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2.

STERILISING STATION

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2. 2.1

SPECIFICATIONS FOR STERILISING STATION Vertical Steriliser 2 Units

Arrangement: 3200mm O/D Vertical c/w bottom auger conveyor.

Capacity: Design:

18tons storage capacity @ 0.55tons/m3 Safe Working Pressure of 45 Psig. Test Pressure: 59 Psig. Working Temperature: 139 deg C Type of Weld: Double V-butt welds

Construction: a) Shell plates use 15mm, liner plate use 9mm Thick Mild Steel SS400 / BS.4360 steel plate. b) 1,200mm OD x 15mm thick Mild Steel SS400 / BS.4360 Gr.70 c/w 4.5mm thick stainless steel 304 dished end full liner and stainless steel groove insert ( 1 unit for FFB inlet and 1 unit for SFB discharge) c) Discharge auger: 15mm thick mild steel auger casing c/w 9mm thick MS liner and 9mm thick mild steel screw ribbon d) Each sterilizing process cycle will be approximately 100 120 minutes. e) Drive: 11 kw Gear Motor for discharge auger, Safety factor 1.5 @ final 15rpm f) 1 lot nozzle pads for steam inlet / exhaust / condensate / safety valve Steam distribution: 3 nos. 4 dia. steam distribution pipe rings and 3 nos mild steel angle ring steam spreaders. Insulation: The vessel shall be lagged with 50mm thick Rock-wool slab of density 60 kg/m3 and totally protected against damage with covered with 0.7mm thk plain aluminum sheets. The entire unit to be designed in accordance with Malaysian Machinery Departments regulation for the Unfired pressure vessels using BS 1500 or ASME Boiler & Pressure Vessel Code, Section VIII Div.1 c/w application and submission of Machinery Department approval

Design:

Approval:

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Testing:

After completion of installation at site the sterilizer shall be Hydrostatically tested to 4.03 kg/cm2 and steam test shall be witnessed and certified by the local machinery inspector and the local Regulation in all respect which shall arrange and pay any fees by Buyer. Externally 1 coat of Apexior No. 3 and internally 2 coats of Apexior No. 1

Finish:

Hydraulic Controls For Sterilizer Doors 1. One (1) unit hydraulic power pack c/w control panels comprises of: a) Heavy duty external Gearpump(8cc) b) 4kw/1450rpm/415AC motor drive c) Directional control valve, shut off valve, pressure gauges d) Power control panel e) 80 liters sand blaster steel tank f) Manifold block,sand blasted steel tank, return line, strainer Two (2) numbers Top Door control system comprises of: a) Manifold block, flow control valve, counter balance valve b) Solinoid operated directional control valve c) Hydraulic cylinder 80mm bore x 56mm rod x 440mm stroke Two (2) numbers Bottom Door control system comprises of: a) Manifold block, flow control valve, counter balance valve b) Solinoid operated directional control valve c) Hydraulic cylinder 80mm bore x 56mm rod x 440mm stroke Two (2) numbers top and bottom door locking cylinder 63mm bore x 36mm road x 175mm stroke Two (2) numbers conveyor sliding door cylinder 63mm bore x 36mm road x 915mm stroke Electrical control panel and auger control panel c/w sensors, MCH, starter, relay, switches Local junction boxes for sensor connection and termination. All wiring / cabling materials include cable, trunking / cable trays.

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7. 8.

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Sterilizer Automation Each Sterilizer consists of: a. 2 nos. 200mm diameter carbon body SS316 Disc steam inlet and exhaust valves. b. 1 no. 200mm diameter full SS316 body & Disc condensate and water discharge valve. c. Valve makes shall be electrical actuator with manual override. d. Rotary chart recorder Rototherm single pen chart recorder. e. Wiring / cabling materials include cable, trunking / cable trays.

Operational algorithm Sterilization process will allow to start ( either manual or auto) only when the doors are closed and locked. ii. The sterilizer control shall be fully programmable for multi-steps and selectable for manual / semi-auto / auto operation. iii. In manual mode everything is done manually. iv. In semi-auto mode, the sterilization shall start as auto mode but certain selected operation can be altered / override like system steam management to sterilizers. v. In auto mode, the operation is fully controlled by the selected recipe. The operator can create and save the various recipe on screen and selectable for use before the auto mode is initiated. vi. Time, steps of the sterilization are shown on screen at all times. Warning lights and alarm are available to warn operator for: Sterilization in progress. Sterilizer in standby. Sterilization completed. All valves offered are with electrical actuators with manual override. i.

