane, sling type un-loader lifts 5 tonnes of cane.
Drives are heavy duty and suitable for continuous outdoor type. The
operator’s cabin is attached to Trolley for both types of cane un-loaders.

All electric Motors are Crane duty, TEFC (Totally enclosed fan cooled)
enclosures suitable for 300 operations/ hour, having following
specifications:

Particulars Type of Motor Horse Power Rating

Long Travel Drive Squirrel Cage 25 HP 1 Hour

Cross Travel Drive Squirrel Cage 25 HP 1 Hour

Hoisting Drum Drive Slip Ring 10 HP 0.5 Hour

Holding Drum Drive Slip Ring 10 HP 0.5 Hour

The height of the lift is generally 8 meters. A suitable shed by extending

main columns by 3 meters helps in operation as well as adds to the
rigidity of the Structure.

The following speeds are normally selected for various motions:

Long Travel 9 meters per minute

Cross Travel 9 meters per minute

Hoisting 15 meters per minute

Holding 15 meters per minute

All gear boxes are totally enclosed, dust proof and helical type gears. Gear
boxes have a service factor of normally 1.7. All couplings are either gear
type or centrifugal Type. Brakes are Electro-hydraulic thyruster operated
type.
Figure: General Arrangement of Cane Unloader
 Main Components of a Cane Un-loader are:
a. Steel construction columns having base plates and extension 3 meters.
b. Gantry having steel channel over top and rail.
c. Un-loader end girders with wheels.
d. Un-loader Bridge.
e. Un-loader trolley with moving control cabin.
f. Steel wire ropes having fastening devices.
g. Mechanical or hydraulic grab.
h. Electric motors for long& cross travel, hoist and hold.
i. Reduction gear boxes
j. Hydraulic system.

3.2. Off Season Maintenance Procedure

a. First support the end carriages& bridge with gantry and dismantle all
the wheels.
b. Check all the bearings of all the wheels, replace defective bearings .
c. Reclaim the groove of wheel by welding and machine accordingly.
d. All the transmission shaft gear be checked repair or replace.
e. Rail alignment/straightening if required be done vis-à-vis levelling.
f. Dismantled the gear boxes check, gears, shaft, oil seal bearing etc.
Replace defective item.
g. Check the grooves of drum for rope, re-condition if abnormal wear &
tear. Un-usable/ broken wire rope(s) be replaced.
h. Check the drum coupling and brake shoe, if required be replaced.
i. Replace oil seals of grab cylinder.
j. Check the hydraulic oil pressure of pump on the close position of
return line valve, if not sufficient or could not achieved to rated
pressure (Range-200kg/cm2 - 250kg/cm2) replace the pump.
k. Pin bush of grab be checked and replaced if abnormal wear or tear is
noticed.
 l. Hard facing to be done on fingers of grab.

3.3 Check list after maintenance

a. Wheels of End Carriage to be checked and ensure that they are
diagonally correct.
b. Ensure all the wheels are identical in dimensions for long travel and
trolley.
c. Axial play of all the Gear Boxes to be checked. Ensure all are within
tolerable limit. (as a Thumb rule 0.025mm/inch diameter of shaft.)

3.4 Preventive maintenance during season

Description Daily Weekly Monthly

Brake liner replacement Yes

Gap between shoe holder and Yes

brake pulley

Greasing of all Bearings and Yes Yes

open Gears ( If installed)

Checking of all bolts, foundation Yes if

bolts of Plummer blocks, gear loose,
boxes. tighten.

Wire Rope (s) replacement Yes, after

assessing visual
condition if not in
order then
replace.

4. AUXILIARY AND MAIN CANE CARRIER

4.1. Equipment Description

Cane is unloaded into the auxiliary carrier by trucks or by Two Motion
cane-loader(s), Cane then is transferred to the main carrier. The size of
carrier (length x width x depth) depends on capacity of plant. The speed
control of main carrier and auxiliary carrier is controlled by ACVFD or
eddy current control followed by ACFC (Auto Cane Feed Controller),
through PLC or DCS.

