1. EVAPORATION
SECTION
1.1. Feed balance
Tank
The tank shall be
provided with necessary connections for water & CIP lines. The tank is
equipped with control valve for milk inlet, soft water supply at low level, CIP
spray ball and sight glass. Flow plate shall be used for connection of milk
line from pasteurized milk storage silos to feed balance tank of evaporation
plant and CIP return lines.
Quantity : 1 No.
Capacity : 1KL
MOC : AISI 304
Type : Closed type,
un-insulated.
1.2. Feed Pump
It shall be used for
the transfer of milk from feed balance tank to Evaporation plant. It shall be
provided with VFD (Variable frequency drive) and magnetic flow meter at the
discharge end of pump for controlling the feed rate to the Evaporation plant.
Quantity : 1 No.
Capacity : To suit
evaporator feed rate
MOC : Product
contact parts - Impeller in AISI 316 and casing in AISI 304
Type : Centrifugal
1.3. Strainer
(Duplex Filter)
It shall be provided
with manual butterfly valves to remove the foreign suspended particle if any.
Quantity : 1 No.
MOC : AISI 304
Type : Pipe in Pipe
1.4. Dead Vapour
Pre Heater
The milk from feed
balance tank shall be preheated in dead vapour preheater by outgoing vapours
from the separator of last effect calandria.
Quantity : 1 No.
MOC : AISI 304
Type : Shell and
tube type
1.5. Low
Thermophilic Pre Heater
The milk coming from
Dead Vapour Preheater shall be preheated into low thermophilic preheater by the
steam/vapour from thermo compressor. The plant shall be designed in such a way
that product contact with metal surface at the thermophilic bacterial zone shall
be avoided and design shall ensure steam economy by using thermo compressor.
Quantity : 1 No.
MOC : AISI 304
1.6. Steam filter
(For Low Thermophilic Heater)
Steam filter shall
be provided for filtration of live steam which shall be further injected in
product. The filter shall be of 75 micron type (common for Low thermophilic and
DSI) followed by 5 micron rating.
Quantity : 75 Micron
– 1 No. and 5 Micron – 1 No.
Capacity : Suitable
MOC : AISI 304
1.7. Direct
Contact Regenerative heater cum Flash Vessel
This shall be used
to heat milk coming from the Low thermophilic preheater by the vapour generated
from flash vessel. It shall also be used for flash cooling of the pasteurized
product provided with specially constructed tangential inlet inclusive of CIP
ring.
Quantity : 1 No.
Capacity : Suitable
MOC : AISI 304
1.8. Milk
Pasteurizer – Direct Steam Injector
To heat the milk to
the required pasteurization temperature by tangential injection of steam in an
on-line piping system. It shall be equipped with de–superheating equipment
& protected against over pressure by a pressure relief valve.
Quantity : 1 No.
Capacity : Suitable
MOC : AISI 304
1.9. Steam filter
(For DSI)
Steam filter shall
be provided for filtration of live steam which shall be further injected in
product. The filter shall be 5 micron rating.
Quantity : 1 No.
Capacity : Suitable
MOC : AISI 304
1.10. Temperature
treatment holder
It shall be used to
hold milk for a required holding time. Selection of required holding time based
on type of powder to be produced and as per the design requirement shall be
done with manual swing bends.
Quantity : 1 Set.
MOC : AISI 304
1.11. Inline
Filter
It shall be installed
before the first effect Calandria for removal of solid particles from milk, if
any. One no. of actuated butterfly valve shall be provided for drain.
Quantity : 1 No.
MOC : AISI 304
1.12. Calandria –
Falling Film Type
The Calandria shall
be of the vertical shell and tube type, specially designed for falling film
evaporation, supported by a stainless steel skirt. The Calandria shall be
equipped with:
Ø Specially designed liquid distribution system at the top
Ø Removable top cover, fixed with swing bolts
Ø Sight glass on shell to observe condensate flow and hand hole on skirt
Ø First effect Calandria shall be insulated with 50 mm thick mineral wool
and cladded with 0.8 mm thick AISI 304 sheet in reverted construction.
Ø Suitable arrangement for proper CIP of Calandria
Quantity : 5 Nos.
MOC : AISI 304
Type : Self
supported Shell & tube type falling film
1.13. Vapour
Separator
Vapour separator
connected with calandria shall be in an all welded construction. The separator
is vertical cyclone type self-supporting and is equipped with sight glass and
arrangement for CIP.
Quantity : 5 Nos.
MOC : AISI 304
Type : Self
supported
1.14. Product
Transfer Pumps
It shall be used for
transfer of product through each pass of the calandrias of evaporation plant.
Quantity : 1 Lot
Capacity : Suitable
MOC : Product
contact parts - Impeller in AISI 316 and casing in AISI 304
Type : Centrifugal
with seal water arrangement
1.15. Concentrate
Discharge Pump
It shall be used for
transfer of milk concentrate from the last effect calandria to feed concentrate
tanks of feed system for Spray drying plant.
Quantity : 1 No.
MOC : Product
contact parts - Impeller in AISI 316 and casing in AISI 304
Type : Centrifugal
with seal water arrangement
1.16. Condensate
Pump
One no. of transfer
pump shall be used for transfer of condensate from first effect calandria.