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1.2

Autofeeder No.1
Arrangement: To regulate the Sterilised FFB from the vertical sterilizer into SFB inclined conveyor. Scraper bar bottom feeding. 1.8 m width x 1.2 m height. 20 tones FFB/Hr Contruction with top & bottom carrier frames. Chain Wear Strip shall be 6mm thk by 50mm wide mild steel flat. The discharge end conveyor shall be incorporated with 4.5 t mm m.s. chute. Push pipe shall be API 75 NB class C install at every 6 links and push pipe & attachment/scrapper shall be install every 12 links The whole conveyor and platform are supported by framed structure fabricated from channel, hollow section and strutted by ms angles/channel/hollow section. The entire frames are to be rigidly braced vertically and diagonally with 50 x 50 m.s. RHS & strut by RHS or RSC. Take up bearings of NTN make shall be fitted as indicated in the drawings and are to be adjustable type c/w taper sleeves and guides. Tail shaft of 100 mm dia. Machined from EN9 shaft is to be fitted with 2 nos. cast steel 18 teeth x 6 pitch chain wheels of 60,000 lbf breaking load of PC make attachments at every 6th link. The ms scraper bars of fabricated from 75 N.B. API class C pipes are to weld onto the fabricated attachments with 2 nos steel bolts lock nuts and spring washers at each side. The 100 dia. Drive shaft fitted with similar chain wheels as the tail shaft but with both wheels keyed in is to be mounted on Plummer block bearing 100 .

Type: Size: Capacity Construction:

Drive:

The drive consists of SEW Gearmotor, 7.5kw, service factor 1.5, powered, final 38 pitch duplex sprocket ratio 1.5:1 couple to 100mm diameter drive shaft. Final 6 rpm

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2.3

Operating Platform for Vertical Sterilisers-1 lot

The catwalk & control platform shall construct & span for the 2 units of Vertical Sterilizers The complete platforms are welded with 4.5 thk ms chequered plate or Code 1000# mesh expanded metal sheet on the plain and incorporated with security railing & 4.5 thk x 100 deep ms flat toe board all round. Adequate piping support to be constructed at site to suit the blow-off & steam inlet steam line. Adequate platform for power pack & panel shall be provided.

2.4

Inclined Sterilised Fruit Bunch Conveyor 1 unit

Arrangement: An inclined conveyor to convey SFB from the autofeder no 1 to autofeeder no 2. Scraper bar bottom feeding. 1 m width x 1 m height. 60 tones FFB/Hr Construction with top & bottom carrier frames. Chain Wear Strip shall be 6mm thk by 50mm wide mild steel flat. The discharge end conveyor shall be incorporated with 4.5 t mm m.s. chute. Staircase connecting the catwalks and the floor shall be fabricated from 2 x 125 x 65 RSC as stringers and 4.5t on the plain chequered plate treads at 200 rises and with a 25mm bent lip at both free ends. Push pipe shall be 75 NB black class C install at every 6 links and push pipe & attachment/scrapper shall be install every 24 links The whole conveyor and platform are supported by framed structure fabricated from channel, hollow section and strutted by ms angles/channel/hollow section. The entire frames are to be rigidly braced vertically and diagonally with 50 x 50 m.s. RHS & strut by RHS or RSC.

Type: Size: Capacity Construction:

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Take up bearings of NTN make shall be fitted as indicated in the drawings and are to be adjustable type c/w taper sleeves and guides. Tail shaft of 100 mm dia. Machined from EN9 shaft is to be fitted with 2 nos. cast steel 16 teeth x 6 pitch chain wheels of 60,000 lbf breaking load of PC make attachments at every 6th link. The ms scraper bars of fabricated from 75 N.B. black class C pipes are to weld onto the fabricated attachments with 2 nos steel bolts lock nuts and spring washers at each side. The 100 dia. Drive shaft fitted with similar chain wheels as the tail shaft but with both wheels keyed in is to be mounted on Plummer block bearing 100 . Drive equipment to be rigidly supported and with adequate platform c/w 38mm/32mm . Handrail around it.

Drive:

The drive consists of SEW Gear motor, 11 kw, service factor 1.5, final 38 pitch duplex sprocket ratio 1.5:1 couple to 100mm diameter drive shaft. Final 12 rpm Roof along conveyor: Color bond equivalent to main building roofing specification.

Walkway:

The walkway running the entire of the conveyor consists of expanded metal mesh, 1000# and shall be rigidly welded to RSC bearers and angle stiffeners @600 c/c and standard hand railing 38mm/32mm dia shall be provided.

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2.5

Steam & Condensate Blow Down Chamber 1 Unit Arrangement: To receive sterilizes condensate & exhaust steam and discharge into the condensate pit and act as silencer. Mild steel construction as shown in the drawing. The contractor shall be responsible to secure the chamber on to foundation. One manhole of 600 dia. shall provide. Accessories: Painting: Inlet and Drain Pipes shall be schedule 40 pipe. the complete chamber is to be painted with aluminium heat resistant paint.

Construction:

2.5

Sterilizer Condensate/Effluent Pit Pump 1 Unit Arrangement: To pump the steriliser condensate and sludge form pit to oil recovery tank Centrifugal type. Sterilizer condensate @ SG: 0.85 25 cu.meter/hr at 15 m head. Driven by motor via pulleys and belts. KEW, SEP 50 Open Impeller. Material: CA15/CA15/SS. Mechanical seal : SKF/FAG/NTN

Type: Liquid Capacity: Drive: Make:

Bearing

Pulley/V Belts : B3 Max. Speed Motor : not more than1650 rpm. : 7.5 Kw TEFC SC/IP54/Class F/415/50/3 c/w base frame

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