The equipment consists of structural Vertical M.S. Columns made of

ISMC250, M.S. side plates, slope plate, Drive and Driven sprocket wheels,
chains having minimum breaking load 40 tons. Idler pulleys are used for
return of chain & slats in some designs.. Inclination (normally not
exceeding 15 degree with the Main Cane Carrier) depends upon the
preparatory devices installed.

Auxiliary cane carrier is installed at right angle to main carrier or in line if

the width is similar to the main cane carrier. Speed variation is generally
in the range of 3 to 7 meters per minute.

Main cane carrier if wider than the width of Mills, facilitates better
preparation and less power consumption in preparatory devices. The
inclination of main cane carrier is 18 degree for a leveller with a minimum
length of 8 meters, and for Fibrizer is around 8 degree. The horizontal
length of cane carrier is kept below the ground level in such a way that
the top of the sloping sides of the carrier is 300 mm above the ground
level.

Normally three strands of chains are installed having 150 mm pitch and
Breaking load 40 tons.( for 915x1830mm Milling Tandem).Main Cane
Carrier is made up of all steel construction, slats 6 mm thick. Three
longitudinal ISMB150 with renewable 8x65 thick spring steel wear pads
are provided as runners for chain rollers.

The carrier chain is driven by or M.S. fabricated or Cast steel sprockets

normally 16 teeth mounted on 250 mm diameter 40 C8 quality shaft and
Tail end shaft is of 200 mm diameter.
Main Components of Cane Carrier are:

a. M.S Steel Construction Columns ISMC 250.

b. Slope plates, inclined plates 6mm thick Plates I:S 2062
c. Runners ISMB 150, C.I. Idlers.
d. Drive & tail end shaft.
e. Chains & Sprockets.
f. M.S. Slats.
g. Reduction Gear box.
h. Motor
i. VFD Drive
 Figure: General arrangement of a cane carrier

Off Season Maintenance Procedure

a. Dismantle chain in pieces two meter long each and detach the slats
from the chain by opening the fasters.
b. Check the elongation of chain if exceed 5mm/meter, dismantled the
Chain into pieces. ( dismantle pin, bushes, link plate and rollers)
c. Cleaning all the pin, bushes & links.
d. Check the wear and tear of pin, bushes & the links.
e. Assemble the all spares, i.e. pin, bushes links.
f. Lying of chain and slats.
g. Inspect all bearings of the driving and tail end shafts. Repair or
replace need based.
h. Sprocket teeth pitch to be checked any deviation, reclaimed and set
right by welding, grinding or machining.
i. Align Drives with Driving shaft coupling.
j. Worn-out runners and side plates of carrier be replaced as required.
k. For runners spring steel flats to bes used.
l. Welding electrode of grade-312 or equivalent be used for welding of
spring steel flat joints and be followed by grinding to ensure levelling
of wear strips.
m. Preferably NY lock nut may be used for tightening the slats .
n. Check the gear box any repair or replacements be done.

4.2. Check list after Maintenance

a. Check the elongation of chain.
b. Ensure the lubrication in all the pins and rollers.
c. Check Gear box oil level and maintain.
4.3. Preventive Maintenance during Season

Description Daily Weekly Monthly

Cleaning of chains Yes Yes Yes

Oil level of Reduction Yes Yes Yes

gear box

Freeness of roller Yes Yes Yes

Shortened the chain See the elongation

and shortened
accordingly.
 CHAPTER II

MAINTENANCE MANUAL

FOR

CANE PREPARATORY DEVICES

Cane preparatory devices mainly used in Sugar Industry are cane chopper,
Cane Leveller, Cane Cutter, Fibrizer or Shredder. A better cane preparation not
only saves power on mills but improves milling results.