Another transfer pump shall be used for transfer of condensate from remaining
calandrias. In both the cases, supplier’s scope shall terminate at the pump
discharge. Further collection, transfer, storage and use shall be in the scope
of purchaser.
Quantity : 2 Nos.
Capacity : Suitable
MOC : AISI 304
Type : Centrifugal
1.17.
De-superheating Arrangement
It shall consist of
one no. of pump with desuperheating nozzle.
Quantity : 1 Set
1.18. Thermo
Vapour Re-compressor (TVR)
The thermo
compressor shall be provided for compression of vapour to a high temperature
level by means of live steam.
The thermo vapour
re-compressors can be operated in combination for various duty conditions. The
thermo vapour re-compressors shall be provided with mineral wool insulation and
0.8 mm thick AISI 304 reverted cladding suitable for thermal insulation
Quantity : 1 Set
MOC : AISI 304
1.19. Vacuum
Pumps
The vacuum pumps
shall be used for the creating the vacuum into the evaporation plant. During
start up both pumps shall in operation and during normal plant operation only
one pump shall be kept under operation.
The housing &
casing shall be in cast iron with AISI 304 impeller & shaft. It shall
consist of floor mounted base frame in Mild Steel with directly coupled motor
and cast iron non-return valve in suction line.
Quantity : 2 Nos.
Capacity : Suitable
Type : Water ring
type with mechanical seal
1.20. Surface
Condenser
Surface condenser
shall be provided for condensing of discharged vapour from last effect
calandria using cooling water with required inlet and outlet connections. It
shall have provision for cleaning of tubes through CIP Liquid.
Quantity : 1 No.
MOC : AISI 304
1.21. Vapour
Ducting
It shall be provided
in welded construction for connection between vapour separators, calandrias,
surface condenser and TVR etc.
Quantity : 1 Lot
MOC : AISI 304
1.22. Seal water
System
Seal water tank (100
L) shall be located at height so that soft water shall flow at required
pressure for seal cooling of process pump. The soft water return shall be
collected in the seal water collection tank (100 L) kept near to process pumps.
The water from the collection tank shall be transferred to Vacuum pumps through
PHE chiller. The chilled water shall be used as a cooling media. The return
water from the vacuum pump shall be drained off.
Quantity : 1 Set
Capacity : Suitable
MOC : AISI 304
1.23. Cooling
Tower
Cooling tower shall
be in FRP construction, having fixed spray nozzles; water distribution system
and Poly Propylene fill pack for heat transfer. The cooling tower is fitted
with a statically balanced axial flow fan having adjustable type non-corrosion
FRP blades. The cooling tower has air inlet louvers and supporting hardware /
MS structures are galvanized for long life and to withstand wind load.
Capacity : Suitable
Quantity : 1 No.
Type : Induced
draught cooling tower made in FRP casing with water distribution system, fan
& electric motor.
1.24. Cooling
Water Pump
Type : Centrifugal
type in CI construction.
Quantity : 1
2. Concentrate
Recovery System
2.1. Concentrate
Recovery Tank
Concentrate recovery
tank shall be provided to recover solids both from evaporation and spray drying
plant under emergency and during water flushing. The concentrate shall be
suitably diluted by adding soft water into concentrate recovery tank.
Quantity : 1 No.
Capacity : 5 KL
MOC : AISI 304
2.2. Concentrate
Transfer Pump
It shall be used to
transfer diluted milk concentrate from the concentrate recovery tank to liquid
milk processing section.
Quantity : 1 No.
Capacity : Suitable
MOC : Product
contact parts - Impeller in AISI 316 and casing in AISI 304
2.3. PHE for
concentrate cooling
It shall be used for
chilling diluted milk concentrate before the transfer from concentrate recovery
tank to liquid milk processing section using chilled water as cooling media.
The diluted concentrate shall be chilled up to 10 Deg. C.
Supplier scope shall
terminate at the outlet of PHE. Further transfer, use and collection shall be
in the scope of purchaser.
Quantity : 1 No
Capacity : Suitable
MOC : Plates of AISI
316 with MS frame in AISI 304 cladded construction
Type : Plate heat
3. SPRAY DRYING
PLANT
FEED SYSTEM
3.1. Feed
Concentrate Tank
It shall be used as
feed tanks for Spray drying plant. The tanks shall be equipped with CIP spray
ball, agitator, level switch and feed nozzle.
Quantity : 2 Nos.
Capacity : 2 KL
MOC : AISI 304
Type : Un-insulated
and Free standing
3.2. Water
Balance Tank
It shall be used for
supply of water during start up and shutdown of the plant and in case of
interruptions in feed supply. The tank shall be equipped with low level switch.
Quantity : 1 No.
Capacity : 200 L
MOC : AISI 304
3.3. Booster Feed
Pump
It shall be used for
transfer of milk concentrate from feed concentrate tank to high-pressure pump
through feed filter & concentrate pre heater.
Quantity : 1 No.
MOC : Product
contact parts - Impeller in AISI 316 and casing in AISI 304
Type : Centrifugal
3.4. Feed Filter
It shall be provided
with manual butterfly valves for removal of foreign particle, if any
Quantity : 1 No.
MOC : AISI 304
Type : Pipe in Pipe
(Duplex)
3.5. Concentrate
pre-heater
It shall be used for
heating of milk concentrate to necessary feed inlet temperature to Spray dryer.
The principle is essentially a tube in tube design, with the product flowing in
inner tube in a single product channel. The milk concentrate pre heater shall
be suitable for continuous operation of 20 hours without any intermediate CIP.
It shall be inclusive of indigenous make equipment’s including support stand,
hot water system (Pump & PHE) & steam control valve and interconnecting
pipework.
Quantity : 1 No.
Capacity : Suitable
to match with dryer feed rate
3.6. High
Pressure Feed Pump cum Homogenizer
It shall be used to
pump milk concentrate to the high-pressure nozzle atomizer. The high-pressure
pump cum two stage Homogenizer shall be of the multi piston type. The pump
shall be provided with necessary safety valve and local pressure gauge.
The speed of the
pump shall be regulated by variable frequency drive.
Quantity : 1 No.
Capacity : Suitable
3.7. Feed pipes
& fittings
For the concentrate
leading from feed pump to atomizer complete with necessary bends and fittings.
End connection to nozzle atomizer assembly shall be through flexible hose pipe.
Quantity : 1 Lot
ATOMIZER ASSEMBLY
Complete with set of
nozzles, supporting unit, manifold & pneumatically operated valves.
3.8. Nozzle
Atomizer
Quantity : 1 Set
MOC : AISI 304
3.9. Tools for
Atomizer
Special tools for
assembly of the nozzle atomizer & changing the nozzle orifice insert.
Quantity : 1
3.10. CENTRALISED
COMMON AIR FILTERATION UNIT
Dryer air filtration
shall be with two stage air filtration of EU4 & EU 7 grade. Dry/cool air
shall be filtered (complete air required for the plant) prior to heating. The
filter shall be of the dry cell type and panel shall have number of cells
arranged for easy access and removal for cleaning inclusive of filter mats.
The air filtration
system shall be only for the process air for drying chamber, air disperser neck
cooling, fines return conveying air, integrated fluidized bed and Vibro
Fluidizer.
There shall be a
common air filtration room with required quality filtering media. There shall
be sufficient opening in the room covered by SS wire mesh for sucking fresh air
from outside of the building. For this purpose a fan shall be installed in the
filtration room.
From the filtered
air room suitable size SS ducting shall be laid for drawing of filtered air to
the inlet of man supply fan..
Quantity : 1 Set
3.10.1 AIR FILTER
(EU-4 & EU-7)
Air filter shall be
of self-supported pocket type. The coarse filter units shall have pockets with
frames and mounted in stainless steel housing. The filter units are removable
for inspection, cleaning and replacement. Incl. of necessary transition ducting
made of stainless steel.
Quantity : 1 Set
MOC : AISI 304
3.10.2 Common Air
filtration - Fan
One No. of Fan shall
be provided to maintain a slight over-pressure in the filter/fan room. It shall
be coated with anti-corrosion paint. The speed of the unit shall be controlled
through frequency converter.
Quantity : 1 Set
MOC : Mild Steel
DISPERSER COOLING
SYSTEM
3.11. Supply fan
for air disperser cooling
It shall be used for
supply of air through steam air heater for air disperser cooling. The supply
fan shall be provided with electric motor & flexible connections.
Quantity : 1 No.
MOC : Air Contact
parts in AISI 304 construction with base frame in MS
Type : Centrifugal
3.12. Steam Air
Heater for air disperser cooling
It shall be used for
indirect heating of the air by means of dry & saturated steam. The heater
shall contain AISI 304 tubes with Aluminium fins.
It shall have mineral type insulation with Aluminium
cladding.
Quantity : 1 No.
DRYING CHAMBER
ASSEMBLY
For mixing and
establishing contact between the spray of atomized droplets and drying air to
secure optimum conditions for rapid and controllable water evaporation and
lenient drying, comprising of
3.13. Air
Disperser
Air disperser is
built into the roof of drying chamber and through which drying air flow is
introduced into the drying chamber. The air disperser housing welded onto the
ceiling of the drying chamber.
Quantity : 1 No.
MOC : AISI 304
3.14. Multi Stage
Drying Chamber
This shall consist
of cylindrical body with ceiling to support the air disperser and a conical
part, designed to include built in stationary fluid bed. The air exhaust ducts
shall be placed in the ceiling.
The drying chamber
shall consist of cylindrical vessel with a conical bottom and top roof made of
AISI 304 constructed, also the Chamber supporting ring shall in AISI 304
Construction and the chamber shall be on a framework of MS (Mild Steel)
stiffeners.
The ceiling supports
the air disperser. Ceiling shall have MS (Mild steel) structural with mineral
wool insulation embedded in it and covered with MS (Mild steel) chequered
plate.
The chamber assembly
shall be provided with:
1) Switch for
preventing critical vacuum and pressure in the chamber.
2) Imported Chamber
door
Quantity : 1 No.
3.15. Insulation
for Drying Chamber
The Cylindrical
portion & cone of drying chamber shall be insulated with 75 mm thick resin
bonded mineral wool of density 100-120 kg/m3 to prevent the heat loss and
conductive working environment. The insulation shall be cladded with 0.8 mm
thick AISI 304 sheet in riveted construction wherever required to prevent heat
loss and comfortable working environment.
Quantity : 1
3.16. Integrated
Fluid Bed
For secondary drying
of product, designed and mounted on the conical part of the drying chamber.