Main Cane Preparatory Devices are:

1. CANE CHOPPER/ CANE LEVELLER
2. CANE CUTTER
3. FIBRIZER / SHREDDER

1. CANE CHOPPER / CANE LEVELLER

1.1. Equipment Description

Cane Chopper of all steel construction with raised sides plates 8mm thick
and 10 mm thick deflector plate at the top is mounted on first cane carrier.
The cane chopper / Cane levellers are provided with hard faced 45 to 48
HRC cutting knives which are mounted on Cast steel hubs of IS:1030
grade and Forged Steel shaft 40C8 quality. The diameter over the tips of
knives is normally 1600mm.
The chopper generally has less no. of knives and more cane bed clearances,
while leveller has more no. of cane knives and less clearance (800mm for
Chopper and 300 to 350 mm for Cutter) with respect to cane carrier slats.
The leveller/chopper is installed just before the inclined portion of cane
carrier. Suitable Fly Wheels of C.I. Grade 20 duly machined both for
Chopper and Cutter are provided. The Knife set is totally enclosed by a
suitably enforced hood of minimum 10/12mm thick mild steel plate
attached to the cane carrier frame work and provided with suitable swing
flaps and bolted doors at the top of the hood.
For a 915x1830mm Mill 30 knives confirming to IS: 8461-1977 are
provided for Cane Chopper and 40 for Cane Cutter. The knife shaft 230mm
diameter is supported on 200 bore, heavy duty self-aligning, double row
spherical roller bearings with adopter or with-drawl sleeve in cast steel
Plummer blocks.

Cane Chopper or Leveller is driven by continuously rated slip ring motor of

adequate HP and 600 rpm synchronous speed at a total slip of 15% ( For
2500 TCD 250HP Motor and 500 HP for 5000 TCD Plant).
Figure: General Arrangement Cane chopper / Leveller
2. CANE CUTTER

2.1. Equipment Description

The construction of cane cutter is almost similar to Cane leveller specified

for Fibrizer installation except that number of cane cutting knives are not
less than 56 for a 915x1830mm Milling Tandem.

The cutter is installed on inclined portion of cane carrier with a suitable

device for adjusting the clearance in between the knife tips and slats from
300mm to 350mm in between leveller and Fibrizer. The hood is so
designed that cutter can be run in both the direction i.e. reverse or
forward. The rotation direction is changed as per the quality of cane
preparation required.

The knife set of a Cane Cutter is totally enclosed by suitably reinforced

hood of 10/12 mm thick mild steel plate attached to the main cane carrier
frame work and provided with swing flaps and bolted/ hinged doors at the
top of the hood.

Cane Cutter is driven by a suitable HP (Normally 350 0r 600HP depending

on rate of cane crush) 600 rpm synchronous speed, slip ring motor having
a total slip of about 15%.
 Figure: General Arrangement of Cane Cutter
Main Components of Cane Chopper/ Leveller,& Cutter.
a. Main driving shaft not less than 230mm diameter for 915x1830mm
Milling Tandem.
b. Knives 36, 40, 56 and more depending upon size and type/design of
the equipment
c. Hubs Cast steel or Mild Steel Fabricated.
d. Bearings normally Heavy duty self-aligning, double row spherical
roller bearings.
e. Sleeves
f. Locking nuts
g. Fly wheels Cast Iron Grade 20 duly machined and balanced.
h. Gear coupling
i. Motor slip ring SPDP Or TEFC Enclosure
 j. Starter Suitable for motor Auto Stator rotor Starter.

2.2 Off Season Maintenance Procedure

a. Dismantle the hood of cutter/chopper.
b. Clean the hood and then Hard-facing to be done on Edges of pockets
by Welding Electrode(s) ………..
c. Dismantled all the knives.
d. Dismantle Top covers of plumber blocks clean and then grease (if
grease lubricated bearings fitted).
e. Check the Bearing clearance between rollers and outer race.
Maintain clearances limiting to maximum 0.025mm/inch diameter
of shaft, if exceeding the tolerance, tighten the sleeve or replace the
bearing.
f. Check the limit of sleeve, if reached at dead end and clearance is
more than tolerance limit then replaces the bearing(s).
g. All Hubs need to be Hard faced by Welding Electrodes ……..
h. Cracks and any deformation to be checked by ultrasonic test and is
any cracks detected in hub, replace the Hub in question.
i. Close the plumber block top cover. Tighten the Bolts.
j. All new knives to be fitted in hubs and tightened the bolt as per
strength grade. Bolts to be of 32mm diameter and knives 32mm
thick.