The fluid bed shall
consist of housing divided in an upper product part and a lower air plenum by a
flex plate. The dividing sheet shall be self-supporting and provided with
inclined perforations providing an even powder flow and a fluidized powder
layer.
The fluid bed shall
be insulated with mineral wool, and furnished with inspection and cleaning
access, CIP nozzles and powder outlet arrangement.
Quantity : 1 No.
MOC : AISI 304
3.17. Rotary
Valve
It shall be easy
slide type used to form an air lock within the passage of powder. It shall
consist of housing, rotor and a motor with gearbox.
Quantity : 1 No.
MOC : Product contact
parts in AISI 304
3.18. Product
Duct
For product
discharge from the drying chamber to Vibro Fluidizer
Quantity : 1 Lot
MOC : AISI 304
3.19.
Electromagnetic Hammers on Chamber
It shall be provided
on the outside of the drying chamber to minimize deposits on the wall.
Quantity : 1 Lot
HOT AIR SYSTEM
FOR DRYING PLANT
3.20. Spray
Drying Supply Air Fan
It shall be used for
supply of air to spray drying chamber through steam heater. The supply fan will
be provided with variable frequency drive to maintain the required quantity of
hot air in the drying chamber.
Quantity : 1 No.
MOC : Air Contact
parts in AISI 304 construction with base frame in MS
Type : Centrifugal
3.21. Steam Air
Heater
It shall be used for
heating the process air by means of dry saturated steam. The steam air heater
shall be provided with AISI 304 casing with AISI 304 tubes with Al fins. The
heater shall be divided into two sections, one for steam and another for
pre-heating the drying air by means of condensate. The heater shall be complete
with all intermediate steam and condensate piping, steam stop valve, pressure
gauge, steam trap.
It shall have
mineral type insulation with Aluminium cladding.
Quantity : 1 No.
HOT AIR SYSTEM
FOR STATIC FLUID BED
The system shall
comprise of following:
3.22. Supply Air
Fan for SFB
It shall be used for
the supply of air to static fluid bed. The supply fan shall be provided with
flexible connections and electrical motor.
Quantity : 1 No.
MOC : Air Contact
parts in AISI 304 construction with base frame in MS
Type : Centrifugal
3.23. Steam Air
Heater
It shall be used for
heating the process air by means of dry saturated steam. The steam air heaters
shall be provided with AISI 304 casing with AISI 304 tubes with AL fins. The
heater shall be divided into two sections, one for steam and the other for pre-heating
the drying air by means of condensate. The heater shall be complete with all
intermediate steam and condensate piping, steam stop valve, pressure gauge,
steam trap.
It shall have
mineral type insulation with Aluminium cladding.
Quantity : 1 No.
AIR EXHAUST
SYSTEM
3.24. Cyclones
It shall be provided
for efficient separation of powder carried from the drying chamber by the
outgoing air. Differential pressure transmitter shall be provided across both
the cyclones.
Quantity : 2 Nos.
MOC : AISI 304
3.25.
Electromagnetic Hammer on Cyclones
Provided on the
outside of the Cyclone to minimize powder deposits on the wall.
Quantity : 2 Nos. (1
no. on each cyclone).
3.26. Exhaust Fan
It shall be provided
with frequency drive to maintain the vacuum inside the Spray drying plant.
VFD for exhaust fan
shall be IP 54.
Quantity : 1 No.
MOC : MS (Mild
Steel)
Type : Centrifugal
FINES RETURN
SYSTEM
For continuous
transport of fines from cyclones to the drying chamber / Vibro fluidizer for
agglomeration.
3.27. Roots air
blower
It shall be used for
supply of air under pressure to convey the fines return to drying chamber. It
shall consist of safety valve, non-return valve, pressure gauge and electric
motor. It shall be provided with acoustic enclosure.
Quantity : 1 No.
MOC : Air Contact
parts in AISI 304 construction with base frame in MS.
3.28. Blow
through Valves
It shall be used for
feeding milk powder to the fines return duct from cyclone outlet. It shall
consist of electric motor & solenoid valve to provide the compressed air
for cleaning of blow through valve. It shall be easy slide type.
Quantity : 2 Nos. (1
no. below each cyclone)
MOC : Product
contact parts in AISI 304
3.29. Diverter
Valve
It shall be used to
divert milk powder either to drying chamber or to discharge end of Vibro
fluidizer. It shall manual type valve.
Quantity : 1 No.
MOC : Product
contact parts in AISI 304
3.30. Conveying
piping for fines return
It shall be used to
return fines from cyclones to the drying chamber. It shall be provided with
complete with necessary bends & fittings.
Quantity : 1 Lot
VIBRO-FLUIDIZER
ASSEMBLY
3.31. Vibro
Fluidizer Supply Air Fan
For supplying air to
the Vibro fluidizer. The fans shall be statically and dynamically balanced and
shall be provided with electrical motor.
Quantity : 3 Nos.
MOC : Air Contact
parts in AISI 304 construction with base frame in MS
Type : Centrifugal
3.32. Vibro
Fluidizer Steam Air Heater
For heating the
process air by means of dry saturated steam. The steam air heaters shall be
provided with AISI 304 casing, AISI 304 tubes & Al fins.
The heater shall be
complete with all steam and condensate piping, steam stop valve, steam trap.
It shall have
mineral type insulation with Aluminium cladding.
Quantity : 2 Nos.