2.2. Check list after Maintenance

a. Ensure all bolts are tight, check by hammering method.
b. Ensure Grease and lubricants are applied sufficient in quantity.
c. Gap should be maintained in between bolt head and side plate of
main carrier, to ensure no rubbing of moving parts with stationary
parts.
d. Check direction of rotation.

2.3. Preventive maintenance during season

 Description Daily Weekly Monthly

Breakage of bolt Yes Yes Yes

check

Visual sound and Yes Yes Yes

vibration

Replacement of Yes or see the condition of knives

knives edge, it is good condition the
increase the period for replacement

3. FIBRIZER

3.1. Equipment Description

Fibrizer of all steel construction is located at the head end of cane carrier.
Fibrizer fiberizes the cane into long fibres.
Two types of Fibrizers are in use in sugar Industry. Fixed Hammer Fibrizer
and Swing Hammer type Fibrizer. Swing type Fibrizer is commonly used
having edge over Fixed Hammer Type Fibrizer and imparts better cane
preparation/ higher Preparatory Index.
Weight of each hammer is normally 18-20 kg or as per design by the
manufacturer. The no of hammers are decided as per crushing capacity.
Rotor shaft is heavy duty minimum 400mm diameter at the hubs and
260mm at the at the bearing journal of 40C8 quality.
The hammer shank is minimum 65mm thick having 600BHN hardness.
The Hammers are secured in 50mm thick Forged or Fabricated MS Hubs.
Fibrizer discs and hammer shanks have G M bushes to suit SS pins. The
Domite tips made of special alloy steel are fitted in Hammers and are
detachable.
The Deflector plate is normally 25mm thick and Anvil 75mm thick while
chute plate is 16mm with 2.5mm thick having Stainless Steel lining. Rotor
is supported on two heavy self-aligning double row spherical roller bearings
with adopter/with-drawl sleeve.
The diameter over the Tips of Hammers is 1800mm when running at
750rpm. A matching Fly Wheel is fitted at both ends of the shaft duly
machined and balanced to reduce the peak load to 150% of full load. Rotor
bearing Plummer blocks are of cast steel double jacketed for cooling water
.External pressure lubricating system is provided with standby
arrangement to ensure uninterrupted lubrication of bearings.
Anvil plate is another important construction part and is of pocketed type
having wrap angle 90 Deg or 120 Deg or may be higher as required. It is
completely covered by reinforced steel fabricated hood and attached to cane
carrier frame and is provided with deflector plate, fixed or oscillating type.
Drive for Fibrizer may be LT & HT electric motor directly coupled or steam
turbine coupled through reduction gear box. Fibrizer speed is in range of
700-800RPM.

Main Components of Fibrizer :

a. Main driving shaft, heavy duty 40C8 quality not less than 400mm
diameter for 915x1830mm Milling Tandem.
b. Hammers 25mm thick shank and 600 BHN hardness.
c. Hubs 50mm thick Cast steel or Mild Steel Fabricated.
d. Anvil 75mm thick having serrations or pockets.
e. Stainless Steel pins for Hammer holding.
f. Bearings normally Heavy duty self-aligning, double row spherical roller
bearings.
g. Sleeves
h. Locking nuts
i. Fly wheels Cast Iron Grade 20 duly machined and balanced.
j. Gear coupling
k. Motor slip ring SPDP Or TEFC Enclosure Starter Suitable for motor
Auto Stator rotor Starter
Figure: General Arrangement of Fibrizer
3.2. Off Season Maintenance Procedure
a. Dismantle anvil plate.
b. Clean the pocket of anvil plate, if required repair and hard face the
edge/ serrations.
c. Dismantle side locks and then take out pin and hammer
simultaneously.
d. After all the hammers are taken out, check the condition of hammer
neck, if it is abnormally worn out then replace.
e. Replace the donate tips.
f. Open the top cover of Plummer blocks, and check the condition of
bearing and also clearance of bearing rollers.
g. If bearing clearance beyond the tolerance limit, then tighten the
sleeve.
h. Ultrasonic testing of pin to be done and then be fitted in hubs.
i. Hard-facing to be done on hubs.
j. Bushes to be checked, if abnormally worn out or broken replace.
k. Fit the hammers and lock the pins.
l. Fit the side covers of Fibrizer.
m. Anvil plate to be set right as per setting prescribed by the
manufacturer.