3.33. Vibro
Fluidizer Air Dehumidifier
It shall be used for
dehumidification of process air using chilled water as cooling media &
steam as heating media. It shall be provided with AISI 304 casing, AISI 304
tubes & AL fins. It shall consist of necessary valves and piping. It shall
consist of two sections. In the first section, air shall be cooled by chilled
water. In 2nd section, cooled air shall be heated by
steam.
It shall be complete
with all intermediate steam and condensate piping, steam stop valve, pressure
gauge, steam trap.
It shall have
mineral type insulation with Aluminium cladding.
Quantity : 1 No.
MOC : AISI 304
3.34. Air Fine
Filter – (HEPA FILTER – EU-12 GRADE)
It shall be provided
for the cooling section of the Vibro Fluidizer and fines return line. MOC of
filter housing, inlet flange, outlet flange, Filter frame shall be AISI 304
with base frame in MS.
Quantity : 1 No.
Type : EU 12
3.35. Vibro Fluidizer
The Vibro fluidizer
consists of drying, conditioning & cooling section. It consists of
vibrating tubular housing divided into an upper and a lower part by an imported
flex plate. Vibro fluidizer shall be made as per sanitary standards.
Air is blown into
the lower part (Plenum chamber) for fluidizing & drying of the product
which flows through the upper part. An Imported vibrator element mounted in the
lower part of the housing shall generate the vibrations. To prevent vibrations
being transferred to surroundings the Vibro-fluidizer shall be mounted on
spiral springs on a mild steel frame. The upper part of the Vibro-fluidizer
shall be provided with inspection doors. The outlet air of Vibro Fluidizer
shall be fed to cyclones through suitable ducting.
Quantity : 1 No.
MOC : AISI 304
3.36. Rotary
Valve
It shall be easy
slide type used to form an air lock within the passage of powder. It shall
consist of housing, rotor and a motor with gearbox.
Quantity : 1 No.
MOC : Product
contact parts in AISI 304
3.37. Powder
Sifter
It shall be used for
screening the milk powder and separating out the lumps from final product. The
MOC of vibrating screen with powder contact parts made of AISI 304 and other
parts of painted MS. It shall be provided with top cover and flexible connections
inclusive of motor.
Quantity : 1 No.
3.38. Air Ducting
The ducting shall be
provided wherever necessary for air supply to drying chamber including air
disperser, Static Fluid bed, Vibro Fluidizer, and exhaust. It shall be provided
with necessary bends, transition pieces and dampers.
Quantity : 1 Lot.
MOC : AISI 304
FIRE
EXTINGUISHING SYSTEM
Fire Extinguishing
System shall be used for the safety of Spray drying plant and operators in the
event of an accident occurring in spite of the precaution measures taken in the
design of the plant to minimize the risk.
3.39. Explosion
vent
It shall be
diaphragm type, placed in the cylindrical part of the drying chamber. It shall
be designed to burst at a certain air pressure in order to protect the chamber.
The diaphragm is fixed between flanges with bolts. To be vented into safe area.
Quantity : 1 Set
3.40.
Over-Pressure Duct
It shall be from
explosion vents of drying chamber to outside of building through openings.
The duct is provided
with inspection opening and the maximum length of the duct is 3 meters.
Quantity : 1 No.
MOC : AISI 304
3.41. Fire
Extinguishing System for Drying chamber & Vibro fluidizer
For drying
chamber
It shall be provided
for the drying chamber, designed for water hosing of the total inner surface.
The system comprises
a set of nozzles placed in the chamber cylinder, connected to a ring-pipe with
main valve and drain valve. The nozzles are flush with the inner surface during
normal operation and are opened by the water pressure when the system is
activated.
A PT100 temperature
sensor is placed in the chamber outlet duct for detecting and signaling the
pre-set temperature rise to the control panel. The temperature sensor is
hardwired to a control panel comprising a monitoring relay with High and High
High alarms.
The system is
designed for a water supply of approx. 140 l/min. per nozzle at a dynamic
pressure of 2 bar g at the nozzle in operation.
Quantity : 1 No.
For vibro
fluidizer
It shall be for the
VIBRO-FLUIDIZER™, designed for water hosing of the inner surface. The system
comprises nozzle with main valve and drain valve. The nozzle is flush with the
inner surface during normal operation and will open by the water pressure
A PT100 temperature
sensor is placed in the VIBRO-FLUIDIZER™, outlet duct for detecting and
signalling the pre-set temperature rise to the control panel. The temperature sensor
is hardwired to the control panel comprising a monitoring relay with High and
High High alarms.
The system is
connected to the control panel.
The system is
designed for a water supply of approx. 140 l/min. per nozzle at a dynamic
pressure of 2 bar g at the nozzle in operation.
Quantity : 1 No.
3.42. Fire
Control Panel
It shall be used for
control of the fire extinguishing system, made of lacquered mild steel and to
be mounted on the wall. The panel contains controls for manual and automatic supervision
and activation of the system, including acoustic and visual alarms for water,
compressed air and power supply.
Quantity : 1 No.
The powder plant
will be put in operation mode only when Overhead tank is filled with water. The
system will receive the signal from the powder plant control panel in case
plant is subjected to temperature beyond the set value. The ring main shall
always remain under set limit of pressure values and it will maintain the
pressure throughout the operation of the powder plant.