3.3. Check list after maintenance

a. Anvil plate setting
b. Bearing clearance.
c. Grease and lubricant should be applied in sufficient quantity.
d. Gap should be maintained in between pin and side cover.

3.4. Preventive maintenance during season

 Description Daily Weekly Monthly

Replacement of demit trip./turn Yes/as per see the

the demit tip conditions.

Check the lubrication and Yes Yes Yes

visual sound
 CHAPTER - III
OPERATION MANUAL
FOR
MILLING PLANT

1 MILLS

Milling is a mechanical process used for extracting cane juice from cane.
Mainly number of Mills and combination of rollers are responsible for
better juice extraction from cane. The number of mills and size of roller
depend on capacity and efficiency of plant. In one tandem four or five mills
and several combinations of mills as detailed below are popular in
common practice.

Different combinations of mills:

a. Four roller mills (Three main rollers with one under feed roller.)
b. Six roller mills (Three main rollers top, feed and discharge and one
under roller with Grooved Roller Pressure Feeders GRPF.)
c. Six roller mills (Three main rollers top, feed and discharge and one
under roller with Toothed Roller Pressure Feed rollers TRPF.)

Main Components of a Mill:

a. Drives/prime movers (motors or turbines).

b. Open Transmission Gearing train. ( Bull Gear and Pinion)
c. Transmission Gear Shaft and Bearings
d. Enclosed Reduction Gear Box
e. Head stocks with Wear Plates.
f. Top and Side Caps.
g. Static Collars with Stainless Steel cladding.
h. Combination of rollers. (Top, Feed and Discharge Roller)
i. Crown Pinions on each roller.
j. Trash beam. ( With Trash Plate Holding Bolts)
k. Trash plate.
l. Scrapper.( For Top and Discharge Roller)
m. Messchaert Knives. ( For Feed Roller)
n. Trash Turning Arms.(Both sides of Head Stocks)
o. Scraper Holding Arms. (Both sides of Scraper)
p. Tail Bar With Fish Plates and Square Couplings both sides of Tail Bar.
q. Juice Tray.
r. Hydraulic accumulators.
s. Hydraulic pump and tank assembly.
t. Bearings Top, Side Feed and Discharge with GM or white metal lining.
u. Pressure chute.( may have Stainless Steel Lining)
v. Donnelley Chute.(may have Stainless Steel Cladding)
w. Inter rake carriers (Cane blanket conveyors).
 Figure : General Arrangement of a Mill

GROOVING

The grooved rollers rupture the bagasse more completely and thus facilitate the
extraction of Juice. The grooves of Rollers in a Mill are arranged in such a way
that teeth of top roller, mesh with two bottom rollers. The size of grooves
generally decreases from 1st to last mill. This is because of bagasse becomes
finer and finer as it proceeds from 1st to last mill. The types of grooving
generally provided are as under:
 Circumferential grooving
  Messcheart grooving

Circumferential grooving
Circumferential grooving are made along the length of the roller and round the
circumference. The depth of groove is slightly less than the pitch of the grooves.
Depending upon the size these grooves are termed as Fine, Medium and Coarse
grooves. Differential Grooving is also in common use having differential angles
to the tune of 3 to 5 degree in Top, Feed and Discharge rollers.