Overhead tank of
suitable capacity & water at pressure of 2 Bar g at the inlet of fire
nozzle shall be made available by purchaser.
3.43. Fire Water
Piping to feed to Ring Main of Dryer
From Overhead tank to
ring main system of spray drying plant
Quantity : 1 Lot
4. CIP
ANCILLARIES:
4.1. CIP Return
Pumps
One no. of pump
shall be connected at the outlet of the pig tank and another at the outlet of
feed concentrate and recovery tank (Self Priming type) for CIP return.
Quantity : 2 Nos.
Capacity : Suitable
MOC : Working parts
- Impeller in AISI 316 and casing in AISI 304
Type : Centrifugal
type
4.2. Cleaning
Turbine
The cleaning turbine
shall be used for cleaning of drying chamber. It shall be of rotary type with
hose and manual winch.
Quantity : 1 No.
MOC : AISI 304
4.3. CIP Nozzle
It shall be used for
CIP of Vibro Fluidizer, ducts, SFB and Cyclones.
Quantity : 1 Lot
MOC : AISI 304
Type : Retractable
4.4. Pig Tank
It shall be used for
collection of CIP solution and returning it to CIP tanks / drain.
Quantity : 1 No.
Capacity : 1 KL
MOC : AISI 304
5. Automation
5.1. Automation (
Evaporation Plant)
PC-PLC based control
system shall make various operations in milk Evaporation plant automatic
(Through PLC). Operations as listed below shall be carried out automatically.
However, manual interventions shall be needed in case of alarm conditions are
reached or if there are manual activities required to be carried out (like
connecting swing bends, hoses, dumping/unloading, damper/valve setting etc.,
whichever applicable).
Evaporation
section
The following
process operations are considered automatic (Through PLC) in Evaporation
section:
Ø Steam pressure monitoring & Control for Thermo compressor
Ø Steam pressure monitoring and PID control loop based on DSI temperature
Ø Vacuum monitoring for last effect & Control of Cooling water flow
to Condenser based on Vapour Temperature of Last effect.
Ø Level control for Feed Balance Tank
Ø Temperature control of Low Thermophilic Heater
Ø Feed flow monitoring & flow control loop implemented through VFD
Driven feed pump & flow meter
Ø Final concentrate density monitoring based on density transmitter
Ø Automatic start / Stop of Motors in evaporator section. The status of
each motor would be available on the screen.
In addition to
above, the following indication / alarms shall be displayed & monitored on
SCADA screen:
Ø Condensate conductivity measurement, monitoring & Diversion.
Ø Low level alarms for Seal water tank and Feed balance tank
The other
operations automated through PLC system are:
Ø Start-up
Ø Vacuum on
Ø Heating
Ø Circulation
Ø Stabilization
Ø Production
Ø CIP
Manual
Interventions:
Ø Feed Inlet to Evaporator Feed balance tank.
Ø Changing of holding tubes i.e. for selection of holding time.
5.2. Automation
(In Spray Dryer)
Dryer section
PC-PLC based control
system shall make various operations in Spray drying plant automatic (Through
PLC). However, manual interventions shall be needed in case of alarm conditions
are reached or if there are manual activities required to be carried out (like
connecting swing bends, hoses, dumping/unloading, damper/valve setting etc.,
whichever applicable).
The following
process operations are considered automatic in dryer section:
Ø Pre-heating temperature of feed concentrate to Spray dryer through
concentrate preheater.
Ø Feed flow control through HPP by frequency drive based on Dryer outlet
temperature.
Ø Booster Feed pump with frequency drive and pressure transmitter to
ensure required head at the suction of HPP.
Ø Steam control based on inlet Air temperature to Dryer.
Ø Steam control based on inlet Air temperature to SFB.
Ø Steam control based on inlet Air temperature to heating section of the
VF.
Ø Chilled water control loop for Dehumidifier of VF section.
Ø The drying chamber pressure monitoring & control through Frequency
drive at Exhaust fan.
Ø Remote start / Stop of Motors in dryer section. The status of each
motor would be available on SCADA screen
The other operations
that shall be automated by PLC system are
Ø Sequential start-up
Ø Sequential shut down
The following
operations shall be done manually / operator.
Ø Control of Manual Valves & Air flow dampers
Ø Control of air flow for false air by Manual damper if required.
5.3. Fire
extinguishing system
Following
operations, Indications / alarms for fire extinguishing system through PLC
shall be provided:
Ø Dryer outlet temperature High, High- High alarm & Solenoid
operations for fire water flow based on alarm conditions.
The logic for fire
system operation conditions including start /stop of fire water pump & /or
opening of fire water valve shall be through fire control panel.
5.4. Programmable
Logic Controller (PLC) ( 1 Number - Common for both - Dryer and Evaporator)
The proposed PLC
based system shall have following main features as:
Ø Digital I + O : Point IO module Type.
Ø Analog I + O : Point IO module Type.
Ø Programme Memory : shall be suitable for ladder logic
Ø All the Field Instruments shall be connected to Smart JB type RIO
Panels. Instruments will be connected directly to Terminals of I/O Module.
5.5. Operator
Station (OS)
The proposed
operator station shall be as follows:
Computer with
22" inch colour monitor for the purpose of SCADA
(Supervisory Control
& Data Acquisition Station)
Operator station
comprises of:
Ø 2nd generation Intel i5 processor, 2.5GHz PC, PC-IDE, 4 GB RAM,1 MB
Cache, 160 GB HDD, standard Keyboard & mouse With Windows 7
Ø Run time software for 2 operator station.