Messcheart grooving
Deep circumferential grooves in between or in alternate circumferential groove
is universally adopted as is termed as Messcheart Groove. Special scrapers are
required for cleaning Grooves and are called as Masscheart Knives. These type
of grooving provide extra drainage area and help in avoiding juice re-
absorption.

Mill Roller
Rollers are made up of a shaft 40C8 Forged steel confirming to IS:1570-1979
and Shell of coarse grain Cast Iron material confirming to IS 11201:1985 and
hardness 180-210 BHN. All shafts have square ends approximately 420mm or
more to have inter-changeability with other rollers.

Figure: General Arrangement of a Roller

Donnelly Chute:

These are gravity pressure feeding devices to increase the feed ability of
cane blanket. The level is maintained in Donnelly chutes which are
controlled by mill control system which helps to achieve the performance
.Stainless Steel lining in side facilitates cane feeding to the Mills.

Figure: General Arrangement of Mills showing Donnelly Chutes

Scrapper

The use of scrapper is to clean the bagasse from roller grooving so that
roller rows are clear and extracted juice does not get re-absorbed. Top roller
scraper is floating type. Scrapers for Top and Discharge rollers have
renewable Cast Iron tips.
 Scrapper

Trash Beam and Trash Plate

Trash beam of cast steel material is fitted in between head stocks. For
achieving Trash Plate settings a tilting mechanism is provided for tilting the
Trash Plate and Beam assembly. Trash Plate has matching teeth to fit
closely with feed roller teeth.

Trash plate normally is made up of Cast Steel IS: 1030

grade22/45,however for higher loads Forged Steel Trash plates are
preferred.
 Figure: Trash Plate

Hydraulic accumulators:

The hydraulic Accumulator contains a bladder of synthetic rubber

containing Nitrogen gas under pressure. Hydraulic pressure is applied on
roller journals, so that unnecessary lift of roller is restricted and proper
compression is applied on roller to extract the juice from cane blanket
passing through mill.

1.2 Off Season Maintenance Procedure

a. Dismantle the mills by first taking out tail bar square couplings and
tail bar.
b. Dismantle Donnelly chute.
c. Dismantle of top cap assembly of G.R.P.F. top roller.
d. Take out G.R.P.F. rollers.
e. Dismantle hydraulic cap assembly of top roller of mills.
f. Take out top roller and its bearing.
g. Dismantle all the accessories like scrappers, static collars &
discharge chute
h. Dismantle discharge cap, feed cap etc.
i. Take out discharge roller and feed roller.
j. Measure and note the sizes of roller, journal, wear & tear and
position of shaft and tabulate as :

Mills Roller Shell Shell New Setup Journal Remarks

Shaft no diameter diameter Size
& position before after
crushing crushing

k. Re-arrange the rollers according to crushing and identify the roller to

be sent for re-shelling.
l. Re-groove the roller as per selection of the roller, if required.
m. Polish the journal at the time of grooving when roller is on lathe
machine, by emery paper and oil.
n. Embed the bearing on journal by way of applying blue and scraping.
o. Assembly of mill should be started in sequence.
p. Static collars to be fixed properly and ensure that Lotus holes of roller
do not over-lap with static collars.
q. Trash plate to be bolted with trash beam and lock the nut by welding.
r. Clean all the lotus drainage pipe mechanically or chemically.
 s. Roughening of all the rollers to be done by suitable electrodes after
grooving 2/3 height of groove.
t. Setting of rollers and trash plate respect to top roller be done as per
the calculations.
u. Messchaert knives with messchaert groove must be set right.
v. GRPF pressure chute angle must be checked and ensure placement is
line with settings.
w. All the crown pinions to be matched with original profile, for any
deviation reclaim by welding so as to match with original profile.
x. After fixing the crown pinion key stoppers must be welded to the roller
shaft.
y. All the bearing assemblies of gearing train should be opened and after
embedding the bearing proper gap should be maintain between journal
and top bearing, while in case of Anti friction bearings ,all bearings to
be checked if defective replace and then grease.
z. Alignment of output shaft with respect to top roller must be checked
and should be made perfect.
aa.Mill top roller centre height must be lesser than low speed gearing
centre height. Maintain as per recommendation of manufacturer or as
per top roller left ranging from 10mm to 20mm.
bb. Backlash of Gears must be checked every year and record. Gears the
replaced if badly worn out.
cc. Assemble Donnelley chute and set the opening of Donnelley chute as
per prescribed setting.
dd. Maintain heel clearance of trash plate 20-25mm with discharge roller.