Quantity : 2 Nos.
Main features
that shall be made available in workstation are
Ø Process diagrams in multiple colors in pixel based graphics, complete
with Trend curves, bar graphs, real-time values of process parameters, latest
status of all equipment and 3 latest alarms.
Ø Real-Time Trending of process parameters for analysis.
Ø Automatic printing of alarms, events
Ø Prioritized data acquisition cycles. Instantaneous operator-command
execution.
5.6. Printer
LaserJet colour
suitable for A4 :1 No.
5.7. Network
Hardware
UTP / STP Cables : 1
Lot
Field
Instruments, Control Valves and Accessories
Field Instruments
shall be suitable for area in which these are located. In general, field
instruments shall be weatherproof, dust tight and corrosion resistant with
Protection Class IP-65. Field instruments shall be suitably mounted, supported
and terminated in local junction boxes. All field instruments are hardwire type
(4-20 mA, 24 v DC signal) & connected to automation system through Junction
Box / RIO panel in the field.
6.1. Pressure
Transmitter
The transmitters
shall be provided as per requirement for process & utility .The hard wired
signals (4-20 mA) shall be connected with automation system through remote I/O
panel in field.
Proper sanitary type
mounting arrangement shall be provided for installation of the sensors in
various tanks/ pipelines, suitable for Dairy application. Tri-clamp type
sanitary mounting arrangement shall be provided for the sensors to be installed
in pipelines & for Non sanitary type application ½ “NPT threaded connection
shall be provided.
Measuring ranges of
transmitters shall be selected in such a way that the rated value of the
measuring variables appears at approx. 50-80% of the span.
The sensing elements
and internal parts shall be constructed with AISI 316.
Quantity : 1 Lot
6.2.
Pressure/Temperature Gauge
Process gauges shall
be provided for local indication on all utility lines & process tanks (as
necessary).
Pressure gauge
sensing element shall be Bourdon/Bellow/ Diaphragm type in general depending
upon the process condition. Direct reading Pressure/Differential Pressure
gauges shall be used of SS 316 sensing element and AISI 304 movement material.
Local temperature
measurement shall be done bi-metal Temperature gauges. Temperature gauges may
be direct mounted type (every-angle). The sensing element shall be of SS 316
for temperature gauges.
Quantity : 1 Lot
6.3. Temperature
element with transmitter
All Temperature
Sensors Elements shall be of Duplex type with SS 316 sheath, suitable for area
in which these are located. Pt-100 Resistance Temperature Detector (RTD) shall
be used.
RTD heads shall be
via cast aluminium suitable for head mounted temperature transmitter mounting,
with chain holder, shall be of the waterproof type, gasketed cover and
stainless steel chain. Screwed covers shall be used.
Proper sanitary type
mounting arrangement shall be provided for installation of the sensors in
various tanks/ pipelines, suitable for Dairy application. Tri-clamp type
sanitary mounting arrangement shall be provided for the sensors to be installed
in pipelines.
The temperature
transmitters shall be provided as per requirement for process & utility
having best accuracy/reliability, as available in the market and the hard wired
signals (4-20 mA) shall be connected with automation system through remote I/O
panel in field. The transmitters shall head mounted & blind type.
Quantity : 1 Lot
6.4. Control
Valves
Control valves of
required turn down for process & utility application shall be provided
having reliability & accuracy, the conventional E/P positioner shall be
provided with hard wired signals (4-20 mA) signal i/p. The CVs shall be connected
with automation system through PLC Remote I/O panel in the field.
Quantity : 1 Lot
6.5. Motors
Quantity : 1 Lot
6.6. Instrument
Hardware
All type of
instruments fittings & pneumatic fittings shall be provided for proper
installation & operation.
Quantity : 1 Lot
6.7. Control
Cables , Cable trays & Cable Glands
Quantity : 1 Lot
Level instruments
6.8. Level Switch
The level switches
shall be tuning fork type (or suitable type as per process requirement) for all
process & CIP applications. The hard wired signals (24 V DC) shall be
connected through PLC Remote I/O panel in the field.
Quantity : 1 Lot
6.9. Mass /
Density Meter
The flow sensors
shall be sanitary type & suitable for Dairy application.
The Mass flow meter
envisaged shall be Coriolis twin curved tube type. The Mass flow meter shall be
capable of measuring mass flow rate, density, temperature, volumetric flow rate
and totalized flow.
The flow tube/wetted
parts material shall be SS 316 / SS 316L or as per the requirement of process
fluid. SMS type process connection may be used for the mass flow meters.
Digital display of
mass flow rate, density, temperature, volume flow rate as well as totalized
flow shall be provided.
The flow meters
shall be smart type of required turn down capacity having required diagnostic
features with separate local display unit & the hard wired signals (4-20
mA) shall be connected with automation system through PLC Remote I/O panel in
the field. The transmitters shall have field diagnostic / configuration
facility. The flow meters shall be configurable from the in the field. Accuracy
shall be +/-2%.
Quantity : 1 No.
6.10. Magnetic
Flow meter
The flow tube
material shall be of SS-304 with PTFE/PFA lining. The electrode material shall
be SS 316L depending upon process condition. In general, SMS type process
connection may be used for magnetic flow meters for sanitary application &
for non-sanitary application flange type process connection shall be provided.