1.3 Check List after Maintenance

a. Setting of mill roller to be done (top to feed, top to discharge, top to
trash plate) in accordance with the setting.
b. Gap between sides of roller and static caller should be less than 1
mm, if either less or more to be set right.
c. Check the heel clearance and set right, if not as per requirement.
 d. Check the centre height of low speed gear shaft and top roller shaft
centre it should be 10-15mm (or match with design data)
e. Ensure that all the lubrication points regularly feed oil/grease
regularly.
f. Ensure all open gearings are submerged in lubricant.

1.4 Preventive Maintenance During Season:

Description Daily Weekly Monthly

Roughening of roller yes

Setting to be checked Yes

Scrapper tightening Yes

Monitoring of feeding of lubricant. Yes Yes Yes

Monitor bearing temp. Yes Yes Yes

Hydraulic pressure to be checked and fill Yes Yes Yes

Following are the checks to be carried every week or whenever any

shutdown is available apart from what has been indicated in the table:

a. Check all Trash Plates bolts and ensure tightness.

b. Check all Scrapers bolts and ensure tightness.
c. Check if all scrapers are properly cleaning the roller grooves visavis
messchaert grooves.
d. Check all Foundation bolts of all cane preparatory devices, Mill
drives, Transmission gears etc. and ensure tightness.
e. Check Mill settings i.e. Feed and Discharge roller opening either by a
Gauge or Lead Bricks.
f. Check all chains, split pins, nut and bolts, rake fixing mechanism
and ensure cleanliness and free movement of chain rollers.
g. Check all GM Bearings & Anti-friction bearings.
 h. Check Top rollers lift indicators to indicate zero when roller in rest
position.
i. Check clearance pressure plate and bottom of hydraulic ram.
j. Check hydraulic system and ensure no leakage of hydraulic oil.
k. Check Lubrication system and ensure proper quantity of oil is
pumped in all oil points.
l. Check oil levels in all gear boxes.
m. Check geared coupling and lubricate with grease if required.
n. Check and ensure desired quantity of water is given to Mill Roller
Bearings & oil coolers.
o. Check wear and tear of Crown Pinions and ensure tray full of oil is
available.
p. Clean juice rotary screens and ensure no tearing of filter segments.
q. Check all glands of Juice and water pumps and ensure no leakage of
juice and water.
r. Cleanliness of all journals, juice trays, whirler tanks be checked.
s. Check all electric connections, cables and control cable condition for
wear and tear or shot-circuiting stage.

2. PRIME MOVERS

Following are the prime movers which are in use as Mill Drives:
A. Steam turbine.
B. Electric Drives . . DC motors/AC Motors With VFDs
C. Hydraulic drive.

2.1 Steam Turbine

Equipment Description
Steam Turbines were used as Mill drives in the year 1947 in Louisiana.
Most of Sugar Mills are still using single stage back pressure turbines
while Multi-stage, back pressure turbines are also in use, which are
more efficient.
The steam turbines (Back Pressure Type) are used to drive the Mills and
the Fibrizer or shredder. The Steam Turbine as a Mill drive is capable of
developing continuously rated BHP Normally 350-500BHP at 80% of its
rated speed when supplied with Steam at normal parameters. These
Turbines have 2 hand operated overload valves to control steam flow in
such a way that Turbine can develop additional BHP and have 200%
starting Torque and 160% stalling Torque capability.
Turbines are coupled to a suitable enclosed reduction gear box of
hardened and ground gears suitable to transmit 500 BHP at 80% of the
rated speed of Turbine at service factor 1.7.