The flow sensors shall be sanitary type & suitable for Dairy application.
Accuracy of magnetic
flow meter shall be plus or minus 0.5 %of measured flow rate or better. Digital
display of flow rate as well as totalizer display shall be provided.
The flow meters of
required turn down capacity shall be smart type having required diagnostic
features with separate local display unit & the hard wired signals (4-20
mA) shall be connected with automation system through PLC Remote I/O panel in
the field. The transmitters shall have field diagnostic / configuration
facility in field in field.
Quantity : 1 No.
6.11.
Conductivity Transmitter
The conductivity
transmitters of required turn down capacity shall be used for measuring
concentration of CIP chemicals/ milk solid TS based on conductivity measurement
having best accuracy & reliability suitable for Dairy application, as
available in the market. SMS type process connection may be used for the
sanitary type CTs. The conductivity transmitters shall have separate field
display (digital) unit with hard wired (4-20 mA) signals & field
diagnostic/configuration facility. Connectivity with automation system shall be
through PLC Remote IO panel in the field.
Quantity : 1 Set
6.12. Instrument
signal Cable
Instrument cable
shall be of multi-stranded annealed plain copper conductor, extruded PVC type A
insulated. Overall screened with Al. Mylar tape .Extruded PVC ST1 inner sheath
unarmored / armored. Extruded PVC type ST1 outer sheathed instrument signal cables
Min. Size of the instrument cable shall be 0.75 sq.mm.
Quantity : 1 Lot
6.13. Cable Tray
Cable trays shall be
AISI 304 mesh type for powder plant with AISI 304 conduit / tray drop.
Necessary accessories of cable trays such as coupler side plates for joining
cable trays, bends, riser, inside riser, tee etc. shall also be supplied. Cable
glands shall be provided at both ends of armored/ unarmored cables.
Quantity : 1 Lot
7. ELECTRICAL
DISTRIBUTION SYSTEM
7.1. Motor
Control Centre
The purchaser shall
provide power to MCC.
The incoming and
outgoing feeders from the MCC in the electrical control room shall have all the
feeders’ entry & exit from the top.
Quantity : 2 Nos.
Specification
The motor control
centre shall be completely dust & vermin proof conforming to IP 42 standard
and shall be fixed non draw-out type compartmental / Wardrobe type
construction. The MCC would receive, control & distribute electrical power
at 433 V, 50 Hz AC to all electrical loads to be connected in drying plant. MCC
will be manufactured as per latest ISI specifications, Indian electricity
rules.
Type
The MCC shall be
suitable for Indoor Installation. It would be fabricated as per detailed
specification described below.
Bus bar rating
The bus bars shall be
made from high electrolytic Aluminium. Conforming to grade E91E of IS 5082 with
0.8 Amp. / sq.mm current.
The bus bar shall be
capable of carrying 1.2 times of full load current.
Feeders
Feeders up to 63 A
will be protected by proper 3 pole /4 pole MPCB or Switch Fuse units, 63 Amp to
630A with MCCBs and 800A and above will be protected by Air Circuit Breakers
The Incomer shall
have 3-phase 4-wire energy meter / multifunction meter with necessary
Indications and CT's and phase Indication lamps. For Incomer of the panel, the
rating of the switchgear shall be 1.2 times of rated full load current of
connected load of the panel.
All motor feeders
above 10HP shall have Star-delta starters and up to 10 HP shall have
DOL Starters.
7.2. Power Cables
(LT)
Power cables for use
on 415 V system shall be of 1100 volt grade, Aluminium / Copper conductor, XLPE
insulated, XLPE sheathed, armoured and overall XLPE sheathed, strictly as per
IS: 1554 (Part I) - 1976. Unarmoured cable to be used for vibrating equipment’s
& only if specifically mentioned in schedule of quantities. Up to 12.5 hp
2.5 sq.mm copper conductor Armored cable & above12.5 hp Aluminium conductor
Armored cable shall be used. Min size of copper conductor shall be 1.5 sq.mm
Quantity : 1 Lot
7.3. Control
Cables (LT)
Control cables for
use on 415 V system shall be of 1100 volt grade, Copper conductor, PVC / XLPE
insulated, armoured and overall PVC sheathed, strictly as per IS: 1554 (Part I)
– 1976 / IS 7098.
Size of copper
conductor shall be 1.5 sq.mm
Quantity : 1 Lot
7.4. Cable Trays
These shall be mesh
type, heavy duty, inward bend shape, manufactured from AISI 304. Width of cable
tray shall be as per the requirement.
Necessary
accessories of cable trays such as coupler side plates for joining cable trays,
bends, riser, inside riser, tee etc. shall also be supplied.
Quantity : 1 Lot
MOC : AISI 304
7.5. Local Push
Button Stations
The push button
station shall be made in AISI 304, will be provided with Mushroom head
emergency stop push buttons near the motor in field.
Quantity : 1 Lot
7.6. Junction Box
Quantity : 1 Lot
MOC : AISI 304
7.7. Variable
Frequency Panel & Hammer Panel.
Quantity : 1 Set
a) VFD Panel
Specifications:
Type of Panel : Self
standing, Wall mounted, straight vertical
Degree of protection
: IP 42
Thanks For sharing very helpful information
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