Main Components of a Turbine are:

a. Turbine Casing
b. Turbine Rotor
c. Rotor Bearings
d. Labyrinths
e. Governor (Hydraulic / mechanical or Electronic)
f. Emergency Trip Mechanism
g. Diaphragm with static nozzles
h. Steam Inlet valve
i. Exhaust Steam Valve
j. Hand Operated Nozzle Valves
k. Steam Drains
l. Oil Pumps Main and Auxiliary
m. Oil cooler arrangement
n. Instruments (Speedometer, Steam gauge, pressure
gauge,thermometer)
o. Oil reservoir with oil Filters
p. Base Plate
Figure: General arrangement of a steam turbine showing components
Maintenance procedure during off seasons.
a. All the inlet and outlet valve should be closed and connect with
dehumidifier to protect the rotor blades and nozzles from corrosion.
b. Open the governor/control valve.
c. Open the trip lever and take out.
d. Take out the governor.
e. Take out Carbon ring.
f. Open the top casing bolts and lift with the help of crane using proper
slings.
g. Decouple the Turbine Rotor from driven apparatus
h. Record the internal clearances and then lift the rotor and take out
form turbine casing.
i. Take out fixed nozzles.
j. Inspect the appearance of the rotor, fixed blades and then clean the
scale of rotor, diaphragm nozzles and journals.
k. Embed bearings with shaft using blue and maintain clearance as
recommended by the manufacturer.
l. After all the inspection if satisfactory then start assembly.
m. Fix the fixed nozzles.
n. Keep the bearing in position.
o. Keep the rotor on in position.
p. Check the bearing clearance and note down.
q. Check the axial thrust and backlash of main oil pump gears.
r. Fix the carbon ring of exhaust end and steam end.
s. Assemble the top casing of turbine.
t. Place the governor in position.
u. Check the backlash of governor wheel.
v. Adjust the trip lever at original position.
w. Control valve should be assembled.
x. Check the high speed gear box bearing clearances, axial thrust and
backlash in pinion and gears.
y. Assembled the top cover of gear box.
z. Check the alignment in between gearbox and turbine.
aa.Box up the Turbine, Tighten all casing Bolts with a torque wrench
having Torque as per recommendation of the manufacturer.
bb. PS: Turbines must be overhauled under the supervision of Turbine
Expert.

Checks after Maintenance

a. Run the Auxiliary oil pump and check the lubrication system that as
per our working parameter.
b. Check the emergency lever and ensure it is operative.
c. Check all Casing bolt are tightened.
d. Hydraulic governor oil level.
e. All the drain line should be clean and steam traps are working.
f. All pressure gauges should be calibrated.
g. Oil cooler leakages.
h. Oil tank condition.

Preventive maintenance during season:

Description of work Daily Weekly Monthly

Pressure difference across oil strainer Yes

Steam leakages Yes

Oil Leakage, Oil Level Yes Yes

Observed the chest pressure/working Yes

pressure

Abnormal Sound or Vibrations Yes

Hand Trip and Over Speed Mechanism

2.2 Electric Drives

Electric Drives Such as DC Motors also Ac Variable frequency drives are

now in popular use in sugar Industry. Each Mill is driven by a separate
Motor. The advantages of Electric drives over Steam Drives are:
a. An Electrical driven Mill House is neat and clean as no steam, water
and oil leakages.
b. Motors have better and definite control.
c. Wide range of speed control.
d. Ease of On and Off operation also reversal is possible within the
system and no mechanism for reversing the Mill direction is required.
e. Repair and maintenance cost is much less as compared to steam
turbines.
f. Exhaust steam is free from water and oil traces.

2.3. Hydraulic Drives

Quite a few Hydraulic drives have been installed in some Sugar Mills but
are not popular even few advantages have been noticed:

a. Huge speed variation is possible

b. Less space is required for installation as compared to Steam and
Electric Drives.
c. Since no gear train is required, hence transmission losses are bare
minimum.

Since Hydraulic Drives are not installed in the factories hence not
described while Electric drives have been explained in “Electricals”.